Fa HD1500-7 SN 80001-Up Gen00100-00

GEN00100-00
Field Assembly Instruction
DUMP TRUCK HD1500 -7

SERIAL NUMBERS 80001 and up
FOREWARD
This manual is provided to aid assemblers during field assembly of the standard Komatsu HD1500-7 dump truck.
Variations of design required for specific truck orders may require some modification of the general procedures out-
lined in this manual. Follow all safety notices, warnings, and cautions provided in this book when assembling the
truck.
General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the
current production truck model.
This manual lists metric (SI) and U.S. standard dimensions throughout.
All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator's normal seated posi-
tion.
It is recommended that all maintenance personnel read and understand the materials in the service manual before
performing maintenance and/or operational checks on the assembled truck.
FAM0014 Introduction i
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.
WARNING identifies a specific potential hazard

which may result
in either injury or death
if proper precautions are not used.
CAUTION is used for general reminders

of proper safety practices
or
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
ii Introduction FAM0014
TABLE OF CONTENTS
SUBJECT PAGE NUMBER

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY RULES, TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHASSIS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DUMP BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
DUMP BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FINAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
FAM0014 Introduction iii

KOMATSU HD1500-7 DUMP TRUCK
iv Introduction FAM0014
SAFETY RULES, TOOLS & EQUIPMENT
SAFETY RULES
The following list of safety practices is intended for 11. When welding, connect the ground cable to the
use by personnel during field assembly of the truck. part being welded. DO NOT allow welding cur-
rent to pass through bearings, engine, etc.
This list of safety rules is not intended to replace local
safety rules or regulations and federal, state, or local 12. DO NOT weld the transmission housing unless
laws. The safety precautions recommended here are it has been completely disassembled.
general and must be used in conjunction with all pre- 13. DO NOT weld the fuel tank or hydraulic tank
vailing local rules and regulations. unless the tanks have been properly purged
1. All personnel must be properly trained for the and ventilated.
assembly operation. 14. Use the proper tools for the job to be performed.
2. Wear safety equipment such as safety glasses, Never improvise wrenches, screw drivers, sock-
hard toe shoes and hard hats at all times during ets, etc. unless specified.
assembly.
15. Lifting eyes and hooks must be fabricated from
3. Thoroughly inspect the assembly site. Remove the proper materials and rated to lift the
weeds, debris and other flammable material. intended load.
4. Use only solid, hard wood for supports. When 16. When the weight of any component(s) or any
using metal support stands, place wood blocks assembly procedure is not known, contact your
between the support and the frame to prevent customer support manager for further informa-
metal to metal contact. tion.
5. Inspect all lifting devices. Refer to the manufac-
turer's specifications for correct capacities and
safety procedures when lifting components.
6. Perform a daily inspection of all lifting cables
and chains. Replace any questionable items.
Use cables and chains that are properly rated
for the load to be lifted.
7. DO NOT stand beneath a suspended load. Use
of guy ropes are recommended for guiding and
positioning a suspended load.
8. Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
charged and in good working condition.
9. Cap screws and/or nuts being replaced must be
the same grade as originally supplied.
10. Disconnect the battery charging alternator lead
wire before welding on the frame or its compo-
nents.
FAM0111 Safety Rules, Tools, & Equipment Page 1-1

TOOLS AND EQUIPMENT FOR
ASSEMBLY
The following equipment is recommended for field
assembly of the truck.
12. Two, ratchet pullers - 2.7 metric ton (3 ton)
13. Two, ratchet pullers - 1.4 metric ton (1.5 ton)
1. Equipment and tool storage trailer with a lock-
able door. Approximately 12 x 2.5 m (40 x 8 ft) 14. Set of standard master mechanics hand tools.
2. Cranes • Thread taps and dies of both inch and metric
sizes.
a. Two, 45 metric ton (50 ton) cranes to remove
the chassis from the freight trailer and place • Metric sockets and open end wrenches, 6mm
on cribbing. These cranes can also be used to 36mm.
to lift the assembled body onto to the chas-
• Inch sockets and open end wrenches up to 1
sis.
3/4 in.
b. One, 109-136 metric tons (120-150 ton)
crane. The crane is needed to turn the body
• Torque wrenches - 339 N·m (250 ft lb) with
over after completion of the underside weld- 18:1 multiplier. Torque wrenches - 339 N·m
ing. A 45 metric ton (50 ton) crane is also (600 ft lb) with 4:1 multiplier. Hydrotorque - 1
required for this task. 1/2 in. drive with capability of 5559 N·m
(4100 ft lb) or greater.
3. One fork lift - 6804 kg (15,000 lb) capacity, with
high lift capability. • Box wrench 1 3/8 in. (Snap-On p/n X440B)
4. Two, 300 amp portable welding units and an with 12 inch extension to tighten ROPS cap
oxy-acetylene cutting set. screws.
5. One, propane torches for weld preheating. • Sockets: 2 1/4 in. (Snap-On P/N J15036) and
6. Portable air compressor - 3.5 cmm (125 cfm) 2 5/8 in. (Snap-On P/N J15042) to tighten
and 690 kPa (100 psi) capacity. front suspension hardware.
15. Heavy duty 3/4 in. & 1 in. square drive impact
Two, 15 m (50 ft) air hoses.
wrench sets.
7. Metal stands and a sufficient amount of wood
cribbing - sizes from 1.2 m x 30.5 cm x 30.5 cm 16. Impact sockets for 3/4 in. & 1 in. square drive
(4 ft. x 12 in. x 12 in.) and 1.2 m x 15 cm x 15 tools.
cm (4 ft. x 6 in. x 6 in.) - such as railway cross 17. Special tools (see list, following pages)
ties
18. Two, hydraulic or pneumatic porta-power jacks,
8. Tire handler - Wiggins/Iowa Mold Tooling. 4.5 and 9 metric ton (5 and 10 ton)
9. Miscellaneous air tools
19. Various hooks and shackles
10. Ladders - 3.5 m (12 ft), 2.5 m (8 ft), & 2 m (6 ft)
20. Miscellaneous: i.e. grinders, containers, rags.
11. Chains, lifting cables, slings:
21. Spreader bars for cab and decks.
• Two, 4 point slings, 3 m (10 ft) in length 22. Two ratchet hoists of 2.7 metric ton (3 ton)
• Two, 4 point slings, 2 m (6 ft) in length capacity.
• Two, 1 m (4 ft) and two, 2 m (6 ft) 23. Pry bars
• Two, 3 m (10 ft) nylon straps 24. Solvent - 38 liters (10 gal)
• Four lengths of 2.54 cm x 15 m (1 in. x 50 ft) 25. Paint remover - 19 liters (5 gal)
of rope 26. Rust preventive grease
Page1-2 Safety Rules, Tools, & Equipment FAM0111

LIFTING SLING GENERAL
INFORMATION

PART NO. DESCRIPTION USE
562-98-31301 Disc Gauge Brake Disc Wear
Tool

NItrogen Suspension &
EC3331 Charging Kit accumulator
nitrogen charging
NOTE: Not included with all trucks.

PC2061 Belt Tension A/C Belt Tension
Tester
569-86-87361 Download PLM Download

Harness Data

EL8868 V-Belt Align- Aligning A/C
ment Tool pulleys

SE21188 Driveshaft Aligning driveline
Alignment Tool components

ASSEMBLY SCHEDULE AND RESOURCE LAYOUT

MAJOR COMPONENTS AND SPECIFICATIONS
Engine Power Steering
The Komatsu HD1500-7 dump truck is powered by a The HD1500-7 truck is equipped with a full time
Komatsu SDA12V160 diesel engine. This engine is power steering system. The system provides positive
Tier 1 compliant. steering control with minimum effort by the operator.
Nitrogen-charged accumulators automatically pro-
vide emergency power if steering pressure is
reduced below an established minimum.
Transmission
The Torqflow transmission is a planetary gear, multi-
ple disc clutch transmission. The transmission is
Brake System
hydraulically actuated and force-lubricated for opti-
mum heat dissipation. consists A three-element, sin- Depressing the brake pedal, or operating the
gle-stage, two-phase torque converter is mounted to retarder, actuates the hydraulic front and rear service
the front of the transmission. brakes. Both front and rear service brakes are oil-
cooled, multiple-disc brakes. The brakes are auto-
The Torqflow transmission is capable of seven for-
matically applied when engine speed exceeds the
ward speeds and one reverse speed. Automatic
rated revolutions for the shift range. The system
shifting is controlled by an electronic shift control sys-
includes two nitrogen-charged accumulators for
tem with automatic clutch modulation in all gears. A
quick response. The accumulators provide emer-
lockup system consisting of a wet, double-disc
gency braking if a problem occurs in the primary
clutch, is activated in F1-F7 gears for increased fuel
braking circuit.
savings.
Retarder
Final Drive
The operator can manually apply both the front and
The final drive consists of a plug-in differential with
rear oil-cooled, multiple-disc brakes by actuating the
planetary wheel drive.
retarding system. The retarder control lever is
mounted on the steering column.
The retarding system is also equipped with an Auto-
matic Retard Speed Control (ARSC) system. The
Operator’s Cab system automatically applies the retarder to maintain
The HD1500-7 operator's cab has been engineered the set speed as initiated by the operator. Refer to
for maximum operator comfort and to allow for effi- Section 32, Operator Cab and Controls, for more
cient and safe operation of the truck. information on the ARSC system.
The cab provides for wide visibility, with an integral

four-post ROPS/FOPS, and an advanced analog
operator environment. It includes the following: tinted
safety-glass windshield, power-operated side win- Suspension
dows, deluxe interior with a fully adjustable seat with
Hydro-pneumatic suspension cylinders are mounted
lumbar support, fully adjustable tilt steering wheel,
at each wheel to reduce shock. The suspensions
controls mounted within easy reach of the operator,
provide riding comfort for the operator and machine
and an electronic display/monitoring panel to keep
stability for safe travel.
the operator informed of the truck's operating circuits.
Audible alarms and indicator lights warn the operator
of system malfunctions.
FAM0214 Major Components and Specifications 2-1

MAJOR COMPONENT LOCATION
2-2 Major Components and Specifications FAM0214

SPECIFICATIONS
Engine Service Capacities
Komatsu . . . . . . . . . . . . . . . . . . . . . . . SDA12V160* . . . . . . . . . . . . . . . . . . . . . . . .Liters . . U.S Gallons
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 12 Engine . . . . . . . . . . . . . . . . . . 193 . . . . . . (51)
Operating Cycle (diesel) . . . . . . . . . . . . . . . 4-Stroke (Includes Lube Oil Filters)
Rated . 1108 kW (1486 SAE Brake HP) @ 1900 rpm Cooling System . . . . . . . . . . . 532 . . . . . . (141)
Flywheel . . . 1048 kW (1406 SAE HP) @ 1900 rpm Fuel Tank . . . . . . . . . . . . . . . . 2120 . . . . . (560)
Weight (dry) . . . . . . . . . . . . . . . .5813 kg (12,815 lbs) Transmission . . . . . . . . . . . . . 153 . . . . . . .(41)
* Tier 1 Compliant And Torque Converter
Hydraulic System . . . . . . . . . 900 . . . . . . (238)
Transmission
Differential . . . . . . . . . . . . . . . 297 . . . . . . .(78)
Automatic Electronic Shift Control with Automatic Final Drive (each planetary) . 120 . . . . . . .(32)
Clutch Modulation In All Gears.
Torque Converter. . . . . . . . 3-Element, Single-stage,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-phase Hydraulic System
Lockup Clutch . . . . . . . . . . . . . . . Wet, Double-disc, Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . (3)
. . . . . . . . . . . . . . . . . . . . . . Activated in F1-F7 gears. Hoist (Tandem Gear)
Transmission . . . . . . . 7 Forward Speeds, 1 Reverse . . . . 805 l/min. (213 gpm) @ 18 960 kPa (2,750 psi)
. . . . . . . . . . . . .Planetary Gear, Multiple Disc Clutch,
Steering (Piston)
. . . . . . . . . . Hydraulically Actuated, Force-lubricated
. . . 221 l/min. (58.5 gpm) @ 18 960 kPa (2,750 psi)
Gear . . . . . . . . . . . . . . . . . . . . . kph . . . . . . . . mph Brake (Tandem Gear) . . . . . 1512 l/min. (400 gpm)
1 . . . . . . . . . . . . . . . . . . . . . . 11.0 . . . . . . . . . 6.8 Hoist Control Valve . . . . . . . . . . . . . . . . . Spool Type
2 . . . . . . . . . . . . . . . . . . . . . . 14.6 . . . . . . . . . 9.1 Positions. . . . . . . . . . Raise, Hold, Float, and Lower
3 . . . . . . . . . . . . . . . . . . . . . . 19.5 . . . . . . . . 12.1 Hydraulic Cylinders
4 . . . . . . . . . . . . . . . . . . . . . . 24.5 . . . . . . . . 15.2 Hoist . . . . . . . . . . . . . 3-Stage Telescoping Piston
5 . . . . . . . . . . . . . . . . . . . . . . 32.6 . . . . . . . . 20.3 Steering . . . . . . . . . . . Twin - Double Acting Piston
6 . . . . . . . . . . . . . . . . . . . . . . 44.2 . . . . . . . . 27.5 Relief Valve Setting . . . . . . . .18 960 kPa (2,750 psi)
7 . . . . . . . . . . . . . . . . . . . . . . 58.0 . . . . . . . . 36.0 Filtration . . . . . . . . . . . In-line Replaceable Elements
Reverse . . . . . . . . . . . . . . . . . . . 10.6 . . . . . . . . . 6.6 Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Hoist & Steering . . . . . . . . . Dual, Full Flow, In-line
. . . . . . . . . . . . High Pressure. Beta 12 Rating = 200
Final Drive Transmission . . . . . . . . . . . . . .Dual, High Pressure
Final Drive . . . . . . . . . . . . . . . . . Plug-in Differential
Service Brakes
. . . . . . . . . . . . . . . . . . . . with Planetary Wheel Drive
Actuation: . . . . . . . . . . . . . . . . . . . . . . . All-Hydraulic
Reduction Ratios: Front . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Bevel Set . . . . . . . . . . . . . . . . . . . . . . . . . 2.647:1 Rear . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Planetary Final Drive . . . . . . . . . . . . . . . . . 7.235:1
. . . . . . . . . . Both act as service and retarder brakes
Total Reduction . . . . . . . . . . . . . . . . . . . 19.151:1
Retarder Brakes:
Normally Applied . . . . . . . . Manually By Operator.
. . . . . . . . . . . . . . . . . . . . . . . . . . (w/ ARSC control)
Electrical System
Automatically Actuated . . . . . . . . . . . . . . . . . . . . . .
Batteries (series-parallel). . 4 x 12V / 140 Amp-Hour when engine speed exceeds the rated revolutions
Alternator . . . . . . . . . . . . . . 24 Volt, 140 Amp Output of the shift position for the transmission.
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt Parking Brake: . . . . . . Spring-Applied, Oil Released
Cranking Motors . . . . . . . . . . . Two - 24 Volt Electric . . . . Dry Caliper Disc Actuates On Rear Drive Shaft
Emergency Brakes: Manual or automatic operation.
FAM0214 Major Components and Specifications 2-3

Steering Overall Truck Dimensions
Turning Circle Diameter (SAE) . . . . . . . 24.4 m (80 ft) Loading Height . . . . . . . . . . . . . . . . 4.965 m (16' 3")
Minimum Clearance Height . . . . . . . . 5.85 m (19' 2")
Automatic Emergency Steering . . . . 2 Accumulators
Overall Length . . . . . . . . . . . . . . . . . 11.37 m (37' 4")
Maximum Width. . . . . . . . . . . . . . . . . 6.62 m (21' 9")
Tires
Rock Service (E-3) . . . . . . . . . . . . . . . . . . . Tubeless Weight Distribution
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 33.00 R51 Empty . . . . . . . . . . . . . . . Kilograms . . . . .Pounds
Rim Size . . . . . 61x 12.95 x 12.7 cm (24 x 51 x 5 in.) Front Axle . . . . . . . . . . . . . . 51,714. . . . . . 114,008
Phase II Generation™ . . . . . . . Separable Tire Rims Rear Axle . . . . . . . . . . . . . . 54,041 . . . . . . . 119,140
Total . . . . . . . . . . . . . . . . . . 105,755 . . . . . 233,148
Loaded (150 Ton Payload)

Dump Body Capacity (Standard)
. . . . . . . . . . . . . . . . . . . . . Kilograms . . . . .Pounds
Struck . . . . . . . . . . . . . . . . . . . . . . . 54 m3 (71 yds3) Front Axle . . . . . . . . . . . . . . 83,824 . . . . . . .184,800
Heaped @ 2:1 (SAE) . . . . . . . . . . 78 m3 (102 yds3) Rear Axle . . . . . . . . . . . . . . 165,651 . . . . . .365,199
Total * . . . . . . . . . . . . . . . . . 249 475 . . . . . .550,000
*Not to Exceed 249 475 kg (550,000 lbs.).
Including Options, Fuel & Payload
2-4 Major Components and Specifications FAM0214

MAJOR COMPONENT WEIGHTS
The condition of lifting slings, chains, and/or cables used for lifting components must be inspected before
each use. Lifting equipment must be in good condition and rated for approximately two times the weight
being lifted. DO NOT use worn or damaged lifting equipment. Serious injury and damage may result.
Optional equipment added onto the truck may cause an increase to the component weights listed in this
chapter. Contact your customer support manager for concerns or questions about lifting truck compo-
nents.
NOTE: All component weights are dry weights. The additional weight of coolant, fuel, and oil that may be in the
components are not calculated into this list.
ITEM KILOGRAMS POUNDS
CHASSIS AND CAB

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32,228 . . . . . . . . . . . . . . . . . . . . . 71,050
Wheel Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003 . . . . . . . . . . . . . . . . . . . . . . . 2211
Tire 33R51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2177 . . . . . . . . . . . . . . . . . . . . . . .4800
Wheel & Tire Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3180 . . . . . . . . . . . . . . . . . . . . . . . 7011
Center Deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 . . . . . . . . . . . . . . . . . . . . . . . .527
Left Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 . . . . . . . . . . . . . . . . . . . . . . .1000
Right Deck with Battery Box and Handrails. . . . . . . . . . . . . . . . . . . . . . . . . 1021 . . . . . . . . . . . . . . . . . . . . . . .2250
RH Deck Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 . . . . . . . . . . . . . . . . . . . . . . . .350
LH ROPS Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590 . . . . . . . . . . . . . . . . . . . . . . .1300
RH Upright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 . . . . . . . . . . . . . . . . . . . . . . .1000
LH Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 . . . . . . . . . . . . . . . . . . . . . . . .825
Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2019 . . . . . . . . . . . . . . . . . . . . . . .4450
RH/LH Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . . . . . . . . . . .100
Rear Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . . . . . . . . . . .100
Fire Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . . . . . . . . . . . . . . . . . . . . .175
FAM0313 Major Component Weights 3-1

ITEM KILOGRAMS POUNDS
ENGINE, TRANSMISSION AND RELATED COMPONENTS

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6431 . . . . . . . . . . . . . . . . . . . . . . 14,178
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1191 . . . . . . . . . . . . . . . . . . . . . . . 2626
Upper Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 . . . . . . . . . . . . . . . . . . . . . . . . . 66
Lower Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 . . . . . . . . . . . . . . . . . . . . . . . . . 51
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3268 . . . . . . . . . . . . . . . . . . . . . . . 7205
Battery Box with batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363 . . . . . . . . . . . . . . . . . . . . . . . . 800
FRONT AXLE COMPONENTS

Front Wheel Hub, Suspension Cylinder & A-arm . . . . . . . . . . . . . . . . . . . .3629 . . . . . . . . . . . . . . . . . . . . . . . 8000
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 . . . . . . . . . . . . . . . . . . . . . . . . 289
FLUID COMPONENTS
Steering Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 . . . . . . . . . . . . . . . . . . . . . . . . 309
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685 . . . . . . . . . . . . . . . . . . . . . . . 1510
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .975 . . . . . . . . . . . . . . . . . . . . . . . 2150
Hydraulic Brake Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343 . . . . . . . . . . . . . . . . . . . . . . . . 756
REAR AXLE COMPONENTS

Rear Suspension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455 . . . . . . . . . . . . . . . . . . . . . . . 1003
Rear Axle Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 . . . . . . . . . . . . . . . . . . . . . . . . 243
Anti-Sway Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 . . . . . . . . . . . . . . . . . . . . . . . . 201
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,288 . . . . . . . . . . . . . . . . . . . . . . 31,500
3-2 Major Component Weights FAM0313

FIELD WELDING FOR ASSEMBLY OR REPAIR
When welding on Komatsu equipment, whether at WELD PROCEDURES
initial field assembly or during normal maintenance
repairs, special procedures must be followed. Electric arc welding, either the semi-automatic “MIG”
(GMAW), Flux Core (FCAW), or “Stick” electrode
Due to the continuous program of research and welding (SMAW), are approved processes for field
development, periodic revisions may be made to this installation and maintenance welding. Welding of
publication. It is recommended that customers con- highly stressed structural members such as castings,
tact their distributors for information on the latest revi- torque tubes, top and bottom plates on the frame
sion. rails, and the curved intersection points of frames
The welding information contained in this chapter is should be done with the specific detailed instructions
general information that must be followed unless oth- from Komatsu Product Service. See Annex A for
erwise specified in a detailed repair procedure pro- repair procedures. These repair procedures are
vided on an engineering drawing or a detailed detailed instructions for most high stressed structural
specific repair procedure. Additional specific informa- members.
tion, or detailed instructions can be obtained through
your local Komatsu customer support manager.
APPROVED CONSUMABLES
GMAW - LW102-15 or ER80S-D2
WELDER QUALIFICATION AND
TRAINING FCAW - E70T-5, E71T-8, or E71T8-NI1
The welding technique must be of the highest stan- SMAW - E7018-1, E8018-C1, or E8018-C3
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
WELD QUALITY REQUIREMENTS
or (AWS) D14.3 only, are allowed to perform the 1. Each weld must be homogeneous with low
welding. The welding instructions for field assembly porosity, free from cracks, and slag inclusions.
of Komatsu components are normally provided by 2. Each weld must have complete fusion between
engineering drawings. Additional detailed welding the base metal and weld metal added by the
instructions for field repairs are provided in the field electrode.
repair manual SEB14001. A full understanding of the
3. All welds must be reasonably smooth, without
AWS standard welding symbols is necessary to per-
excessive deformity, and all craters filled. No
form and inspect such field welds. Weld sizes speci-
cracks are permitted.
fied on the drawings are intended to reflect minimum
requirements. 4. The toe of a weld to a stressed member must
have a smooth transition. Excessive convexity
in multi-pass fillet welds is not permitted. Exces-
sive convexity produces high residual stress in
the throat of the weld, and is not permitted.
5. Undercut in excess of 0.8 mm (0.03 in.) on criti-
cal welds must be reworked by the application
of welding an additional cover pass. It is impor-
tant that this pass is blended with the existing
weld.
FAM0404 Field Welding Procedures 4-1

6. When welding in the vertical position, always 2. Low Ambient Temperature - DO NOT weld in
weld using the vertical up technique. Large temperatures below 50°F (10°C). At low tem-
wash weld weaves should not be used when perature conditions, preheating of all welding
welding on truck frames. Properly applied multi- joint work areas is required. See preheat and
ple pass welding is the required procedure on post heating requirements as detailed in Annex
truck frames. A.
7. Slag is to be removed from all weld beads, and 3. Weld Cooling - Protect the weld area from a
must be completely removed before each pass rapid cooling rate. Heat retardation may be
in a multiple pass procedure. It is also required accomplished through the use of heat lamps,
that all slag is removed and tie in all areas. torches, insulating blankets, etc.
Grind all welds where a weld crosses or inter- 4. Moisture - Any moisture on the steel surfaces to
sects with another weld. 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
MATERIALS, CONTROLS, AND affect weld quality.
PRECAUTIONS 5. Foreign Materials - Any foreign substances
The steel used in the fabrication of all Komatsu (dirt, paint, rust, scale, and carbon deposits
equipment is of high strength low alloy (HSLA) mate- from cuttings) must be removed prior to weld-
rial of different grades. The standard dump body ing. Clean all weld areas and surfaces with a
main plates are made from abrasion resistant materi- grinder to ensure that all foreign materials have
als. These materials offer themselves very well to been removed.
welding during fabrication, and repair.
The welding consumables are often supplied by
Komatsu America Corp. with the new equipment as WELD INSPECTION
part of the field welding / assembly package. For field All welding repairs are subject to inspection by a
welding and repairs, the approved consumables as Komatsu appointed inspector or laboratory to insure
detailed, should be procured from a local, reliable quality. After the weld has been made it can be
supplier. Other highly specialized welding consum- inspected by a number of non-destructive evaluation
ables are available but have limited use on Komatsu techniques. The inspections can include any of the
structural components. Approval is required from methods listed below. All assembly welds and weld
your Komatsu customer support manager. repairs that are deemed unacceptable by the inspec-
Control of the welding area environment is essential tor must be corrected at no additional cost to
for producing proper and sound welds. Essentially, Komatsu. All weld repairs are also subject to addi-
five areas require attention and control. tional inspection.
1. Air Movement - Avoid areas where air move- 1. Visual Inspection - This is the process of look-
ment from wind, drafts, or blowers is prevalent. ing for potential defects such as undersized
This is particularly important when a shielding welds that can be checked with weld gauges
gas is being used as part of the welding pro- for, surface cracks, surface porosity, craters,
cess. and undercuts.
4-2 Field Welding Procedures FAM0404

RECORDS
2. Dye Penetrant Inspection - This is an easily Komatsu requires record keeping of all welding work.
applied process which indicates cracks or sur- This information is valuable when personnel or job
face conditions. The process is relatively inex- conditions change. The service and warranty depart-
pensive, but does not produce a permanent ments of Komatsu must be provided with inspection
record except by normal photography. reports and photographs of the weld area before,
3. Fluorescent Penetrant Inspection - Similar to during, and after the repair. The photographs must
dye penetrant inspection. This process uses a be clear and close enough to show the weld joint
black (ultraviolet) light for increased efficiency preparation complete, with backer bars installed, etc.
and accuracy. just prior to welding. These photos easily identify if
4. Magnetic Particle Inspection - This process the required preheating and post heating have been
requires special equipment that is usually more done with a three inch circumference around the
costly than the dye penetrant inspections. This weld repair area. Without this documentation,
process does not provide a permanent record Komatsu will not cover any weld repair claim made
except by normal photography. under warranty. No exceptions will be made.
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, ANNEX A
operator records with equipment settings and The following are general repair procedures, which
test results are normally recorded. must be followed for all repair and rework of major
6. X-Ray Inspection - This process provides a load carrying members on Komatsu equipment.
view of the weld and base materials but it is
highly specialized. This procedure provides a
permanent visual record, but is more expensive 1. The repair or rework area must be protected
than most other inspection techniques. from wind and moisture during the entire proce-
dure. If the repair work is to done outside addi-
tional precautions must be taken to protect the
weld repair process from outside elements. All
welding should be done at an ambient tempera-
ture of 10°C (50°F) or above.
2. Clean and grind the entire repair area to
remove all rust, grease, oils, paint, and any
other foreign materials likely to contaminate the
weld.

3. Air arc the entire crack leaving a V-shape joint. 9. All welds are to be made with approved con-
The depth of the V (or U shaped) joint will be sumables only. The SMAW (Stick) welding rod
determined by the depth of the crack. The width must be used within four hours after being
to depth ratio should be approximately 1.25:1 removed from a new sealed container or from a
and never less than 1:1. All cracks through the 52°C (125°F) minimum drying oven. Any rod
parent material will require a slightly wider root that exceeds this exposure time must be dried
opening than the original, usually 6 mm (0.25 for one hour at 427°C (800°F) before being
in.) to allow the installation of a backup strip. used. Keep all weld starts and stops to a mini-
Backup strips are required for all cracks that mum.
have gone through the parent material and can- 10. When the weld is complete, immediately (before
not be welded from both sides. If a weld repair the weldment cools) post heat the entire weld
allows access to both sides of the plate, no area to 150°C (300°F). Even if the area is over
backup strip is required as long as complete 150°C (300°F) heat must be applied to maintain
weld penetration is achieved. If backup strips this temperature for 15 minutes, and then allow
are not used, the surface profile on both sides it to cool slowly. In some cases this might
must be ground smooth with no undercut. Doc- require wrapping with insulation blankets.
umentation must support this repair. Photo-
graphs of surface condition are required by the 11. Grind all butt-welded repairs smooth using 36 or
service and warranty departments of Komatsu. finer grit grinding material. All grinding marks
should be parallel to the direction of primary
4. Use dye penetrant to ensure the cracks are
stress if possible (and if known).
completely removed.
5. After air arcing and inspections (Steps 3 & 4) all 12. Hammer peen the toes of repair fillet welds as
areas cut by the air arc should be cleaned thor- detailed in Annex B, see attached.
oughly with a grinder to remove all possible car- 13. Inspect repaired areas (for surface defects)
bon deposits and dye penetrant. using magnetic particle or dye penetrant
6. Fill gouges with weld and grind all surfaces inspection procedures.
smooth to avoid defects in the new weld. 14. If surface defects are found, remove all defects
7. Grind all surfaces to be welded so they are free by grinding to a maximum depth of 1.5 mm
of slag, rust, and any other foreign materials. (0.06 in.). Larger defects must be removed as
8. Preheat the entire weld joint area until the sur- per the above mentioned procedures. All spot
rounding surface area reaches 150°C (300°F) welding also requires preheating and post heat-
at a distance of 76 mm (3 in.) from all areas to ing.
be welded.

ANNEX B
1.0 TOE HAMMER PEENING 2.0 TOE GRINDING WITH A ROTARY BURR
Equipment:
1. Hand held pneumatic hammer Equipment:
2. Adequate air supply 1. High speed rotary air tool (15,000-20,000 rpm)
3. Adequate lighting 2. Tungsten carbide rotary burr 13 mm (0.50 in.)
4. 6 mm (0.25 in.) diameter spherical tip bit diameter with 13 mm (0.50 in.) spherical tip
5. Protective clothing, gloves, includes eye, face, 3. Adequate air supply
and ear protection. 4. Adequate lighting
5. Protective clothing, gloves, includes eye, face,
Procedure
and ear protection
1. The toe of the weld should serve as a guide for
the peening tool resulting in the area of defor- Procedure
mation being approximately equally divided 1. The toe of the weld should serve as a guide for
between the base material and the weld metal the burr tool resulting in the material removed
face to the specified depth and not to exceed 5 being approximately equally divided between
mm (0.19 in.) in width. Refer to Figure 4-1. the base material and the weld metal face to the
NOTE: Peening shall only be performed after weld specified depth and not exceed 8 mm (0.31 in.)
acceptance by visual inspection. in width. Refer to Figure 4-2.
2. The weld must have a smooth profile and the 2. The weld must have a smooth profile and the
toe must have a good transition to the parent toe must have a good transition to the parent
material (no overlap) before the peening opera- material (no overlap) before the grinding opera-
tion is performed. Grinding the weld face and tion is performed. Grinding the weld face and
toe area is permitted to correct unacceptable toe area is permitted to correct unacceptable
conditions. Visual inspection/acceptance is to conditions. Visual inspection/acceptance to be
be done after peening with the appropriate done after grinding with the appropriate radius
radius and depth gauge. and depth gauge.
3. Hold the hammer tool at approximately one half 3. The axis of the tool should be maintained at
the included angle between the weld face and about 45° to the parent plate and inclined at
the parent material and perpendicular to the about 45° to the direction of travel. The depth of
direction of travel. This will normally require the grinding must be between 0.8 mm to 1.0
approximately four passes of the peening tool mm (0.030 to 0.040 in.). The final surface must
with the pressure of near full operator weight be clean, smooth and free of all traces of under-
being applied. The depth of the indentation cut or slag.
must be between 0.6 mm to 0.8 mm (0.02 to
0.03 in.).

FIGURE 4-1. TOE HAMMER PEENING

FIGURE 4-2. TOE GRINDING WITH A ROTARY BURR

BIBLIOGRAPHY
American Welding Society Bulletin No. D14.3-94/
D1.1 - Specification for Welding Earthmoving and
Construction Equipment
Metals and How to Weld Them - James F. Lincoln
Arc Welding Foundation. Cleveland, Ohio
Procedure Handbook of Arc Welding - Lincoln Elec-
tric Company, Cleveland, Ohio
American Welding Society - Welding Handbook
British Standard BS5135 - Metal Arc Welding of Car-
bon and Carbon-Manganese Steels
Welding Steels Without Hydrogen Cracking - The
Welding Institute, F. R. Coe, Author

RECEIVING & ASSEMBLY PREPARATION
1. Inspect all components for possible shipping 5. Clean all mounting surfaces on the chassis and
damages. Note any damage found and report to on the individual components.
shipping agent. 6. Check all electrical connectors and verify they
2. Spread out all parts and organize per unit num- are free of paint and/or corrosion. Clean any
ber. Check for missing parts. List the unit num- connector with questionable electrical continu-
ber of all major components. Verify the cab and ity.
decks are with the correct chassis. 7. Check all factory installed components for the
3. Inspect rear suspension spherical bearings to proper tightening torque.
ensure proper pin fit and movement. 8. Arrange the work site as shown on the following
4. Install support blocks under the frame at the page.
hoist cylinder mounts. The support blocks must
be approximately 76 cm (30 in.) high.
FAM0504 Receiving & Assembly Preparation 5-1

ASSEMBLY LAYOUT
5-2 Receiving & Assembly Preparation FAM0504

CHASSIS ASSEMBLY
Due to differences in machine configurations and
shipping restrictions/requirements throughout the
world, the shipping and packaging of large machines BASIC ASSEMBLY PROCEDURE
varies. Photographs or illustrations used in the fol-
lowing procedures are provided as general guide- 1. Site preparation
lines only. Actual assembly may be different, but this 2. Unload truck components
general procedure provides a basic outline for 3. Assemble the chassis
assembly. 4. Weld the body
Items like the hydraulic tank and the accumulators NOTE: Chassis assembly and body welding may be
may have been removed for shipping and will have to done in either order, or simultaneously. The most
be locally installed. logical order depends on available resources such as
Each shipment may be different, depending on the cranes, welders, assemblers, etc.
truck configuration and destination. 5. Static checkout (electrical & mechanical)
6. Install the body
7. Dynamic checkout (electrical & mechanical)
RECOMMENDED ASSEMBLY DATA 8. Site cleanup
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. Toe-In Adjustment Procedure (Section 10,
Appendix)
7. Hydraulic Checkout Procedure (Section 10,
Appendix)
8. Hydraulic Brake Checkout Procedure (Section
10, Appendix)
10. Filter List (available in parts book)
11. Lubrication & Service PM Forms (available in
the operation and maintenance manual)
12. Component Weights - for crane reference
(available in Section 3 of this manual)
13. Standard Torque Chart (available in Section 10
of this manual)
FAM0614 Chassis Assembly 6-1

ORDER OF ASSEMBLY
The following list outlines a general assembly order 15. Weld both uprights
for building the truck. It is possible for some of these 16. Front ladders
tasks to be performed out of order depending on fac-
17. Wheels and tires
tors such as manpower and location on the truck.
Before changing the order of assembly, however, 18. Install the dump body
consider the impact on subsequent tasks.
19. Connect hoist cylinders
NOTE: As stated earlier, shipping and packaging of 20. Install body accessories - mud flaps, body posi-
large machines will vary. Some of these steps may tion switches, etc.
change due to different shipping configurations and/
or truck options. 21. Clean the truck
22. Install decals
1. Chassis - Unload and place on support blocks 23. Install lighting wiring
2. Connect the rear axle. 24. Check and adjust suspension oiling and charg-
ing
3. Front suspension, wheel and brake assembly
4. Fuel tank 25. Charge accumulators
5. Fit LH upright 26. Add fluids
6. Fit RH upright
NOTE: Prior to starting the engine, ensure the
steering pump case is full of oil.
27. Perform system check-outs
28. Clean the assembly area
29. Touch up paint
Do not weld the uprights until all decks and the
operator cab are installed. Ratchet pullers may 30. Operator training
be required to help align the structures for a 31. Install fire suppression system, if applicable
proper fit.
7. Fit LH deck/ROPS support

8. Fit RH deck support
9. Weld deck supports
10. Air intake tubes
11. RH deck, handrail and mirrors
12. Hydraulic brake cabinet
13. LH deck and handrails
14. Operator cab
6-2 Chassis Assembly FAM0614

CHASSIS ASSEMBLY
The photographs referenced in this procedure depict
an actual truck assembly. Assembly at another loca-
tion may be different. However, this outline will pro-
vide a general basis for assembly.
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 wire
before welding on the frame or its components.
Follow all safety recommendations in this man- Fasten the welding machine ground cable to the
ual. Follow all local, state, and federal regula- component being welded.
tions. DO NOT allow welding current to pass through
bearings.
DO NOT lay welding cables over truck electrical
In the procedures that follow, many very heavy com-
cables and harnesses. Welding voltages could be
ponents will be required to be lifted into place and
induced into the truck wiring and cause damage
secured.
to components.
DO NOT weld on the fuel tank or the hydraulic
tank unless they have been properly purged and
ventilated.
Maintain fire control equipment. Inspect fire
extinguishers regularly to ensure they are fully
• Inspect all lifting devices. Slings, chains, and charged and in good working condition.
cables used for lifting components must be
inspected daily for serviceable condition.
Refer to the manufacturer’s guidelines for
correct capacities and safety procedures Mark cap screws and nuts with paint or ink after tight-
when lifting components. Replace any ening to the specified torque. This method provides
questionable items. verification that the hardware has been properly
tightened.
• Slings, chains and cables used for lifting
must be rated for approximately two times the
intended load.
• When in doubt as to the weight of
components or any assembly procedure,
contact your customer support manager for
further information.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the
intended load.
• Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
• Before lifting, ensure there is adequate
clearance from overhead structures or
electric power lines.

GENERAL PRECAUTIONS AND
INSTRUCTION 14. Brake accumulators are normally charged with
1. Clean and remove all foreign material from nitrogen when shipped from the factory. Use
component mounting surfaces. proper precautions when checking pressures.
2. Lubricate all pins with clean NLGI No. 2 (5% 15. Verify the lube system is lubricated, purged and
molybdenum disulfide) grease prior to installa- all levels full prior to start up.
tion. 16. Purge air from the steering pump before truck
3. Mount the front suspensions first so that deck operation. The steering and brake circuits will
supports can be installed while other compo- not pressurize if air is present. Air in the system
nents are installed. may damage the pump. Refer to the Hydraulic
4. Open the battery disconnect switch before arc Checkout Procedure in Section 10 of this man-
welding. Connect the weld ground near the ual.
weld area. 17. Verify that the correct oils and coolant are being
5. DO NOT weld the front uprights until all upper used for the operating conditions. Different cli-
decks are installed. mates require different fluids. The oils and cool-
6. Torque the deck mounting bolts before the ant must be formulated for the correct operating
exhaust tubes, etc. are installed. temperatures. Refer to the lubrication chart
located in the appendix for different temperature
7. Verify all electrical connectors are free from range fluid specifications.
paint and/or corrosion. Clean any connector
that may be questionable.
8. Do not torque the diagonal ROPS beam until
after the operator cab & LH air intake tubes are
in place.
9. Before installing the cab to the substructure, tap
all threaded holes to remove paint.
10. Verify all wiring is properly connected before
attempting to start the engine.
11. Recheck the torque on hardware installed at the
factory.
12. Use blocks for charging the suspension (oil &
nitrogen). Follow the procedures outlined in
Section 10, Appendix.
13. Steering accumulators are normally not charged
with nitrogen when shipped from the factory.
Use proper precautions when checking the
nitrogen pressure and oil level in the cylinder.

NOTES

1. The weight of the chassis, as shipped, is approximately 32,228 kg (71,050 lb). Lift the chassis off the trans-
port using two cranes. The cranes must be a minimum 45 metric ton (50 ton) capacity. Install support blocks
at the front and the rear of the frame to raise the chassis for rear axle installation. The support blocks must be
approximately 76 cm (30 in.) high.
Thoroughly clean all mating surfaces if not done prior.

FIGURE 6-1.
FIGURE 6-2.

FIGURE 6-3.
FIGURE 6-4.

FIGURE 6-5.

2. The weight of the rear axle, as shipped, is approximately 14 288 kg (31,500 lb). Install the rear axle under the
frame. Connect the upper and lower links and the anti-sway bar. Install all pins and keepers. Install the lower
suspension mounting pins and keepers.
Lubricate all pins with clean NLGI No. 2 (5% molybdenum disulfide) grease prior to installation.
The normal shipping arrangement for the chassis will include the three final drive attachment links (1
upper center, two lower sides) already installed to the main frame end. However, if for some reason these
are shipped separately, then they must be identified by part number and length to be certain that they are
installed correctly.
• The length of the center, upper link is 1460 mm (57.5 in.).
• The length of the lower links is 1490 mm (59 in.).
Misalignment of the rear drive shaft and final drive housing will occur if these parts are not installed cor-
rectly.

FIGURE 6-6.
FIGURE 6-7.

FIGURE 6-8.
FIGURE 6-9.

FIGURE 6-10.

3. Lift the rear drive shaft into position between the transmission and the rear axle. The weight of the drive shaft
is approximately 220 kg (485 lb). The male end of the slip shaft mounts on the rear axle. The female end
mounts on the transmission.
Align the yokes on the drive shaft. The yokes must be positioned in the same phase angle.
4. Apply sealant (09940-00030) (or other available thread lock) to cap screws (2). Install the eight cap screws
and tighten to 382 ± 38 N·m (282 ± 28 ft lb).

FIGURE 6-11.

5. When installing the rear axle brake cooling hoses, position the hose fittings at a 45° angle facing inward.
Pointing the hose fitting inward positions the hoses away from the frame to prevent chafing. The RH hose
must be a minimum distance of 105 ± 5 mm (4.1 ± 0.2 in.) from the frame. The LH hose must be a minimum
distance of 80 ± 5 mm (3.2 ± 0.2 in.) from the frame. Verify these measurements after the dump body has
been installed.

FIGURE 6-12.

6. Lift the front suspension/wheel hub assemblies into position on each side of the truck. Each assembly weighs
approximately 3,629 kg (8,000 lb).
Lubricate all pins with clean NLGI No. 2 (5% molybdenum disulfide) grease prior to installation.
Install the suspension pins and keepers, first. Then install the A-arm dust boots, spacers, pins and keepers.
Move the steering cylinders into position and install the dust boots, pins, and keepers.
Finally, move the tie rods into position and install the dust boots, pins and keepers.

FIGURE 6-13.
FIGURE 6-14.

FIGURE 6-15.
FIGURE 6-16.

FIGURE 6-17.
FIGURE 6-18.

7. Thoroughly clean the fuel tank trunnions. Lift the fuel tank into place on the trunnions. The weight of the fuel
tank is approximately 975 kg (2,150 lb). Install the trunnion caps. The chamfer on the trunnion caps faces the
fuel tank. Install the lower mounts. Tighten all cap screws to standard torque.
8. Attach the filter bracket to the rear of the fuel tank.
FIGURE 6-19.

FIGURE 6-20.
FIGURE 6-21.

9. Lift the hydraulic brake cabinet into position. The weight of the cabinet is approximately 343 kg (756 lb). Install
the mounting hardware and tighten to standard torque.

FIGURE 6-22.

10. Lift the RH upright into position. The upright weighs approximately 454 kg (1,000 lb). Secure the upright with
the mounting cap screws. DO NOT weld the upright at this time.
11. Lift the LH upright into position. This upright weighs approximately 374 kg (825 lb). Secure the upright with the
mounting cap screws. DO NOT weld the upright at this time.
FIGURE 6-23.

FIGURE 6-24.
FIGURE 6-25.

12. Lift the air intake tubes into position and install on the engine. The weight of the tubes are approximately 21 kg
(46 lb). Install the intake tube hangers after the decks are installed.

FIGURE 6-26.
FIGURE 6-27.

13. Lift the ROPS support into place. This support weighs approximately 590 kg (1,300 lb). Secure the support
with the mounting cap screws. Weld the support according to the specifications shown if Figure 6-34.
14. Lift the right deck support into place. The support weighs approximately 159 kg (350 lb). Secure the support
with the mounting cap screws. Weld the support according to the specifications shown if Figure 6-35.

FIGURE 6-28.
FIGURE 6-29.

FIGURE 6-30.
FIGURE 6-31.

FIGURE 6-32.
FIGURE 6-33.

FIGURE 6-34. LH DECK SUPPORT WELD SPECIFICATIONS

FIGURE 6-35. RH DECK SUPPORT WELD SPECIFICATIONS

10. Lift the RH deck into position. The weight of the assembly is approximately 1021 kg (2250 lb). Install the
mounting hardware to secure the deck and tighten to standard torque.

FIGURE 6-36.
FIGURE 6-37.

11. Lift the LH deck into position. The weight of the deck is approximately 454 kg (1000 lb). Install the mounting
hardware to secure the deck and tighten to standard torque.
Install the handrails and mirrors onto the deck. These may be installed prior to deck installation.

FIGURE 6-38.
FIGURE 6-39.

12. Lift the operator cab into position on the left deck. The weight of the cab is approximately 2019 kg (4,450 lb).
Install the cab mounting hardware and tighten to 950 N·m (700 ft lb).

FIGURE 6-40.
FIGURE 6-41.

13. Lift the front ladders into position. The weight of each ladder is approximately 45 kg (100 lb). Install the mount-
ing hardware to the ladders and tighten to standard torque.

FIGURE 6-42.
FIGURE 6-43.

14. After installation of the decks and the cab, the uprights can be welded into place. Refer to the welding specifi-
cation in Figure 6-46. To complete the weld, remove the bolt blocks from the bumper and weld the entire
groove as shown in Figure 6-45.
FIGURE 6-44.
FIGURE 6-45.

FIGURE 6-46. UPRIGHT WELDING SPECIFICATIONS

15. Lift the exhaust into position on the engine. Install the clamps the secure the exhaust in place.
FIGURE 6-47.

FIGURE 6-48.
FIGURE 6-49.

16. Remove all dirt, debris and rust from mating parts before installing the wheel.
Grasp the wheel with the tire handler and position the wheel on the wheel hub. Align the notch in the wheel
hub with the rim stopper.
Install the wheel clamps and nuts. Moderately tighten the clamp nuts in the sequence specified in Figure 6-48.
Rotate the wheel, then check that the lateral runout of the rim is within 5 mm (0.20 in.). Adjust the wheel as
necessary.
Continue tightening the nuts to 2210 ± 245 N·m (1630 ± 181 ft lbs) following the proper sequence.
Adjust the tire inflation to the tire manufacturer's recommended pressure.
After the truck is ready for use, operate the truck for one haul cycle and tighten the wheel nuts again. Use the
same torque specifications as previously outlined.
Check the torque daily until the specified torque value listed above is maintained on each nut. Check the
torque intermittently, thereafter.
FIGURE 6-50.

FIGURE 6-51.
FIGURE 6-52. FRONT TIGHTENING SEQUENCE

17. Clean all tire mounting surfaces. Ensure all contact surfaces are free of damage and debris.
Move the tire handler into position and install the inboard tire. Align the notched groove in the wheel hub with
the rim stopper.
NOTE: Use caution when installing the wheel. The air valve is susceptible to damage.
Install the three clamps and nuts that secure the inner wheel. Tighten the nuts to 2210 ± 245 N·m (1630 ± 181
ft lbs).
Install the spacer between the dual wheels. Use the tire handler or other lifting device to lift the spacer. The
weight of the spacer is approximately 93 kg (205 lb).
Move the tire handler into position and install the outboard wheel. Align the notched groove in the wheel hub
with the rim stopper.Use caution when installing the wheel. The air valve is susceptible to damage.
Install the wedge ring. Position the wedge ring so that the protrusion of the ring from the cover surface is
equal around the entire circumference. Install the wheel clamps and nuts. Only tighten the nuts enough to pre-
vent the tire/rim assembly from moving.
Install the air valve lock plate.
Lower the truck to the ground.
Tighten the clamp nuts to 2210 ± 245 N·m (1630 ± 181 ft lbs). Use the sequence shown in Figure 6-54 to
tighten the clamps.
Rotate the wheel and verify the lateral runout of the rim is within 5 mm. (0.20 in.)
After assembly of the truck is complete, drive approximately 5 - 6 km (3 - 4 miles) to seat the wheels. Then
tighten the clamp nuts again to the specifications listed earlier in this procedure. Check the torque periodically
until the specified torque is maintained.
FIGURE 6-53.

FIGURE 6-54.
FIGURE 6-55.

FIGURE 6-56.
FIGURE 6-57.

FIGURE 6-58. REAR TIGHTENING SEQUENCE

18. Complete all hydraulic piping, electrical wiring, mechanical connections, and clamping.

FIGURE 6-59. BATTERY DISCONNECT
FIGURE 6-60. FRONT WHEEL / BRAKE

FIGURE 6-61. FRONT WHEEL LINKAGE

FIGURE 6-62. FRONT BRAKE
FIGURE 6-63. REAR AXLE

FIGURE 6-64.
FIGURE 6-65.

FIGURE 6-66. REAR DRIVE SHAFT
FIGURE 6-67.

FIGURE 6-68.
FIGURE 6-69.

FIGURE 6-70.
FIGURE 6-71.

FIGURE 6-72.
FIGURE 6-73.

FIGURE 6-74.
FIGURE 6-75.

FIGURE 6-76.
FIGURE 6-77.

FIGURE 6-78.
FIGURE 6-79.

19. Install remaining ladders.
FIGURE 6-80.
20. Install the dump body. Refer to Sections 7 & 8 for dump body assembly and installation. After the body is
installed, all remaining body accessories, mud flaps and covers may be installed.

DUMP BODY ASSEMBLY
GENERAL INFORMATION If the body is being welded in a cold climate, it is

advisable to move the parts to be welded into an
enclosed shop area. Surfaces to be welded must be
dry and the temperature must be above 10°C (50°F).
If shop space is not available, it may be necessary to
provide a portable enclosure and pre-heat the parts
The total weight of the body is approximately prior to welding.
20,000 kg (44,082 lb). Use two cranes for assem- In most instances, it is easier to assemble and weld
bling the body. A 45 metric ton (50 ton) crane and the body while the sections are upside down. After
a 109-136 metric tons (120-150 ton) crane are the pivot, guide pin, and body pads are welded in
required. The larger crane is needed to help turn place, the body can be turned over and the remain-
the body over after completion of the underside der of the assembly can be completed.
welding.
All paint must be removed from surfaces to be
Assembly of the body must be performed on flat ter- welded. Use a wire brush or paint removal equip-
rain with an adequate area for welding machines and ment.
for maneuvering lifting equipment. Refer to the assembly blueprints shipped with the
truck for specific welding details and the parts
required for assembly.
Body sections must be assembled as originally

manufactured. Match the shipping numbers sten-
ciled on the body sections to mate the correct
parts. DO NOT mix components.
FIGURE 7-1. BODY PARTS NOMENCLATURE

1. Canopy 4. Lift Hole 7. LH Side Sheet
2. Front Sheet 5. Floor
3. RH Side Sheet 6. Pivot
FAM0704 Dump Body Assembly 7-1

BODY ASSEMBLY
NOTE: References to LH and RH in the following

procedures assume the body is in its' normal, upright
position, as shown in Figure 7-1.
1. Organize the body sections in a large, flat,
open space. Position the sections side by side
and upside down. Arrange the sections so they
are properly oriented for assembly. Refer to
Figure 7-2 for domestic configuration, and 7-3
for international configuration.
FIGURE 7-4.
5. Use the hydraulic jack to align the body halves
at the rear. Install cap screw (1, Figure 7-5) and
the sleeve.
NOTE: Figure 7-5 shows the hardware numbered in
installation sequence. Cap screws (1, 2 & 7) are
marked with an asterisk (*). These cap screws are
installed with sleeves. The remainder of the cap
screws do not have sleeves.
6. Install cap screw (2) and the sleeve at the front
FIGURE 7-2. DOMESTIC LAYOUT of the floor.
7. Install cap screw (3) in the front sheet near the
floor. Attach a wedge or a clamp inside the
body as necessary to align the front sheet.
8. Use a wedge to align the front sheet and can-
opy. Install cap screws (4, 5 & 6).
9. Install cap screw (7) and the sleeve in the front
of the canopy.
10. Install cap screws (8 & 9).
11. Install the backer strips on the front sheet center
joint as shown on the assembly blueprint.
NOTE: The backer strips must be tack welded in a
location where the tack will be burned away on the
FIGURE 7-3. INTERNATIONAL LAYOUT first pass.
12. Loosely install cap screws (10 & 11) in the floor.
13. Loosen cap screws (1 & 2).
2. Remove the paint from the weld areas. 14. Attach appropriate lifting apparatus to the body
3. Lift the RH body half and support the front pivot. Insert the lifting apparatus through the
sheet, side sheets, and rear edge of the floor body pin bores. The weight of the pivot is
with blocks. Refer to Figure 7-4. approximately 1317 kg (2904 lb). DO NOT dam-
4. Lift the LH body and support with blocks under age the bores.
the front sheet and side sheet. Position a 15. Lift the pivot over the body. Lower the pivot into
hydraulic jack on blocks at the tail end to sup- position against the rear of the body, as shown
port the floor at the rear. Refer to Figure 7-5. in Figure 7-6. Align the pivot with the body sills.
7-2 Dump Body Assembly FAM0704

NOTE: Figures 7-5 & 7-6 illustrate a domestic configuration with the canopy attached to the body halves. The
canopy for international bodies is shipped as a separate piece. Do not attach the international canopy at this
time
FIGURE 7-5. BODY ASSEMBLY HARDWARE INSTALLATION SEQUENCE
FIGURE 7-6. BODY PIVOT INSTALLATION

16. If necessary, use a hydraulic jack or crane to BODY WELDING
raise the center of the body to allow the pivot to
fit inside the bolsters. Loosely install the cap Follow the guidelines listed below when welding the
screws in the pivot. body:
17. If assembling an international body (three- • Use dry weld rod or weld wire.
piece), lift the canopy into position at this time.
• Weld surfaces must be dry and above 10°C
Install the canopy cap screws and tighten.
(50°F).
18. Tighten all floor, front sheet, and canopy cap
• If stick electrode is used, use as large a diameter
screws. Use a chalk line to align the front of the rod as practical to weld the floor and front sheet
canopy. joints.
19. Tighten the pivot cap screws. • The following sequence must be followed for the
20. Install the filler plates and backer strips for the front sheet:
pivot to body sill weld joints. First Pass: Back step and skip weld in 10
21. Check the alignment and fit of all components increments along the entire length of the joint.
Refer to Figure 7-7.
22. Tack weld the joints.
Repeat the same procedure until the entire joint
is filled. DO NOT stop welding until entire joint is
complete.
• The body floor “V” groove must also be welded
using the same procedure as the front sheet.
Weld from the front to the rear. Refer to Figure 7-
7.
FIGURE 7-7. FRONT SHEET & FLOOR JOINT

WELDING SEQUENCE
1. Complete the welds at the center seam, the

front sheet and the canopy. Refer to the assem-
bly blueprints for welding requirements.
2. Remove the canopy alignment blocks.

3. Install the remaining gussets, the body guide
and the body pad mounts.
DO NOT install the heated body exhaust boxes

onto the body at this time. The exhaust boxes
must be installed after the body is installed onto
the truck.
4. Once the body underside is completed, the

body can be turned over. Use two cranes to
invert the body, a 45 metric ton (50 ton) crane
and a 109-136 metric ton (120-150 ton) crane.
Position the body onto support blocks as shown
in Figure 7-14.
FIGURE 7-9.
The following photographs show a typical exam-

ple of a body being inverted with two cranes. The
pictures were taken from a different model truck
and are only used as a reference.
FIGURE 7-10.
FIGURE 7-8.

FIGURE 7-11. FIGURE 7-13.
FIGURE 7-12.
FIGURE 7-14.

5. Refer to Figure 7-7 and the body assembly 6. Install any remaining components as specified
print to complete the welds on the inside of the on the installation blueprints.
body. 7. Install any optional equipment such as body lin-
ers and side boards.
8. Clean the weld joints and paint.
FIGURE 7-15.
FIGURE 7-16.

NOTES

DUMP BODY INSTALLATION
• Inspect all lifting devices. Slings, chains, and 1. Attach appropriate lifting cables and a hoist of
cables used for lifting components must be to the dump body. A typical body, as shown in
inspected daily for serviceable condition. Figure 8-1, weighs approximately 20,000 kg
Refer to the manufacturer’s guidelines for (44,082 lb). Lift the body and lower into position
correct capacities and safety procedures over the truck frame. Align the body pivot and
when lifting components. Replace any frame pivot holes.
questionable items.
2. Install shims (2 & 3, Figure 8-2) in both body
• Slings, chains and cables used for lifting pivots as required to fill the gaps. Center the
must be rated for approximately two times the body on the frame pivot. A minimum of one
intended load.
shim is required at the outside end of both
• When in doubt as to the weight of frame pivots.
components or any assembly procedure,
contact your customer support manager for
further information.
• Lifting eyes and hooks must be fabricated
from the proper materials and rated to lift the
intended load.
• Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
• Before lifting the body, ensure there is
adequate clearance between the body and
overhead structures or electric power lines.
• Use a lifting device that is rated for at least a
25 ton capacity.
FIGURE 8-2. DUMP BODY PIVOT PIN

(Section B-B, Figure 8-4)
1. Body Pivot Pin 4. Pivot Bushing

2. Shim/Spacer 5. Cap Screw
3. Shim/Spacer 6. Lock Nut
3. Lift the pivot pin into position and align the pin
retainer cap screw hole. The weight of the pin is
approximately 49 kg (108 lb). Push pivot pin (1)
through the shim(s) and into the pivot bushings
in each side of the frame.
4. Install cap screw (5) through each pin. Install
FIGURE 8-1. DUMP BODY REMOVAL nut (6) and tighten.
1. Lifting Cables 2. Guide Rope
FAM0813 Dump Body Installation 8-1

7. Remove the shipping plates from the hoist cyl-
inder ports, and reinstall the hoses onto the
ports. New hardware is provided to install the
hoses without the plates.
Failure to remove the shipping plates from the

hoist cylinder hose ports may result in hose fail-
ure, personal injury, or death. Remove the plates
and reinstall the hoses before operating the
dump body. The shipping plates are installed
during factory assembly to prevent inadvertent
cylinder extension.
FIGURE 8-3. HOIST CYLINDER UPPER MOUNT

1. Retainer 4. Retainer Ring
2. Cap screw & Washer 5. Bearing
3. Pin 6. Hoist Cylinder
5. Align the hoist cylinder upper mounting eye

between the mounting ears. Align the retainer
slot in pin (3, Figure 8-3) with retainer (1). Install
the pin.
6. Install pin retainer (1) and cap screws (2). Posi-
tion the retainer to obtain 0.5 mm (0.020 in)
clearance between the retainer and the bottom
of the slot in body pin (3). Tighten the cap
screws to standard torque. Repeat for the FIGURE 8-4. SHIPPING PLATE REMOVAL
remaining cylinder.
1. Shipping Plate 2. Hoses
8. Install the mud flaps, electrical cables and lubri-

cation hoses.
9. Install the rock ejectors. Refer to Rock Ejectors
in this chapter for installation information.
8-2 Dump Body Installation FAM0813

FIGURE 8-5. BODY COMPONENT LOCATIONS
1. Dump Body View A-A. Rock Ejector (See Figure 8-8)
2. Body-Up Retention (Safety) Cable View B-B. Body Pivot Pin (See Figure 8-2)
View C-C. Body Guide (See Figure 8-7)
View D-D. Body Pads (See Figure 8-6)
BODY PADS
Inspect the body pads during scheduled mainte-
nance inspections. Replace if damaged or worn,
excessively.
1. Raise the body to a height sufficient to allow
access to all body pad mounts.
Place blocks between the body and the frame.

Secure the blocks in place.
2. Remove the hardware attaching the pads to the
dump body. Refer to Figure 8-6.
3. Install the body pads and shims, noting the
quantity of shims required at each pad. The rear
pads have one less shim than the other pads. FIGURE 8-6. BODY PAD INSTALLATION
4. Install the mounting hardware and tighten. 1. Nut 6. Mounting Pad
5. Remove the blocks from between the body and 2. Lock Washer 7. Shims (as required)
the frame. Lower the body onto the frame. 3. Cap Screw 8. Body Pad
4. Flat Washer 9. Main Frame
5. Dump Body

Body Pad Adjustment BODY GUIDES
NOTE: The truck must be parked on a flat, level Install the body guides as shown in Figure 8-7.
surface for this adjustment. Inspect body guide wear plugs (2, Figure 8-7) each
1. All pads, except the rear pads, should contact time a body pad inspection is performed. If the gap
the frame with approximately equal compres- becomes excessive, replacement parts must be
sion of the rubber. installed.
2. A gap of approximately 1.5 mm (0.06 in.) is
required at each rear pad. This can be obtained
by using one less shim at each rear pad.
3. If pad contact appears to be unequal, repeat the
above procedure.
Proper body pad to frame contact is required to

ensure maximum pad life.
FIGURE 8-7. BODY GUIDE

1. Body Guide 3. Body Rail
2. Body Guide Wear Plug 4. Main Frame

BODY-UP RETENTION CABLE ROCK EJECTORS
Rock ejectors are placed between the rear dual
wheels to keep rocks and other material from lodging
between the tires. Failure to maintain the rock ejec-
tors could result in a build up of debris between the
dual wheels. Debris build up may lead to tire dam-
When performing maintenance on the vehicle age.
with the dump body raised, the body-up retention
cable must be installed. Inspection
1. The ejectors must be positioned on the center
line between the rear tires within 5 mm (0.20
To install the cable: in.).
1. Raise the body to it's maximum height. Refer to 2. With the truck parked on a level surface, the
Figure 8-5. arm (refer to Figure 8-8) must be approximately
2. Remove cable (2) from its stored position on the 109 mm (4.3 in.) from the wheel spacer ring.
body. Connect the cable between dump body NOTE: With rock ejector arm (1, Figure 8-8) hanging
(1) and the axle housing ear. vertical as shown in Figure 8-8, there must not be
3. Secure the cable clevis pins with cotter pins. any gap between the arm and the stop on bracket
4. Allow the body to lower until supported by the (2).
cable. 3. If arm (1) is bent, remove the arm and
5. After maintenance is complete, reverse the straighten.
above procedure to remove the cable assembly 4. Replace wear plates that are severely worn.
and place it in the storage position. 5. Inspect brackets (2) and pins (3) at each shift
change for wear and damage. Repair as neces-
sary.
FIGURE 8-8. ROCK EJECTORS

1. Rock Ejector Arm 4. Washer
2. Rock Ejector Bracket 5. Cotter Pin
3. Pin

HEATED BODY EXHAUST BOX
The standard body on HD1500 trucks utilizes a
heated body design. Engine exhaust flows through
the exhaust piping and enters dump body (1, Figure
8-9) through exhaust coupling (3). From the box,
exhaust flows into the front sheet to warm the body
and its contents. Exhaust exits the body through the
side panels. When the body is raised, the connection
to the body is broken. Exhaust is vented to the atmo-
sphere at exhaust tube (4).
The exhaust coupling is mounted on exhaust box (2).
The adjustment of the exhaust coupling is extremely
important in ensuring that no exhaust leakage occurs
at the coupling-to-exhaust tube joint. The coupling
contains a spring mechanism that maintains suffi-
cient force to create a seal between the tubing and
the exhaust coupling when the body is lowered. If the
exhaust box or the coupling is not properly installed,
exhaust leakage will occur.
FIGURE 8-9. BODY HEATED EXHAUST COUPLING
Because of the many tolerances in the body assem-
1. Dump Body 3. Exhaust Coupling
bly and installation, it is not possible to attach the
2. Exhaust Box 4. Exhaust Tube
exhaust box to the body before installing the body
onto the chassis. The dump body, body guides, and
body pads must be properly installed and adjusted
before welding the exhaust box to the body.
The details and specifications for installing the
exhaust box are located on the installation prints sup-
plied at machine shipment. Follow the exact instruc-
tions on the prints to ensure proper installation,
operation, and component durability.

BODY POSITION SWITCHES
Two magnetically activated proximity switches sense Inside the body limit switch, there are two magnets of
the position of the truck dump body. The body-up slightly varying strengths in line with one another.
switch (5, Figure 8-12) is located inside the left frame The magnets are located on separate ends of a
rail, forward of the body pivot. This switch provides a rocker lever assembly which contains the functional
"body seated" signal to the transmission controller switch contacts. In the non-actuated or rest state, in
when the body is resting on the frame. When the which there is no disturbance in the internal switch
body is raised above the frame rail (magnetic field natural magnetic fields, the stronger magnet domi-
removed from the switch sensing area), the switch nates the rocker into the “normal” position. Refer to
sends a "body float" signal to the transmission con- Figure 8-10.
troller. A warning lamp on the instrument panel left When the field of the dominate magnet becomes dis-
pod illuminates to inform the operator. tracted by a target, (a ferrous plate, or an opposite
NOTE: The body float lamp will also illuminate if the polarity magnet field (south pole)), the weaker mag-
hoist control is not in the FLOAT position or if there is net in the switch will then become more dominate
an open circuit between the switch and the and move the rocker lever. The switch is then consid-
transmission controller. ered to be actuated or in the “sensed” position.
Hoist limit switch (9) is located on the left frame rail
just behind the pivot. The hoist limit switch sends a
signal to the hoist limit solenoid (in the hydraulic cab-
inet), which activates and blocks oil flow from the
hoist pilot valve to the hoist valve. The “power up” oil
supply is blocked to prevent full hoist cylinder exten-
sion, and possible damage to the cylinders. Proper
switch adjustment insures the hoist cylinder travel
stops slightly before full extension.
If either the body up switch or the hoist limit switch do
not function as described above, adjust the switches
according to the procedure on the following pages.
Proximity Switch Operation

The body position switches on these trucks are mag-
netic field change operation switches. The switches
can sense a ferrous material target, as well as a spe-
cific pole (south pole) magnet field. When a switch is
activated by ferrous material, the maximum sensing
distance is approximately 13 mm (0.5 in.). When a
magnet is used instead of ferrous material, maximum
sensing distance is approximately 95 mm (3.75 in.).
Therefore, use of a magnet target allows the switch
to activate at greater sensing distances.
FIGURE 8-10. SWITCH CONTACTS - NORMAL

AND SENSED POSITIONS

Body-Up Switch Adjustment
Figure 8-12 shows two views of the body-up switch 2. If necessary, loosen the cap screws securing
(5) and the magnet used to activate the switch. the proximity switch to the mounting bracket
and slide the switch in or out until the passing
If switch adjustment is necessary, follow the proce- distance between the two targets is 45 mm
dure below: (1.77 in). Tighten the cap screws after adjust-
1. With the body resting completely on the frame, ing. Refer to Figure 8-11 for an illustration of
loosen the switch mounting cap screws (6) and/ optimum setting of the switch.
or the magnet adjustment cap screws (3). 3. Lower the body onto the frame.
2. Position the lower edge of the magnet near the 4. Check operation of the switch to verify that the
upper edge of proximity switch (5) as shown in hoist cylinders extend, but stop before reaching
view A-A. maximum cylinder stroke. If the cylinders
3. Adjust the proximity switch so the passing dis- extend full stroke, adjust the switch, as neces-
tance between the two targets is 15 mm (0.59 sary, to prevent full extension.
in). Tighten cap screws (6) and recheck vertical
adjustment. If necessary, readjust and tighten
cap screws (3).
Hoist Limit Switch Adjustment

Prior to adjustment, the body must be raised to maxi-
mum hoist cylinder extension and supported.
1. With the body fully raised, loosen the proximity
switch adjustment cap screws (8, Figure 8-12),
and slide the switch up or down to position the
top of the switch 25 mm (1 in.) away from the
lower edge of magnet (10). Tighten the cap
screws when adjusted properly.
NOTE: Since a magnetic target is used to activate
the switch, a larger initial distance in setting the
switch is required. This is due to the fact that
magnetic fields are not crisp 90 degree boxed fields
but are instead curved about the shape of the
magnet. The sensing field boundary limit takes on
the same curved sensing area shape of the magnet
field. The curved sensing area results in the
actuation of the switch approximately 25 mm (1 in.)
prior to reaching the edge of the magnet. Therefore,
it is crucial that the 25 mm (1 in.) is observed when
setting the body limit switch.
FIGURE 8-11. HOIST LIMIT SWITCH

OPTIMUM SETTING

FIGURE 8-12. BODY-UP AND HOIST LIMIT SWITCHES
1. Body - Raised Position 6. Switch Mounting Cap Screws
2. Body - Resting on Frame 7. Mounting Bracket (On Frame)
3. Magnet Adjustment Cap Screws 8. Switch Mounting Cap Screws
4. Magnet 9. Proximity Switch (Body Limit)
5. Proximity Switch (Body-Up) 10. Magnet (Body Limit Switch)

NOTES

FINAL CHECKOUT
Final checkout requires truck operation. 4. Purge trapped air from the pumps. Pressure will
not build if air is present. Operating the pumps
Place the operation and maintenance manual and
with air in the system will result in damage.
safety manuals in the operator cab, if not already
there. 5. Perform a final check of all systems. Several
checks are outlined in Section 10, Appendix.
Any personnel involved in the final check-out of the
6. Complete the checks listed in the Field Assem-
truck must read and understand all safety and oper-
bly Inspection Report Form. A copy of the form
ating instructions in the operation and maintenance
is provided with the truck and is also available in
manual.
Section 10, Appendix.
7. Operate the truck in a traffic-free area until safe
1. Complete delivery and warranty forms. operation has been validated.
2. Check the coolant and all lubricants for proper 8. Release the truck for use after all checks have
levels and specifications. Verify that the correct been completed and all deficiencies corrected.
oils and coolant are being used for the operat-
ing conditions. Different climates require differ-
ent fluids. The oils and coolant must be
formulated for the correct operating tempera-
tures. Refer to the lubrication chart located in
Section 10, Appendix for different temperature
range fluid specifications.
3. Verify the shut-off valves in the hydraulic cabi-
net are open.
FAM0906 Final Checkout 9-1

9-2 Final Checkout FAM0906
APPENDIX
This chapter contains additional information and procedures for aiding in field assembly of the truck. Refer to the
list below for contents of this chapter. Refer to the latest service manual for additional information on servicing the
truck.
1. Lubrication Chart - EM4499
2. Suspension Oiling And Charging Procedure
3. Toe In Adjustment Procedure
4. Automatic Lubrication System Checkout Procedure
5. Air Conditioning Checkout Procedure - EL4302
6. Air Conditioning Drive Belt Adjustment Procedure - EL9330
7. Hydraulic Checkout Procedure - EM7619
8. Brake Checkout Procedure - EL5358
9. Electrical Checkout Procedure - EM1710
10. VHMS Setup Procedure - EM1711
11. VHMS Checkout Procedure - EM2129
12. Standard Tables
13. Field Assembly Inspection Report - CEAW003506
14. 50 Hour Post-Commissioning Checksheet - CEAW004301
FAM1009 Appendix 10-1

NOTES
10-2 Appendix FAM1009

NOTES
SUSPENSION OILING AND CHARGING
GENERAL INFORMATION Equipment List
These procedures detail the oiling and charging of 1. Service Kits:

the front and rear suspensions. Suspensions which a. EC6027 Oil Charging Kit (Figure 4-5)
have been properly charged will provide improved
b. EC3331Nitrogen Charging Kit (Figure 4-6)
handling and a better ride while improving the service
life of the suspensions, the truck main frame, and 2. Jacks and/or overhead crane
other main components. 3. Two oiling spacers: height - 95 mm (3.7 in.)
NOTE: Inflation pressures and oiling/charging 4. Jacks and/or overhead crane
dimensions are calculated for original truck Gross 5. Spacers (two) for oiling height; 95 mm (3.7 in.)
Vehicle Weight (GVW). Any accumulation of dirt/ 6. Oil - Refer to Tables 1 & 2
mud/debris on the truck or in the body must be
7. Dry nitrogen - Refer to Table 3
removed before starting these procedures. Additions
to the truck weight (tailgates, water tanks, etc.) must
be considered part of the payload. Keeping the truck
GVW within the specification will result in a better
ride and will extend the service life of the truck main
frame and suspensions.
Proper charging of suspensions requires three basic All suspensions are charged with compressed
conditions be established in the following order: nitrogen gas with sufficient pressure to cause
1. The oil level must be correct. injury or damage if improperly handled. Follow
all safety notes, cautions, and warnings in these
2. The suspension piston rod extension for nitro- procedures to prevent accidents during servicing
gen charging must be correct, and this dimen- and charging.
sion maintained during nitrogen charging.
3. Nitrogen charging pressure must be correct.
For best results, suspensions must be charged in
pairs (fronts together and rears together).
NOTE: Setup dimensions specified in the charts
must be maintained during oiling and charging
procedures. However, after the truck has been
operated, these dimensions will change.
It is extremely important to properly maintain oil

and nitrogen levels on the suspension cylinders.
The oil is not only used to provide dampening,
but also to lubricate internal parts. If an oil leak is
present, it must be repaired, immediately. Excess
nitrogen charging will not compensate for an oil
leak. The lack of oil will cause excess friction in
the cylinder leading to suspension cylinder fail-
ure.
Oiling and Charging Procedures 1

TABLE 1. APPROVED SUSPENSION OILS AND FRICTION MODIFIER
Part Number Description Comments
VJ3911 Komatsu Suspension Oil - 19 liter (5 gal) container Add 6% friction modifier. See Table 2.
AK4063 Komatsu Suspension Oil - 19 liter (5 gal) container Already mixed with 6% friction modifier
AK4064 Komatsu Suspension Oil - 208 liter (55 gal) container Already mixed with 6% friction modifier
Not Available Mobil 424 Add 6% friction modifier. See Table 2.
Not Available Mobil DTE 15 Add 6% friction modifier. See Table 2.
Not Available Texaco TDH Oil Add 6% friction modifier. See Table 2.
Not Available Amoco Ultimate Motor Oil 5W-30 Add 6% friction modifier. See Table 2.
Not Available Sunfleet TH Universal Tractor Fluid Add 6% friction modifier. See Table 2.
Not Available Chevron Tractor Hydraulic Fluid Add 6% friction modifier. See Table 2.
Not Available Conoco Power Tran III Fluid Add 6% friction modifier. See Table 2.
Not Available Shell Donax TDL Add 6% friction modifier. See Table 2.
Not Available Citgo Transgard Tractor Hydraulic Fluid Add 6% friction modifier. See Table 2.
Not Available Duratran Fluid - Petro Add 6% friction modifier. See Table 2.
AK3761 100 % friction modifier - 19 liter (5 gal) container Mix with suspension oil. See Table 2.
TABLE 2 SUSPENSION OIL / FRICTION MODIFIER MIXING RATIO

Proper Ratio = 94% Suspension Oil : 6% Friction Modifier
Suspension Oil Quantity Friction Modifier Quantity
3.8 liter (1 gal) of suspension oil 237 ml (8 oz)
19 liter (5 gal) of suspension oil 1 liter (38 oz)
208 liter (55 gal) of suspension oil 11.4 liter (3 gal)
The following oils may be used as alternatives to those listed in Table 1. DO NOT mix these oils with friction modi-
fier.
• HO-MVK (Koma-Hydro MV)
• Shell Tellus T32
• Shell Tellus 46
• Castrol Hyspin AWS 46
TABLE 3. NITROGEN GAS SPECIFICATIONS

PROPERTY VALUE
Nitrogen 99.9% minimum
Nitrogen gas used in suspension cylinders must meet or Water 32 ppm maximum
exceed CGA Specification G-10.1 for Type 1, Grade F
Nitrogen Gas. Dew Point -55°C(-68°F) maximum
Oxygen 0.1% maximum
2 Oiling and Charging Procedures

FRONT SUSPENSION Front Suspension Oiling
1. Park the unloaded truck on a hard, level sur-
face. Apply the parking brake, and block the
wheels.
2. Verify that the bottom of each cylinder cover is
Lifting equipment (crane or hydraulic jacks) must
within the range designated by the arrows (Fig-
be capable of lifting the weight of the truck.
ure 4-1) signifying correct nitrogen charge.
Ensure that all personnel are clear of the lift area
3. If each suspension is within the area indicated before the lift is started.
by the arrows, no service is necessary for the
front suspensions. See the note below for
guidelines. If a suspension is not within the area
indicated by the arrows, the front suspensions
will have to be serviced.
NOTE: The oil level must be checked:
A common mistake when adjusting the oiling
• Before charging or adding nitrogen. height is the failure to recognize and/or properly
• When there are signs of oil leakage. react to oil that contains trapped nitrogen or
"foamy oil". Oil, such as this, is common when
• After rebuild/repair and the suspension is
installed on the truck the truck has recently been operating and the
suspension oil and gas haven’t been allowed to
. settle and separate. This condition needs to be
handled properly to ensure that the suspension
receives the proper amount of oil. Failure to do
so may cause a low oil level resulting in prema-
ture component wear. Premature bearing and
seal wear can, in many cases, be attributed to
this occurrence.
If the truck has been operating, allow three to
four hours for the oil and nitrogen gas to sepa-
rate. An alternative is to purge the foamy oil and
replace with new oil. The wrong oiling height will
be observed if the oil level is checked/adjusted
with foamy oil or with air bubbles present.
FIGURE 4-1. FRONT SUSPENSION HEIGHT
Oil Quantity (approximate): 62.4 Liters (16.5 Gallons)
NOTE: DO NOT fill the suspension cylinder with oil

based on quantity alone. Oil quantities are given as
reference, only. Fill/adjust the oil level in the front
suspension to the oiling height listed in Figure 4-3.

1. Park the unloaded truck on a hard, level sur-
face. Apply the parking brake, and block the
wheels.
2. Remove the outside suspension covers and
thoroughly clean the area around charging
valves (3, Figure 4-2).
3. Place a hydraulic jack (1, Figure 4-3) under the
main frame, and raise the jack until it contacts
the frame. The jack must be rated for a mini-
mum of 50 tons.
4. While wearing a face mask or goggles, dis-
charge the nitrogen pressure from the suspen-
sion by loosening pressure sensor valve
assembly (2, Figure 4-4) one revolution. DO
NOT exceed one revolution. Nitrogen pressure
cannot be released by loosening the pressure
sensor, itself. The schrader valve in the valve
assembly (2) will prevent nitrogen from being FIGURE 4-2. VALVE AND SENSOR LOCATION
released.
1. Air Bleed Valve 3. Charging Valve
2. Pressure Sensor
Releasing the nitrogen gas from the valve core of

charging valve (3, Figure 4-2) will damage the
valve core. Release the gas by loosening air
bleed valve (1, Figure 4-2) or sensor valve assem-
bly (2, Figure 4-4).
Loosening the pressure sensor valve assembly

more than three revolutions may result in the
component being forced out of the suspension
by the gas pressure inside. This can cause seri-
ous bodily injury. DO NOT exceed one revolution.
Wear a face mask or goggles while relieving
nitrogen pressure.
NOTE: If oil is discharged with the gas, tighten the
pressure sensor valve assembly slightly so only the FIGURE 4-3. OIL HEIGHT
gas will be discharged. If this is not possible, the
foamy oil will need to be purged from the suspension 1. Jack (50 ton min.) A: 97 ± 3 mm
during the oiling procedure, prior to charging. 2. Frame (3.8 ± 0.12 in.)

5. Adjust the hydraulic jack (1, Figure 4-3) so that
dimension "A" of the cylinder is 97 ±3 mm (3.8 ±
0.12 in.).
6. After all nitrogen pressure has been relieved,
tighten valve assembly (2, FIgure 4-4).
FIGURE 4-4. PRESSURE SENSOR

1. Schrader Valve 3. Sensor
2. Valve Assembly
FIGURE 4-5. OIL CHARGING KIT (EC6027)
1. Hose 6. Pressure Sensor

2. Connector 7. Air Bleed Valve
3. Adapter 8. Air Bleed Hole
7. Remove charging valve (5, Figure 4-5), and 4. Fitting 9. Oil Pump Lever
install fitting (4). 5. Charging Valve 10. Oil Pump
8. Install adapter (3) to fitting (4), then connect the
hose and oil pump.
NOTE: Pressure sensor (6) must be installed, and
the air bleed valve (7) must be loose to ensure there
are no air pockets inside the suspension. Use caution when tightening the valves and fit-
9. Loosen air bleed valve (7), then pump oil into tings on the suspensions. DO NOT overtighten.
the cylinder until no air bubbles or foamy oil is Overtightening can damage the fittings or the
discharged from air bleed valve hole (8). suspension housing resulting in gas and oil
leaks. Tighten to the specified torque.
10. When no more air bubbles or foamy oil is dis-

charged, tighten air bleed valve (7) to 44 ± 5
N·m (33 ± 3 ft lbs).
11. Remove pressure sensor valve assembly (6),
then operate the oil pump until no air bubbles or
foamy oil is discharged from the plug hole.
12. After all air and/or foamy oil is discharged,
install and tighten the pressure sensor valve
assembly to 44 ± 5 N·m (33 ± 3 ft lbs).
13. After filling with oil, remove the oil pump and fit-
tings, then install charging valve (5) and tighten
the valve to 44 ± 5 N·m (33 ± 3 ft lbs).

Front Suspension Nitrogen Charging
6. When the left and right cylinders reach the
specified length as shown in Figure 4-7, close
valve (4, Figure 4-6) to stop the flow of nitrogen
gas. Turn the handle of regulator (11) counter-
clockwise to close the valve.
Dry nitrogen is the only gas approved for use in
the suspensions. Charging the suspensions with
oxygen or other gases may result in an explosion
which could cause serious injuries, fatalities,
and/or major property damage. Refer to Nitrogen
Gas Specifications at the beginning of this chap-
ter.
1. Remove the caps from charging valves (3, Fig-

ure 4-2).
NOTE: Before installing regulator (11, Figure 4-6,

blow out the cylinder connector with nitrogen gas,
965 kPa (140 psi) or more, to clean out all dirt or
dust. Dirt or dust in the system can cause
suspension failures.
2. Connect the regulator to the nitrogen cylinder.

Open the valve on the gas cylinder, and check
the pressure reading on regulator gauge (1).
NOTE: The internal pressure of the gas cylinder must

be substantially higher than the suspension charging
pressure (refer to the chart in Figure 4-7).
FIGURE 4-6. NITROGEN CHARGING KIT

3. Install the nitrogen charging kit to the suspen- (EC3331)
sions, as shown in Figure 4-6.
4. Slowly turn the handle of regulator (11) clock- 1. Nitrogen Cylinder Gauge
wise. Adjust the pressure, shown on gauge (2), 2. Charging System Gauge
to the required charging pressure (refer to the 3. Manifold Outlet Valves (from gauge)
chart in Figure 4-7). Then, open valves (3 & 4, 4. Inlet Valve (from regulator)
Figure 4-6) to fill the suspension cylinders with 5. Connection Valve w/EC2253 Adapter Installed
nitrogen gas. 6. Valve "T" Handle
7. Pressure Sensor/Schrader Valve
5. Fill the left and right cylinders at the same time.
8. Air Bleed Valve
Verify the required charging pressure on gauge
9. Manifold
(10) by closing valve (4).
10. Charging Pressure Gauge (Suspensions)
11. Regulator Valve (Nitrogen Pressure)
12. Dry Nitrogen Gas
(see Nitrogen Gas Specifications at the begin-
ning of this chapter)
NOTE: Parts may vary from the illustration above
depending on the charging kit part number.

7. Turn handle (6) on valve adapter (5) fully coun- Dimension "A" is measured from the top of the cover
terclockwise to close the charging valve. Then, to the top of the suspension cylinder plate. DO NOT
remove the charging equipment, the hydraulic include the capscrews in the measurement. The
jack, and install the suspension covers. removal of an access panel on the top cover is
8. Use soapy water to check the charging valve, required.
the air bleed valve and the pressure sensor fit-
tings for leaks. Repair as necessary.
NOTE: Setup dimensions specified in the charts
9. Install the caps and O-rings onto charging
must be maintained during oiling and charging proce-
valves (3, Figure 4-2).
dures. However, after the truck has been operated,
these dimensions may vary. After charging the sus-
pensions, operate the empty truck over a short
course and then park the truck on a level surface.
Record the dimensions again and save for periodic
reference.
FIGURE 4-7. FRONT SUSPENSION
DIMENSION CHARGING CHARGING

HEIGHT PRESSURE
FRONT "A" 287 ± 10 mm (11.3 2758 kPa

± 0.4 in.) (400 psi)

REAR SUSPENSION Rear Suspension Oiling
1. Check whether dimension "A" (Figure 4-11) on
each suspension cylinder is within the specified
GENERAL INFORMATION value listed in Table 4. If dimension “A” is within
specifications, no service is necessary for the
If the rear suspension is being filled with oil while rear suspensions. If a suspension is not within
installed on the truck, the angle in which the rear sus- the area indicated by the arrows, the front sus-
pension is positioned coupled with the location of the pensions must be serviced. Continue with this
charging valve port results in a significantly large vol- procedure.
ume of air being trapped inside the suspension. This
has the effect of lowering the oiling height since the NOTE: The oil level must be checked;
rear suspension can not be filled with the correct • Before charging or adding nitrogen.
amount of oil. To compensate for this, all rear sus-
• When there are signs of oil leakage.
pensions being filled with oil while installed on the
truck must use the "Installed On Truck" oiling heights • After repair/rebuilds.
listed in Table 4.
When the suspension is in a vertical position while off
the truck, the oiling height will be different. All rear
suspensions being filled with oil while off the truck
should use the "On Bench" oiling heights listed in
Table 4. A common mistake when performing oiling pro-
NOTE: Refer to Table 4 for the approximate block cedures is the failure to recognize and/or prop-
height. The oiling height of the cylinder must always erly react to oil that contains trapped nitrogen or
be determined by using Dimensions A or C, only. "foamy oil". Oil, such as this, is common when
the truck has recently been operating and the
The “final charging height” in Table 4 is for suspen- suspension oil and gas haven’t been allowed to
sions at normal operating temperature and must not settle and separate. This condition must be han-
be exceeded. After charging a cold suspension, dled properly to ensure that the suspension
operate the truck for several hours and check/adjust receives the proper amount of oil. Failure to do
the charging height at normal operating temperature. so may cause a low oil level resulting in prema-
If the suspensions are not checked/adjusted at nor- ture component wear. Premature bearing and
mal operating temperature, the suspension height seal wear can, in many cases, be attributed to
may be incorrect, possibly causing excessive drive- this occurrence.
line angles that could result in damage to powertrain
If the truck has been operating, allow time for the
components.
oil and nitrogen gas to separate. This may take
several hours. An alternative action is to purge
the foamy oil from the cylinder during oiling.
Oil Quantity (approx.): . . . 36.3 Liters (9.6 Gallons)

NOTE: DO NOT fill a suspension cylinder with oil
based on quantity alone. Oil quantities are given as
reference, only. Always fill/adjust the oil level in the
suspension cylinders based on the oiling height
dimensions given in Table 4.

All suspensions are charged with compressed
nitrogen gas with sufficient pressure to cause
injury or damage if improperly handled. Follow
all safety notes, cautions, and warnings in these
procedures to prevent accidents during servicing
and charging.
1. Park the truck on a flat level surface. Apply the

parking brake, and chock the wheels.
2. Clean the area around charging valves (5, Fig-
ure 4-9).
3. Position the oiling spacer between the stopper
and the axle housing as shown in Figure 4-8 (if
servicing while on the truck). Dimension "A",
Figure 4-11, must be equal to the proper dimen-
sion listed in Table 4.
NOTE: The proper oiling block dimension is listed in
Table 4.
FIGURE 4-9. OIL CHARGING KIT (EC6027)
1. Hose 5. Charging Valve

2. Connector 6. Pressure Sensor
3. Adapter 7. Oil Pump
4. Fitting
FIGURE 4-8. OILING BLOCK INSTALLATION

1. Oiling Block 3. Dust Cover
2. Cylinder
FIGURE 4-10. PRESSURE SENSOR/VALVE ASSY.
1. Schrader Valve 3. Pressure Sensor

2. Valve Assembly

Dimension "A" is measured from the face of the
retainer to the bottom flat surface of the cylinder
rod. Do not measure from the cap screws or cap-
screw heads.
Dimension "B" is measured from the top of the
housing surface to the mating face for the flange.
Dimension "C" is measured from the center line
of the top pin to the center line of the bottom pin.
FIGURE 4-11. REAR SUSPENSION

1. Housing 2. Retainer
TABLE 4. REAR SUSPENSION OILING & CHARGING DIMENSIONS
Housing Length (Dimension B) 510 mm (20.0 in.)
Installed On Truck 221 ± 3 mm (8.7 ± 0.1 in.)

Oiling Height (Dimension A)
On Bench 154 ± 3 mm (6.1 ± 0.1in.)
Installed On Truck 1148 ± 3 mm (45.2 ± 0.1 in.)

Oiling Height (Dimension C)
On Bench 1081 ± 3 mm (42.6 ± 0.1 in.)
Final Charge Height Dimension A 234 ± 10 mm (9.2 ± 0.4 in.)

(At Operating Temperature) Dimension C 1161 ± 10 mm (45.7 ± 0.4 in.)
Approximate Oiling Spacer Height 95 mm (3.7 in.)

4. Disconnect the pressure sensor harness con- 6. After all nitrogen pressure has been relieved,
nectors and remove the clamps securing the remove the pressure sensor/valve assembly.
harnesses. 7. Remove charging valve (5, Figure 4-9), and
install fitting (4).
8. Install adapter (3) to fitting (4). Connect the
hose and the oil pump.
9. Operate the pump until clear oil (containing no
air bubbles or foam) is discharged from the plug
Releasing the nitrogen gas from the valve core of hole.
charging valve (5, Figure 4-9) will damage the
10. After all air and foamy oil is discharged, install
valve core. Therefore, remove the gas by loosen-
the pressure sensor valve assembly.
ing pressure sensor/valve assembly (6) one revo-
lution.
Use caution when tightening the valves and fit-

tings on the suspensions. DO NOT overtighten.
Loosening the pressure sensor/valve assembly Overtightening can damage the fittings or the
more than three revolutions may result in the suspension housing resulting in gas and oil
component being forced out of the suspension leaks. Tighten to the specified torque.
by the gas pressure inside. DO NOT exceed one
revolution.
11. Tighten the pressure sensor valve assembly to
44 ± 5 N·m (33 ± 3 ft lbs).
NOTE: If oil is discharged with the gas, tighten the 12. After the completion of oiling, remove the oil
valve slightly so only the gas will be discharged. If pump, and install charging valve (5). Tighten to
this is not possible, the foamy oil will need to be 44 ± 5 N·m (33 ± 3 ft lbs).
purged from the suspension during the oiling
procedure, prior to charging.
Verify that all personnel are out of the area and

the support blocks are secure before releasing
the nitrogen. Use a face mask or goggles when
releasing the nitrogen.
5. While wearing a face mask or goggles, dis-

charge the nitrogen pressure from the suspen-
sion by loosening pressure sensor/valve
assembly (2, Figure 4-10) one revolution. DO
NOT loosen more than one revolution.

Rear Suspension Nitrogen Charging
6. When the left and right cylinders reach the
specified length, as shown in Figure 4-11 (Table
4), close valves (3 & 4, Figure 4-6) to stop the
flow of nitrogen gas. Turn the handle on regula-
tor (11) counterclockwise to close the valve.
Dry nitrogen is the only gas approved for use in
7. Turn handle (6) on valve adapter (5) counter-
suspensions. Charging of these components
clockwise to close the charging valve. After the
with oxygen or other gases may result in an
valve is completely closed, remove the charging
explosion which could cause serious injuries,
equipment.
fatalities and/or major property damage. Refer to
Nitrogen Gas Specifications at the beginning of 8. Use soapy water to check the charging valve
this chapter. and pressure sensor joints for leaks. Repair as
necessary.
1. Remove the caps from charging valves (5, Fig- 9. Install the caps and O-rings onto the charging
ure 4-9). valves.
NOTE: Before installing regulator (11, Figure 4-6),

blow out the connector with nitrogen gas at 965 kPa
(140 psi) or more, to clean out all dirt or dust. (Dirt or
dust in the system causes failures.) LENGTH ADJUSTMENT - FRONT AND
REAR CYLINDERS
2. Open the valve on the gas cylinder, and check
the pressure at regulator gauge (1).
NOTE: Adjust the installed length of the cylinder with
NOTE: Internal pressure of the gas cylinder must be the truck on level ground and the body empty.
substantially higher than the suspension charging
pressure, 1882 kPa (273 psi).
3. Slowly turn the handle of regulator (11, Figure

4-6) clockwise, and adjust the pressure at
gauge (2) to the required charging pressure, Depending on the ambient temperature, the gas
1882 kPa (273 psi). Open valves (3 & 4) to fill in the suspension may expand or contract
the suspension cylinders with nitrogen gas. changing the length of the cylinder. In locations
4. Fill the left and right cylinders at the same time. where there are wide differences in temperature
Verify the required charging pressure is present throughout the year, inspect the suspension
at gauge (10). height periodically and adjust to keep the length
within the specified range shown in Figures 4-7
5. When the left and right cylinders reach the and 4-11 (Table 4).
specified length, as shown in Figure 4-11, close
valve (4) to stop the flow of nitrogen gas. Turn
the handle of regulator (11) counterclockwise to 1. To reduce the sliding resistance of the cylinder,
close off nitrogen flow. drive the truck forward approximately 15 m (50
ft) and stop suddenly, then drive in reverse to
the original position and stop suddenly, again.
Repeat this cycle three to four times. Finally,
allow the truck to stop slowly without depressing
the brake. Then measure the installed length.

2. If the result of the check shows that the length is 3. After releasing nitrogen gas and adjusting the
too long, release nitrogen gas to adjust the length, repeat Step 1-2 to check the installed
length. Loosen the pressure sensor/valve length again.
assembly no more than one revolution to 4. Finally, check that there is no leakage of gas
release the nitrogen gas. When doing this, from the valve core, pressure sensor/valve
release only a small amount of gas. The cylin- assembly, and piston rod gland.
der should not move. If too much nitrogen gas is
released and the cylinder moves, the installed Use soapy water to check for leakage of gas. If
length may be below the specified length. The there is any leakage of gas from the valve core,
cylinders will need to be charged to the correct replace the valve core.
dimension. 5. The rear suspensions are now ready for opera-
tion. Visually check piston rod extensions both
with truck loaded and empty. Record extension
dimensions. Maximum downward travel is indi-
cated by the dirt ring at the base of the piston.
Operator comments on steering and suspen-
sion rebound should also be noted.
DO NOT release nitrogen pressure by depressing
the tip of the valve core. Damage to the valve
core may result.

NOTES

TOE IN ADJUSTMENT
The correct toe-in specification for these model trucks is zero with the truck at the empty vehicle weight. As the
truck is loaded, the geometry of the suspension and steering will result in minor toe-in angles.
Adjustment Procedure
5. Measure the distance from the edge of the tire
1. Park the truck on a hard, level surface and
rim to the flat face of the frame. Measure this
chock the rear wheels.
distance at both the front and the rear of the left
2. Ensure the front and rear suspensions are oiled hand wheel. Refer to Figure 11-2.
and charged according to shop manual specifi-
6. Calculate the average distance from the two
cations. Refer to Suspension Oiling and Charg-
measurements obtained in Step 5. Record the
ing Procedures in this section. The suspensions
measurement.
must be properly charged and oiled to ensure
accurate toe adjustment. 7. Start the truck and steer the wheels until the
average measurement is achieved at the front
3. Inspect steering and suspension components
and rear of the left hand tire.
and replace any damaged and/or worn parts.
4. Place a hydraulic jack below the front suspen-
sion to A-arm pin on both sides of the truck. Ele-
vate the truck until the lower portions of the tires
are no longer bulged, but allow for full tread
contact with the ground across each tire.
Keep personnel away from the truck when oper-
Ensure the two jacks are at the same height.
ating the steering wheel. Personal injury may
Refer to Figure 11-1.
result. Depressurize the accumulators before
making adjustments to the steering linkage.
FIGURE 11-1. RAISING THE TRUCK

FIGURE 11-2. TIRE TO FRAME DISTANCES
8. Mark the centerlines of the tires on the faces of 13. Check tire wear periodically. If abnormal wear is
the tread at the front and rear of each tire. The evident, check for damaged or worn steering
vertical centerline should be a distance of 1220 components, and verify the toe is properly
mm (48 in.) from the ground surface. The hori- adjusted. Replace components as necessary,
zontal centerline should be exactly half the and adjust the toe.
width of the tire. Refer to Figure 11-3.
9. Measure the distances between centerlines at
the front and rear of the wheels. Record the
measurements.
10. Adjust the length of the tie rods until the two
measurements obtained in Step 9 are within 3
mm (0.118 in.) of one another. The tie rods must Adjust the toe after replacing integral steering
be adjusted equally. One full turn of the tie rods system components. Failure to adjust the toe
is approximately equal to 25.4 mm (1 in.) of toe after replacing any components that may effect
adjustment. the steering geometry may cause premature wear
11. Record the final distances between the front to the tires and other components.
and rear centerlines for future reference.
12. Remove the jacks and the wheel chocks from 14. Check the toe adjustment at every 500 hour
the truck. Operate the truck through several interval. If abnormal tire wear is evident, check
complete turn cycles. Recheck the measure- the adjustment, immediately.
ments, and readjust if necessary.
FIGURE 11-3. MARKING CENTERLINES ON THE TIRES
NOTES
AUTOMATIC LUBRICATION SYSTEM CHECKOUT
Over-pressurizing of the system, modifying

parts, using incompatible chemicals and fluids,
or using worn or damaged parts, may result in
equipment damage and/or serious personal
injury.
• DO NOT exceed maximum working pressure
for any component in the system.
• DO NOT alter or modify any part of this
system unless factory authorization.
• DO NOT attempt to repair or disassemble the
equipment while the system is pressurized.
• Ensure all fluid connections are securely
tightened before using this equipment.
• Read and follow the fluid manufacturer's
recommendations regarding fluid
compatibility.
• Check all equipment regularly and repair.
Replace worn or damaged parts immediately.
FIGURE 3-1. PUMP & RESERVOIR COMPONENTS This equipment generates very high grease pres-
1. Hose From Filter 8. Pressure Gauge sure. Use extreme caution when operating this
2. Outlet to Injectors 9. Pump Assembly equipment. Pressurized grease can pierce the
3. Hydraulic Motor 10. Flow Control Valve skin causing serious bodily injury. Adequate pro-
4. Pressure Reducing 11. Pressure Switch tection such as safety goggles and protective
Valve 12. Grease Reservoir clothing is recommended.
5. Solenoid Valve 13. Vent Hose
6. Test Switch If fluid penetrates the skin, get medical care
7. Vent Valve immediately! Do not treat as a simple cut. Tell the
attending physician exactly what fluid was
injected.
LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Check the oil level at
1000 hour intervals. To add oil, remove plug (4, Fig-
ure 3-2) and fill the housing to the bottom of the plug
hole.
Pump Pressure Control

High pressure hydraulic fluid from the truck steering
system is reduced to 2240 to 2413 kPa (325 to 350
psi) by pressure reducing valve (1). The reducing
valve is located on the manifold on top of the pump
motor. Operating pressure can be read on the gauge
installed on the manifold. Occasionally check the
gauge to verify pressure is within the specified range.
The pressure reducing valve is not adjustable. If FIGURE 3-2. PUMP CONTROLS
operating pressure is not within limits, the pressure 1. Pressure Reducing 3. Pressure Gauge
reducing valve must be replaced. Valve 4. Oil Level Plug
2. Test Switch 5. Flow Control Valve
INJECTORS (SL-1 Series “H”))
Injector Specifications
• Each lube injector services only one grease
point. In case of pump malfunction, each injector
is equipped with a covered grease fitting to allow
the use of manual lubrication equipment.
• Injector output volume:
Maximum output = . . . . . . . . 1.31 cc (0.08 in3)
Minimum output = . . . . . . . 0.13 cc (0.008 in3)
• Operating Pressure:
Minimum - . . . . . . . . . . 12,755 kPa (1850 psi)
Maximum - . . . . . . . . . . 24,133 kPa (3500 psi)
Recommended - . . . . . 17,238 kPa (2500 psi)
• Maximum Vent Pressure - (Recharge)
4,137 kPa (600 psi)
Injector Adjustment
FIGURE 3-3. TYPE SL-1 INJECTOR
The injectors may be adjusted to supply from 0.13 cc
to 1.31 cc (0.008 in3 to 0.08 in3) of lubricant per injec- 1. Adjusting Screw 11. Spring Seat
tion cycle. The injector piston travel distance deter- 2. Locknut 12. Plunger
mines the amount of lubricant supplied. Piston travel 3. Piston Stop Plug 13. Viton Packing
is controlled by an adjusting screw in the top of the 4. Gasket 14. Inlet Disc
injector housing. 5. Washer 15. Viton Packing
6. Viton O-Ring 16. Washer
Turn adjusting screw (1, Figure 3-3) counterclock- 7. Injector Body Assy. 17. Gasket
wise to increase injector output and clockwise to 8. Piston Assembly 18. Adapter Bolt
decrease injector output. 9. Fitting Assembly 19. Adapter
When the injector is not pressurized, maximum injec- 10. Plunger Spring 20. Viton Packing
tor delivery volume is attained by turning the adjust-
ing screw (1) fully counterclockwise. Turn until the
NOTE: Piston assembly (8) has a visible indicator
indicating pin (8) just touches the adjusting screw. At
pin at the top of the assembly to verify injector
the maximum delivery point, about 9.7 mm (0.38 in.)
operation.
of adjusting screw threads will be exposed. Decrease
the delivered lubricant amount by turning the adjust-
ing screw clockwise to limit injector piston travel. If
only half the lubricant is needed, turn the adjusting
screw to the point where about 4.8 mm (0.19 in.)
threads are exposed. The injector will be set at the
minimum delivery point with about 0.22 mm (0.009
in.) thread exposed.
NOTE: The information above relates only to the
adjustment of injector delivery volume. The timer
adjustment must also be changed if overall lubricant
delivery is inadequate or excessive. Do not adjust
Injector output to less than one-fourth capacity.
SYSTEM PRIMING
The system must be full of grease and free of air
pockets to function properly. After maintenance, if the
primary or secondary lubrication lines were replaced,
it will be necessary to prime the system to purge
entrapped air.
1. Fill the reservoir with lubricant, if necessary.
2. To purge air from the main supply line, remove
the main supply line at the reservoir and con-
nect an external grease supply to the line.
3. Remove plugs from each injector group in
sequence (right front, left front, and rear axle).
4. Using the external grease source, pump grease
until it reaches the injector group. Install the
pipe plug and repeat for the remaining injector
groups.
5. Remove the caps from each injector. Connect
an external grease supply to the zerk on the
injector. Pump until grease reaches the far end
of the individual grease hose or the joint being
greased.
Filter Assembly
Replace element (5, Figure 3-4) if bypass indicator
(2) indicates excessive element restriction.
FIGURE 3-4. FILTER ASSEMBLY
1. Housing 6. Spring
2. Bypass Indicator 7. Bowl
3. O-Ring 8. O-Ring
4. Backup Ring 9. Plug
5. Element
SYSTEM CHECK
To check system operation (not including timer), pro- The fourth dip switch is used to select “memory off”
ceed as follows: or “memory on”. When the switch is set to “memory
1. Start the engine. off”, a lube cycle will occur each time power is turned
on. The lube cycle will start at the beginning of the on
2. Actuate the lube system test switch at the reser- time setting.
voir/pump assembly.
3. The motor and pump should operate until the When the switch is set to “memory on”, the controller
system attains 17,237 kPa (2500 psi). will function as follows:
4. Once the required pressure is achieved, turn • When power is turned off between lube cycles,
the pump motor off. The system should vent. the lube cycle will resume at the point of inter-
ruption after power is restored. In other
5. Check for pump, hose or injector damage.
words, the controller will remember its posi-
Check for leakage with the system pressurized.
tion in the cycle.
6. After checking the system, shut the engine off.
• When power is turned off during a cycle, the
controller will reset to the beginning of the
lube cycle after power is restored.
Lubrication Controller Check
Pressing the manual lube button on the enclosure
cover will initiate a lube event. (See Figure 3-5). Off time switch (1) is used to select units of time.
Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or
30. The mode switch determines whether the off time
units will be minutes or hours.
Lubrication Controller Operation
Cover (3) contains three Light Emitting Diode (LED)
The time between lube events is determined by the windows and a manual lube switch. The LED’s indi-
setting of the rotary switch and the dip switch. The cate system operation and status. When power is on,
rotary switch selects the numeral setting, and the dip a green LED will illuminate. When the pump is on,
switch selects the units in either minutes or hours. another green LED will illuminate. A red LED will illu-
minate when an alarm condition occurs.
The manual lube switch, when depressed, will initiate
Lubrication Controller Components
a lube cycle.
Mode switch (2, Figure 3-5) consists of four dip
switches. The first dip switch controls the maximum
amount of “on time”, either 30 seconds or 120 sec-
onds.
Lubrication Controller Adjustment
The second dip switch controls the mode, either
timer mode or controller mode. When the switch is The lubrication controller is factory adjusted to the
set to the timer mode, the amount of time that the following switch settings:
pump is on will be determined by the setting of the Dip switch 1 . . . . . . . . . . . . . . . . . . . . . 120 seconds
dip switch - 30 seconds or 120 seconds. When the
switch is set to the controller mode, a pressure Dip switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .timer
switch must be installed in the lube supply line. The Dip switch 3 . . . . . . . . . . . . . . . . . . . . . . . . . minutes
pressure switch will detect supply line pressure, and
will reset the timer at a set pressure. If the pump fails Dip switch 4 . . . . . . . . . . . . . . . . . . . . . . . memory off
to reach the set pressure within the dip switch set
time, the controller will initiate an alarm.
Rotary Switch . . . . . . . . . . . . . . . . . . . . . . 15 minutes
The third dip switch is for selecting the units for the
“off time”. This setting is to be used in conjunction
with off time switch (1). Hours or minutes may be
selected.
FIGURE 3-5. LUBRICATION TIMER
1. Off Time Switch 3. Cover

2. Mode Switch
SYSTEM TROUBLESHOOTING CHART
NOTE: If the following procedures do not correct the
problem, contact a factory authorized service center.
Symptom Possible Causes Corrective Action

Lube system not grounded. Correct grounding connections to pump assem-
bly and truck chassis.
Electrical power loss. Locate cause of power loss and repair. 24 VDC
power required. Ensure key switch is ON.
Pump Does Not Operate
Controller malfunction. Replace the controller assembly
Solenoid valve malfunctioning. Replace the solenoid valve assembly
Motor or pump malfunction. Repair or replace motor and/or pump assembly.
Refer to the service manual for rebuild instruc-
tions.
Pump Will Not Prime Low lubricant supply. Dirt in reservoir, pump inlet clogged, filter
clogged.
Air trapped in lubricant supply line. Prime system to remove trapped air.
Pump Will Not Build Lubricant supply line leaking. Check lines and connections to repair leakage.
Pressure
Vent valve leaking. Clean or replace vent valve.
Pump worn or scored. Repair or replace pump assembly. Refer to the
service manual for rebuild instructions.
NOTE: Normally during operation, the injector indicator stem will move into the
body of the injector when pressure builds. When the system vents and releases
pressure, the indicator stem will again move out into the adjusting yoke.
Malfunctioning injector - usually indi- Replace individual injector assembly.
Injector Indicator Stem cated by the pump building pressure
Does Not Operate and then venting.
All injectors inoperative - pump build up Service and/or replace pump assembly. Refer to
not sufficient to cycle injectors. the service manual for rebuild instructions.
No system pressure to the pump motor. Check hydraulic hose from steering system.
Pressure Gauge Does Not No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system.
Register Pressure
Pressure reducing valve not functioning Refer to Pump Pressure Control.
properly.
Symptom Possible Causes Corrective Action
Pump Pressure Builds Very No signal at solenoid. Check timer.

Slowly Or Not At All
Controller Does Not No electric power to controller. Turn on electric power to pump. “POWER”
Operate LED should light, “PUMP ON” LED should
light when “MANUAL LUBE” is pressed.
“PUMP ON” LED is lit, But Printed circuit board failure. Remove and replace.
Load Connected To Termi-
nals 3 & 4 Will Not Energize
Load Connected To Termi- Printed circuit board failure or key- Remove and replace.
nals 3 & 4 Energized, But pad failure.
“PUMP ON” LED Does Not
Light
Controller memory mode is off. Switch controller memory mode to ON.

Bearing Points
Excessively Lubricated
Injector output adjustment setting Readjust to lower setting.

too high.
Timer/controller cycle time setting Set to longer cycle time or reevaluate lube
too low. requirements.
Injector output adjustment setting Readjust injector output setting.

Bearing Points Are Not too low.
Sufficiently Lubricated
Timer/controller cycle time setting Set to shorter cycle time or reevaluate lube
does not deliver lubricant often requirements.
enough.
System too large for pump output. Calculate system requirements per plan-
ning manual.
PREVENTATIVE MAINTENANCE
Use the following maintenance procedures to ensure
proper system operation. 3. Check the grease reservoir level.
Daily Lubrication System Inspection a. Fill the reservoir as needed. Check the filter
bypass indicator when filling the reservoir.
1. Check grease reservoir level.
Replace the element if grease is bypassing.
Inspect grease level height after each shift of
operation. Grease usage should be consistent b. Check the reservoir for contaminants. Clean,
from day-to-day operations. if necessary.
• Lack of lubricant usage would indicate an inop- c. Ensure all filler plugs, covers and breather
erative system. Excessive usage would indi- vents on the reservoir are intact and free of
cate a broken supply line. contaminants.
2. Check filter bypass indicator when filling reser- 4. Inspect all bearing points for a bead of lubricant
voir. Replace element if bypassing. around the bearing seal.
3. Check all grease feed line hoses from the SL-1 5. System Checkout
injectors to the lubrication points. a. Remove all SL-1 injector cover caps to allow
a. Repair or replace all damaged hoses. visual inspection of the injector cycle indica-
tor pins during system operation.
b. Ensure all air is purged and all new hoses
are filled with grease before truck operation. b. Start the engine.
4. Inspect key lubrication points for a bead of lubri- c. Actuate manual test switch (17, Figure 3-2).
cant around the seals. If a lubrication point The hydraulic motor and grease pump
appears dry, troubleshoot and repair the prob- should operate.
lem.
d. With the grease pressurized, check each SL-
NOTE: It is good practice to manually lube each 1 injector assembly.
bearing point at the grease fitting provided on each The cycle indicator pin should be retracted
Injector. This will indicate if there are any frozen or inside the injector body.
plugged bearings, and will help flush the bearings of
e. When the system reaches 17,237 kPa (2500
contaminants.
psi), the pump should shut off. The pressure
in the system should drop to zero, venting
back to the grease reservoir.
250 Hour Inspection
f. With the system vented, check all of the SL-1
1. Check all grease hoses from the SL-1 injectors injector indicator pins; all of the pins should
to the lubrication points. See Figure 3-2. be visible. Replace or repair injectors, if
a. Repair or replace all worn or broken hoses. defective.
b. Ensure all air is purged and all new hoses g. Reinstall all injector cover caps.
are filled with grease before truck operation. h. Check controller operation.
2. Check all grease hoses from the pump to the NOTE: With the engine on, the lube system should
SL-1 injectors. activate within 5 minutes. The system should build
a. Repair or replace all worn or broken hoses. 13,790 to 17,237 kPa (2000 to 2500 psi) within 25-40
seconds.
b. Ensure all air is purged and all new hoses
are filled with grease before truck operation.
i. If the system is working properly, the
machine is ready for operation.
j. If the system is malfunctioning, refer to the
troubleshooting chart.
1000 Hour Inspection

1. Check the pump housing oil level. Fill to the bot-
tom of the plug hole with SAE 10W-30 motor oil.
NOTES:
NOTES:
NOTES:
STANDARD TABLES
This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard
units in parentheses. References throughout the manual to standard torques or other standard values will be to
one of the following tables. Do not use standard values to replace specific torque values in assembly instructions.
For values not shown in any of the charts or tables, standard conversion factors for most commonly used measure-
ments are provided in Tables 1 and 17.
NOTE: Portions of this truck may be assembled with SAE (US) hardware. Ensure the correct table is referenced
when determining the proper torque.
INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page TABLE1. Common Conversion Multipliers
Metric To English
TABLE 1 Common Conversions Multipliers
Metric -to- English . . . . . . . . . A5-1 Multiply
To Convert From To By
TABLE 2 Standard Tightening Torque For
millimeter (mm) inch (in.) 0.0394
Metric Cap Screws and Nuts . . . . . A5-2
centimeter (cm) inch (in.) 0.3937
TABLE 3 Standard Tightening Torque
meter (m) foot (ft) 3.2808
For Split Flange Bolts . . . A5-2
meter (m) yard (yd) 1.0936
TABLE 4 Tightening Torque For Flared kilometer (km) mile (mi) 0.6210
Tube And Hose Fittings . . . . . . . A5-2
square centimeters (cm2) square inch (in.2) 0.1550
TABLE 5 Temperature Conversions . . . . . A5-3 2)
square centimeters (cm square feet (ft2) 0.001
TABLE 6 Torque Conversions cubic centimeters (cm ) 3
cubic inch (in. ) 3 0.061
kg·m to ft lb. . . . . . . . . . . A5-3
liters (l) cubic inch (in. ) 3 61.02
TABLE 7 Torque Conversions 3 3
cubic meters (m ) cubic feet (ft ) 35.314
kg·m to N·m . . . . . . . . . . A5-3
liters (l) cubic feet (ft )3 0.0353
TABLE 8 Pressure Conversions
grams (g) ounce (oz) 0.0353
kg/cm2 to psi . . . . . . . . . . . A5-4
milliliter (ml) fluid ounce (fl oz) 0.0338
TABLE 9 Pressure Conversions kilogram (kg) pound (mass) 2.2046
kg/cm2 to kPa . . . . . . . . . . . A5-4 Newton (N) pounds (lb) 0.2248
TABLE 10 Pressure Conversions Newton meters (N·m) kilogram meters (kg·m) 0.102
psi to kPa . . . . . . . . . . . . . A5-4 Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram meters (N·m) foot pounds (ft lb) 7.2329
For SAE Cap Screws and Nuts . . . . A5-5 kilogram meters (N·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038
12-Pt, Grade 9, Cap Screws (SAE). . . . A5-5
kilograms/cm2 (kg/cm2) pounds/square inch (psi) 14.2231
TABLE 13 JIC 37° Swivel Nuts
Torque Chart (SAE) . . . . . . . . A5-6 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
kilogram (kg) short ton (tn) 0.0011
TABLE 14 Pipe Thread Torque Chart (SAE) . A5-6
metric ton short ton (tn) 1.1023
TABLE 15 O-Ring Boss Torque Chart (SAE) . A5-6 liters (l) quart (qt) 1.0567
TABLE 16 O-Ring Face Seal liters (l) gallon (gal) 0.2642
Torque Chart (SAE) . . . . . . . . . A5-6 Watts (W) horsepower (hp) 0.00134
TABLE 17 Common Conversions Multipliers kilowatts (kW) horsepower (hp) 1.3410

English -to- Metric . . . . . . . . . A5-7
TABLE 18 Sealants And Adhesives. . . . . . . A5-8
Standard Tables Page-1

TABLE 2. Standard Tightening Torque For
Metric Hex Head Cap Screws And Nut
Cap Screw Thread Width Kilogram meters Newton meters Foot Pounds
Diameter Across Flat (kg·m) (N·m) (ft lb)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
6 10 1.35 13.2 10
8 13 3.2 31.4 23
10 17 6.7 65.7 48
12 19 11.5 112 83
14 22 18.0 177 130
16 24 28.5 279 206
18 27 39.0 383 282
20 30 56.0 549 405
22 32 76.0 745 550
24 36 94.5 927 684
27 41 135 1320 975
30 46 175 1720 1266
33 50 225 2210 1630
36 55 280 2750 2025
39 60 335 3280 2420
TABLE 3. Tightening Torque For

Split Flange Bolts
Cap Screw Thread Width Kilogram meters Newton meters Foot Pounds
Diameter Across Flat (kg·m) (N·m) (ft lb)
10 14 6.7 65.7 48
12 17 11.5 112 83
16 22 28.5 279 206
TABLE 4. Tightening Torque For

Flared Tube And Hose Fittings
Thread Width Kilogram meters Newton meters Foot Pounds

Diameter of Nut Across Flat (kg·m) (N·m) (ft lb)
14 19 2.5 25 18
18 24 5 50 36
22 27 8 80 58
24 32 14 140 101
30 36 18 175 130
33 41 20 195 145
36 46 25 245 180
42 55 30 295 215
Page-2 Standard Tables

TABLE 5. Temperature Conversions
Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F°
Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit
C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
TABLE 6. Torque Conversions

kilogram meter (kg·m) to foot pounds - (ft lb)
1 kg·m=7.2339 ft lb
kg·m 0 1 2 3 4 5 6 7 8 9
0 (ft lb) 7.23 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.5 303.8 311.0 318.2 325.5 332.7 339.9 347.2 354.4
50 361.6 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
TABLE 7. Torque Conversions

kilogram meter - kg·m To Newton meters (N·m)
1 kg·m=9.807 N·m
kg·m 0 1 2 3 4 5 6 7 8 9
0 (N.m) 9.8 19.6 29.4 39.2 49.0 58.8 68.6 78.5 88.3
10 98.1 107.9 117.7 127.5 137.3 147.1 156.9 166.7 176.5 186.3
20 196.1 205.9 215.8 225.6 235.4 245.2 255.0 264.8 274.6 284.4
30 294.2 304.0 313.8 323.6 333.4 343.2 353.1 362.9 372.7 382.5
40 392.3 402.1 411.9 421.7 431.5 441.3 451.1 460.9 470.7 480.5
50 490.4 500.2 510.0 519.8 529.6 539.4 549.2 559.0 568.8 578.6
60 588.4 598.2 608.0 617.8 627.6 637.5 647.3 657.1 666.9 676.7
70 686.5 696.3 706.1 716.0 725.7 735.5 745.3 755.1 764.9 774.8
80 784.6 794.4 804.2 814.0 823.8 833.6 843.4 853.2 863.0 872.8
90 882.6 892.4 902.2 912.1 921.9 931.7 941.5 951.3 961.1 970.9

TABLE 8. Pressure Conversions
kilograms per square centimeter (kg/cm2) to pounds per square inch (psi)
2
1 kg/cm =14.2231 psi
kg/cm2 0 1 2 3 4 5 6 7 8 9
0 (psi) 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 185.0 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.2 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.1 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.0 782.3 796.5 810.7 824.9 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 952.9 967.2 981.4
70 995.6 1009.8 1024.1 1038.3 1052.5 1066.7 1081.0 1095.2 1109.4 1123.6
80 1137.8 1152.1 1166.3 1180.5 1194.7 1209.0 1223.2 1237.4 1251.6 1265.9
90 1280.1 1294.3 1308.5 1322.7 1337.0 1351.2 1365.4 1379.6 1393.9 1408.1

2
kilograms per square centimeter (kg/cm ) to kilopascals (kPa)
2
1 kg·cm =98.068 kPa
2 0 1 2 3 4 5 6 7 8 9
kg/cm
0 (kPa) 98 196 294 392 490 588 686 785 883
10 981 1079 1177 1275 1373 1471 1569 1667 1765 1863
20 1961 2059 2157 2256 2354 2452 2550 2648 2746 2844
30 2942 3040 3138 3236 3334 3432 3530 3629 3727 3825
40 3923 4021 4119 4217 4315 4413 4511 4609 4707 4805
50 4903 5001 5100 5198 5296 5394 5492 5590 5688 5786
60 5884 5982 6080 6178 6276 6374 6472 6571 6669 6767
70 6865 6963 7061 7159 7257 7355 7453 7551 7649 7747
80 7845 7944 8042 8140 8238 8336 8434 8532 8630 8728
90 8826 8924 9022 9120 9218 9316 9415 9513 9611 9709

pounds per square inch (psi) to kilopascals (kPa)
Formula: psi x 6.895 = kPa
psi 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
NOTE: Tables such as Table 6, 7, 8, 9 and 10 may be used as in the following example:
Example: Convert 955 kg·m to foot pounds (ft lb). 950 kg·m = 6871 ft lb
1. Select Table 6. 4. Go to kg·m row 0, column 5; reads 49.0
5 kg·m = 49 ft lb Add to step 3.
2. Go to kg·m row 90, column 5; reads 687.1
95 kg·m = 687.1 ft lb 5. 950 + 5 kg·m = 6871 + 49 = 6920 ft lb
955 kg·m = 6920 ft lb
3. Multiply by 10:

TABLE 11
Standard Torque Chart
SAE Hex Head Cap Screw And Nut Assembly
(Lubricated Threads)
Tolerances ±10%
Cap Torque - Torque - Cap Torque - Torque -
Screw Grade 5 Grade 8 Screw Grade 5 Grade 8
Thread Thread
Size ft lb kg·m N·m ft lb kg·m N·m Size ft lb kg·m N·m ft lb kg·m N·m
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lb = 0.138 N·m = 1.356 N.m
TABLE 12 - Standard Tightening Torque

TABLE 12 - Standard Tightening Torques For 12- for 12-Point, Grade 9 Cap Screws
Point, Grade 9, Cap Screws (SAE)
Torque Torque Torque
The following specifications apply to required assem- Cap Screw Size* ft lb N·m kg·m
bly torques for all 12-Point, grade 9 (170,000 psi min- 0.250 - 20 12 16 1.7
imum tensile), cap screws. 0.312 - 18 24 33 3.3
• Cap screw threads and seats shall be lubricated 0.375 - 16 42 57 5.8
when assembled. 0.438 -14 70 95 9.7
Unless instructions specifically recommend 0.500 -13 105 142 14.5
otherwise, these standard torque values are to be 0.562 - 12 150 203 20.7
used with simple lithium base chassis grease (multi-
0.625 - 11 205 278 28.3
purpose EP NLGI) or a rust- preventive grease (see
list, this page) on the threads. 0.750 - 10 360 488 49.7
0.875 - 9 575 780 79.4
• Torques are calculated to give a clamping force
of approximately 75% of proof load. 1.000 - 8 860 1166 119
• The maximum torque tolerance shall be ±10% of 1.000 - 12 915 1240 126
the torque value shown. 1.125 - 7 1230 1670 170
1.125 - 12 1330 1800 184
1.250 - 7 1715 2325 237
1.250 - 12 1840 2495 254
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
1.500 - 12 3225 4375 445
* Shank Diameter (in.) - Threads per inch

TABLE 13. TABLE 15.
Torque Chart For JIC 37° Swivel NutS Torque Chart For
With Or Without O-ring Seals O-ring Boss Fittings
Size Tube Size Threads Torque Size Tube Size Threads Torque
Code (OD) UNF-2B ft lb Code (OD) UNF-2B ft lb
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
TABLE 14 TABLE 16
Torque Chart For Torque Chart For
Pipe Thread Fittings O-ring Face Seal Fittings
With Without Size Tube Size Threads Torque

Size Pipe Thread Sealant Sealant Code (O.D.) UNF-2B ft lb
Code Size ft lb ft lb –4 0.250 0.438 – 20 11 ±1
–2 0.125 – 27 15 ±3 20 ±5 –6 0.375 0.562 – 18 18 ±2
–4 0.250 – 18 20 ±5 25 ±5 –8 0.500 0.750 – 16 35 ±4
–6 0.375 – 18 25 ±5 35 ±5 – 10 0.625 0.875 – 14 51 ±5
–8 0.500 – 14 35 ±5 45 ±5 – 12 0.750 1.062 – 12 71 ±7
– 12 0.750 – 14 45 ±5 55 ±5 – 16 1.000 1.312 – 12 98 ±6
– 16 1.000 – 11.50 55 ±5 65 ±5 – 20 1.250 1.625 – 12 132 ±7
– 20 1.250 – 11.50 70 ±5 80 ±5 – 24 1.500 1.875 – 12 165 ±15
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10

TABLE 17 - Common Conversion Multipliers
English to Metric
To Convert To Multiply
From By
inch (in.) millimeter (mm) 25.40
inch (in.) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61
square inch (in. ) 2

square centimeters (cm )2 6.45
square feet (ft2) square centimeters (cm2) 929
cubic inches (in.3) cubic centimeters (cm3) 16.39
cubic inches (in.3) liters (l) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft.3) liters (l) 28.3
ounce (oz) kilogram (kg) 0.028

fluid ounce (fl oz) milliliter (ml) 29.573
pound (lb) kilogram (kg) 0.454
pound (lb) Newton (N) 4.448
inch pounds (in. lb) Newton meters (N·m) 0.113
foot pounds (ft lb) Newton meters (N·m) 1.356
foot pounds (ft lb) kilogram meters (kg·m) 0.138
kilogram meters (kg·m) Newton meters (N·m) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
pounds/square inch (psi) kilograms/square centimeter 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (l) 0.946
gallon (gal) liters (l) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745

TABLE 18. Sealants And Adhesives
Nomenclature Code Three Bond * Applications
LT-1A TB1521 Used to apply rubber pads, rubber gaskets and cork plugs.
LT-1B 1000B - 1000W Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
seal is needed.
LT-2 TB1374 Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-2A TB2411 Preventing bolts, nuts and plugs from loosening and leaking oil. (1)
Adhesives
LT-2B TB2403 Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
LT-2C TB2430 or Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
TB2440
LT-3 Main bond TB2001 Provides an airtight, electrically insulating seal. Used for aluminum surfaces.
Hardening agent
TB2105
LG-1 TB1108B Used with gaskets and packings to increase sealing effect.
LG-3 TB1107 Heat-resistant gasket for precombustion chambers and exhaust piping.
Liquid Gasket LG-4 TB1104 Used by itself on mounting surfaces on the final drive and transmission cases.
Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)
LG-5 TB1110 Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
tings in hydraulic circuits of less than 50 mm (2 in) in diameter.
Anti-friction LM-P - Applied to bearings and taper shafts to facilitate press-fitting and to prevent stick-
compound ing, burning or rusting.
Grease G2-LI - Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Vaseline - - Used for protecting battery electrode terminals from corrosion.
* NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations.
(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of
1965 kPa (285 psi) or less.
(2) Used for threaded areas (for example, stud, etc.) which are not removable, and a pressure of 1965 kPa
(285 psi) or less.
The sealants and adhesives listed below are manufactured

and sold by Three Bond USA, Inc. For information concerning Part Numbers
Three Bond products, call or write to: Three Bond Komatsu
Three Bond USA, Inc. TB1374 09940-00030

6184 Schumacher Park Drive TB1521 790-129-9030
West Chester, OH 45069 TB1104 790-129-9020
Telephone: (513) 779-7300 TB1108B 790-129-9010

Fax: (513) 779-7375

FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
MACHINE MODEL MACHINE ENGINE CUSTOMER UNIT

SERIAL NUMBER ENGINE MODEL SERIAL NUMBER NUMBER
HD1500-7
Service Meter Reading Date of Inspection
Location of Machine at Inspection Dump Body Manufacturer

Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:
Signature Remark:
Submitting of this report (and check sheets) to Komatsu is one of the conditions of warranty validation.
All four copies are to be distributed as shown below.
Send White Reports to Manager of Technical Support

Komatsu America Corp.
2300 N.E. Adams St, P.O. Box 240
Peoria, IL 61650-0240 U.S.A.
Send Canary Reports to Manager of Field Assembly

Peoria, IL 61650-0240 U.S.A.
Send Pink Reports to your KAC Regional Service Manager
Send Gold Reports to the Service Manager at the KAC Distributor who sold the truck.
Mark each item with the appropriate symbol as shown below.
CEAW003506 White - Komatsu, Manager of Technical Support Canary - Komatsu, Manager of Field Assembly Page 1 of 5
Pink - Komatsu, Regional Service Manager Gold - Komatsu Distributor, Service Manager
Maintenance
Accepted
N
o. Inspection Item Acceptance Procedures
Inspection Around Machine
1 Parts Visually inspect the unit for loose parts and debris.
2 Hardware Check for missing hardware.
3 Hoses & Cables Verify hoses and cables are free from kinks, sharp edges, chafing, and are properly
attached.
4 Ground Straps Check all ground straps for secure connections.
5 Engine Fan Inspect the fan to shroud clearance and belt alignment.
6 Decks and Ladders Check for proper installation of decks, ladders, handrails, and anti-skid strips.
7 Belt Tension Verify correct tension on engine accessory belts.
8 Tire Inflation Verify tire pressure is within specifications.
9 Tire Flaw Check tires for visible damage or flaws.
10 Cylinders Verify that cylinder plated surfaces are free from rust and other flaws.
11 Verify that batteries are mounted tightly.
12 Battery Verify that battery connections are clean and tight.
13 Verify that caps are tight and electrolyte solution is at the proper level.
Cab Compartment
1 Cab Doors Inspect doors open and close smoothly, latch works properly, O. & M. Manual in door
2 Cab Windows Check window operation. Should open and close smoothly.
3 Door Locks Verify left and right door locks work properly with key.
4 Interior Visually inspect interior for completeness of assembly.
5 Visually inspect for cracked glass, torn upholstery, dirt, stains, holes etc.
6 Verify operators seat adjusts properly (slide lever, back rest operation, seat inclination, seat
Cab Seats height etc.).
7 Inspect seat belt for proper installation (and seat tethers).
8 Passenger Seat Verify back rest tilts forward and back.
9 Steering Wheel Check tilt and telescoping functions.
10 Verify adjustable lever can be locked securely.
11 Wiper Verify wiper works in all speeds, and range does not extend beyond glass surface.
12 Verify windshield washer works properly and washer fluid bottle is full.
13 Cigarette Lighter Inspect lighter operation; should pop up hot after 10 seconds.
14 Horn Check for proper sound, no looseness in horn button.
15 Back Up Alarm Check for proper sound and function.
16 Gauges Verify that gauges operate properly.
17 Indicator Lights Verify that indicator lights illuminate properly.
18 Character Display Verify the character display in the electronic display panel functions properly.
19 Hydraulic Fittings Inspect all hydraulic fittings in front of cab and rear of cab.
20 HVAC System Verify heater and air conditioning systems function properly.
21 Radio Verify all radio functions operate properly.
Maintenance
Accepted
N
Lights
1 Verify headlights work, high and low beams.
2 Headlights Verify high beam indicator is functional.
3 Verify lights are at proper angle.
4 Panel Dimmer Switch Verify dimmer controls brightness of display panel.
5 Verify front and rear turn signals operate properly on both sides of the truck.
6 Turn Signal Directional indicators operate properly.
7 Switch turns off after turn is completed.
8 Hazard Flashers Verify flasher operates properly.
9 Indicator lights operate properly.
10 Back Up Light Verify back up lights operates properly when transmission control is in R position.
11 Ladder Light Verify ladder lights illuminate with switch ON.
12 Dome Light Verify dome light operates with the switch ON.
13 Backup/Deck Lights Verify backup lights illuminate with switch ON.
14 Engine Compartment Verify the engine compartment lights illuminate with switch ON
Lights
Brake Lights
1 Service Brake Lights Verify service brake lights and indicator illuminate with service brake pedal depressed.
2 Brake Lock Verify brake lock indicator light illuminates when activated.
3 Auxiliary Brake Verify auxiliary brake indicator light illuminates when activated.
4 Parking Brake Verify parking brake indicator light illuminates with the parking brake on.
5 Retarder Lights Verify retard indicator light illuminates when activated.
Fluid Levels
1 Fluid Levels Check all fluid levels and observe condition of fluids.
Bolt Torque Checks
1 Drive Shaft (Engine to Verify capscrews are tightened to specified torque.
Transmission)
2 Drive Shaft (Transmis- Verify capscrews are tightened to specified torque.
sion to Differential)
3 Engine Mount Verify capscrews are tightened to specified torque.
4 Transmission Mount Verify capscrews are tightened to specified torque.
5 Cab Mount Verify capscrews are tightened to specified torque.
6 Front Support (LH & RH) Verify capscrews are tightened to specified torque.
7 Hydraulic Tank Verify capscrews are tightened to specified torque.
8 Fuel Tank Verify capscrews are tightened to specified torque.
9 Wheels Verify capscrews are tightened to specified torque.
10 Steering Wheel Verify capscrews are tightened to specified torque.
Leakage
1 Machine Verify that no oil leaks are found throughout the machine.
Maintenance
Accepted
N
Safety Functions
1 Transmission Range Verify transmission control will not shift out of N without pressing the release button
Selector
2 Neutral Safety Verify engine will not start in any position unless transmission range selector is in N. In this
position, centralized warning lamp illuminates, and buzzer sounds.
3 Parking Brake (ON) When parking brake is ON and transmission range selector is in any position other than N,
centralized warning lamp illuminates, and buzzer sounds.
4 Hoist Control When hoist control is any position other than FLOAT and transmission range selector is in
any position other than N, centralized warning lamp illuminates, and buzzer sounds.
5 When hoist control is any position other than FLOAT and transmission range selector is in
R, the truck will not move.
Suspension Cylinders
1 Front Suspension Verify that front suspension cylinder oiling height is 97 ± 3 mm (3.8 ± 0.12 in.). Refer to the
note below.
2 Rear Suspension Verify that rear suspension cylinder oiling height is 221 ± 3 mm (8.7 ± 0.12 in.). Refer to the
note below.
NOTE: Refer to Section H, Oiling And Charging Procedures, in the shop manual for the proper procedures for servicing front and rear sus-
pensions.
Engine Performance
1 Engine Starting Verify that engine starts without difficulty.
2 Engine Noise Verify that no abnormal engine noise exists.
3 Exhaust Gas Color Check for abnormal exhaust colorations during operation.
4 Exhaust Gas Leakage Inspect all exhaust joints for leakage.
Transmission Performance
1 Transmission Noise Verify that no abnormal transmission noise exists.
2 Transmission Shifting Verify transmission shifts smoothly in all speeds.
Braking
1 Service Brake Verify that service brakes do not pull to either side and steering wheel does not vibrate.
2 Check rpm required to overcome the service brakes with the transmission in F5.
Measurement__________rpm
3 Retarder Verify that machine does not pull to either side and steering wheel does not vibrate during
retardation.
4 Check rpm required to overcome the retarder with the transmission in F5.
5 Emergency Brake Verify that the machine will not move with the transmission range selector in F5.
6 Parking Brake Check rpm required to overcome the parking brake with the transmission in F5.
7 Brake Lock Verify brake lock actuates the rear brakes.
Steering
1 Steering Wheel Check steering wheel mounting. Should not have any play on mount.
2 Steering Verify that steering wheel turns easily, steering is smooth, and free from noise or vibration.
3 Emergency Steering Verify that emergency steering functions properly.
Maintenance
Accepted
N
Hoist / Dump Body
1 Hoist Control Lever Verify that control lever functions properly.
2 Hoist Limit Verify that hoist limit functions properly by preventing full cylinder extension.
3 Body Raise Speed Check body raise speed with the dump body empty.
Hydraulic Oil Temperature_________ Engine Speed________ Body Raise Time ________
4 Body Lower Speed Check body lower speed with the dump body empty.
Hydraulic Oil Temperature_________ Engine Speed________ Body Raise Time ________
Service Inspection
1 Lubrication Ensure automatic lube system is serviced and full (and air bled from system)
Ensure automatic lube system is operating properly and timer is set as desired
2 Error Codes Check the machine monitor on the (EDP) for action codes and/or fault codes. Troubleshoot
if codes exist.
3 Payload Meter System Calibrate and check payload meter operation per Operation and Maintenance Manual.
Additional Comments:
NOTES:
50 HOUR POST-COMMISSIONING CHECKSHEET
Make inspections according to this checksheet 50 hours (SMR) after the commissioning of a new truck to ensure machine performance and quality.
MACHINE MODEL MACHINE ENGINE MODEL ENGINE CUSTOMER UNIT

SERIAL NUMBER SERIAL NUMBER NUMBER
HD1500-7
Service Meter Reading Date of Inspection
Location of Machine at Inspection Dump Body Manufacturer

Komatsu Other
Distributor’s Name Dump Body Style
Customer’s Name KAC Area Service Manager Signature Date
Customer’s Address
Inspector’s Comments:
Inspector’s Name KOMATSU USE ONLY:

Sheet receiving Date:
Title By:
Signature Remark:
Send white reports to: Manager of Technical Support

Peoria, IL 61650-0240 U.S.A.
Send canary reports to: Manager of Field Assembly
Peoria, IL 61650-0240 U.S.A.
Send pink reports to your KAC Regional Service Manager
Send gold reports to the Service Manager at the KAC Distributor who sold the truck
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
Inspection Around Machine
1 Parts Visually inspect the truck for loose parts and debris.
2 Hardware Visually inspect the truck for missing and/or loose

mounting hardware.
3 Hoses and Cables Visually inspect hydraulic hoses and electric cables to
ensure they are securely clamped and clear of sharp
edges and other objects that may cause chaffing.
4 Engine Oil Level Verify the engine oil level is at the proper operating
range.
Check the air intake system and verify all intake tube
5 Engine Checks clamps are tightened securely. Ensure no leaks exist.
Inspect the entire engine. Ensure there are no fluid leaks
or abnormalities.
6 Transmission Oil Level Verify the transmission oil level is in the proper operating
range. (Overfilling may lead to overheating.)
7 Hydraulic Oil Level Verify hydraulic oils are filled to the proper levels.
Visually inspect axle mounting rods and rear suspen-

8 Rear Axle sions for proper installation and proper tightening torque.
Verify the correct oil is being used and the housing filled
to the proper oil level.
9 Fuel Tank Verify the fuel tank mounting is secure and there are no
fuel leaks.
10 Radiator Inspect the coolant fill level, cold temperature protection,

and DCA additive.
11 Steering Components Verify proper installation of the steering cylinders, tie rod,
and accumulators.
12 Hydraulic Components Visually inspect the hoist valve, pumps, filters, hydraulic
tank and hoist cylinder installations. All hardware must
be secure, and no leaks evident.
13 Leakage Visually inspect the entire machine for leaks.
Hardware Torque
1 Steering Lever Assem- Verify hardware torque -
bly To Frame Target: 177 N·m (131 ft lb)
2 Steering Cylinder To Verify hardware torque -
Center Lever Target: 177 N·m (131 ft lb)
3 Steering Cylinder To Verify hardware torque -
Frame Target: 177 N·m (131 ft lb)
4 Tie Rod Pin Retainer Verify hardware torque -
Target: 177 N·m (131 ft lb)
5 Front Brake To Spindle Verify hardware torque -
Target: 927 N·m (684 ft lb)
Cab Compartment
1 Horn Check for proper tone and volume. Ensure there is no
looseness in the horn button.
2 Back Up Horn Check for proper tone, volume, and function.
3 Gauges Verify all gauges are operating correctly.

4 Glass Verify no cracks exist on cab windows. Ensure all win-
dows are properly sealed.
No. Inspection Item Acceptance Procedures As Found Corrective
Condition Action
5 Seat/Seat belts Verify the cab seats and seat belts are in proper working
condition.
Service Inspection
1 Front Suspension Verify that the front suspension cylinder heights are
within the arrows on the cylinder decal.
Rear Suspension Verify that the rear suspension cylinder heights are
within specifications.
NOTE: Refer to Section H, Oiling and Charging Pro-
cedure, in the appropriate service manual for com-
plete suspension oiling and charging instructions.
2 Steering Verify that steering system is operating smoothly while
turning from lock to lock.
Verify the steering system is free of noise and vibration.
3 Lubrication Ensure the automatic lube system contains no air and is
filled to the proper level.
Ensure the automatic lube system is operating properly
and the timer is set as desired.
4 Hydraulic Filters Verify the 50 hour change of all hydraulic filters has been
completed.
NOTE: Elements are supplied from the factory in the
parts crate.
Pressure
5 Tires Check and record the tire pressure/size/manufacturer for Size
future reference
Manufacturer
6 Machine Monitor (EDP) Check the machine monitor on the EDP for proper oper-
ation. Verify that no action codes and/or fault codes are
present. Troubleshoot any codes that exist.
7 Payload Meter System Calibrate and check payload meter operation per O&M
manual. Troubleshoot any error codes and delete after
repair.
8 Dump Body Check the dump body for proper alignment, shimming,
and for any abnormal body pad wear. Verify that the
body limit switch and the hoist control lever are adjusted
correctly and working as intended.
MINE OPTIONS - List any mine/site specific options or modifications made to the unit.
No. Description of Modification Reason For Installation

1
ADDITIONAL COMMENTS ___________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
HD1500-7 DUMP TRUCK
Form No. GEN00100-00
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 11-09

Fa HD1500-7 SN 80001-Up Gen00100-00

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Field Assembly Instruction

DUMP TRUCK HD1500 -7

DANGER Identifies a specific potential hazard

WARNING identifies a specific potential hazard

CAUTION is used for general reminders

SUBJECT PAGE NUMBER

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

MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

DUMP BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

FAM0014 Introduction iii

FAM0111 Safety Rules, Tools, & Equipment Page 1-1

Page1-2 Safety Rules, Tools, & Equipment FAM0111

FAM0111 Safety Rules, Tools, & Equipment Page 1-3

PART NO. DESCRIPTION USE

PART NO. DESCRIPTION USE

569-86-87361 Download PLM Download

Page1-4 Safety Rules, Tools, & Equipment FAM0111

PART NO. DESCRIPTION USE

FAM0111 Safety Rules, Tools, & Equipment Page 1-5

Page1-6 Safety Rules, Tools, & Equipment FAM0111

The cab provides for wide visibility, with an integral

FAM0214 Major Components and Specifications 2-1

2-2 Major Components and Specifications FAM0214

FAM0214 Major Components and Specifications 2-3

Loaded (150 Ton Payload)

2-4 Major Components and Specifications FAM0214

ITEM KILOGRAMS POUNDS

CHASSIS AND CAB

FAM0313 Major Component Weights 3-1

ENGINE, TRANSMISSION AND RELATED COMPONENTS

FRONT AXLE COMPONENTS

REAR AXLE COMPONENTS

3-2 Major Component Weights FAM0313

FAM0404 Field Welding Procedures 4-1

4-2 Field Welding Procedures FAM0404

FAM0404 Field Welding Procedures 4-3

4-4 Field Welding Procedures FAM0404

FAM0404 Field Welding Procedures 4-5

4-6 Field Welding Procedures FAM0404

FAM0404 Field Welding Procedures 4-7

4-8 Field Welding Procedures FAM0404

FAM0504 Receiving & Assembly Preparation 5-1

5-2 Receiving & Assembly Preparation FAM0504

FAM0614 Chassis Assembly 6-1

7. Fit LH deck/ROPS support

6-2 Chassis Assembly FAM0614

FAM0614 Chassis Assembly 6-3

6-4 Chassis Assembly FAM0614

FAM0614 Chassis Assembly 6-5

6-6 Chassis Assembly FAM0614

FAM0614 Chassis Assembly 6-7

6-8 Chassis Assembly FAM0614

FAM0614 Chassis Assembly 6-9

6-10 Chassis Assembly FAM0614

FAM0614 Chassis Assembly 6-11

6-12 Chassis Assembly FAM0614