DG675ShopManual630EDUMP TRUCKSERIAL SUFFIXAFE42-M and upAFE46-U CALIFORNIAProposition 65 WarningDiesel engine exhaust, some of its constituents, and certain vehiclecomponents contain or emit chemicals known to the State of Californiato cause cancer, birth defects or other reproductive harm.CALIFORNIAProposition 65 WarningBattery posts, terminals and related accessories contain lead and leadcompounds, chemicals known to the State of California to cause cancerand birth defects or other reproductive harm. Wash hands after handling.Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-sonnel must read and understand this manual before operating or maintaining this machine.This manual should be kept in or near the machine for reference, and periodically reviewed by allpersonnel who will come into contact with it.This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis-closed except in accordance with written authorization from KAC.It is the policy of the Company to improve products whenever it is possible and practical to do so. TheCompany reserves the right to make changes or add improvements at any time without incurring any obli-gation to install such changes on products sold previously.Because of continuous research and development, periodic revisions may be made to this publication.Customers should contact their local Komatsu distributor for information on the latest revision.NON-OEM PARTS IN CRITICAL SYSTEMSFor safety reasons, Komatsu America Corp. strongly recommends against the useof non-OEM replacement parts in critical systems of all Komatsu equipment. Criticalsystems include but are not limited to steering, braking and operator safety sys-tems.Replacement parts manufactured and supplied by unauthorized sources may not bedesigned, manufactured or assembled to Komatsu's design specifications; accord-ingly, use of such parts may compromise the safe operation of Komatsu productsand place the operator and others in danger should the part fail.Komatsu is also aware of repair companies that will rework or modify an OEM partfor reuse in critical systems. Komatsu does not generally authorize such repairs ormodifications for the same reasons as noted above.Use of non-OEM parts places full responsibility for the safe performance of theKomatsu product on the supplier and user. Komatsu will not in any case acceptresponsibility for the failure or performance of non-OEM parts in its products,including any damages or personal injury resulting from such use.CEHQ000700 - Komatsu America International Company 12/99 EMISSION CONTROL WARRANTY EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1. Products Warranted Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively Komatsu) produce and/or market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada. 2. Coverage Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser. 3. Limitations Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, downtime expense, related damage, fines, all business costs or other losses resulting from a warrantable failure. KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE. GARANTIE SUR LE CONTRLE DES MISSIONS NONC DE GARANTIE SUR LE CONTRLE DES MISSIONS (APPLICABLE AU CANADA SEULEMENT): 1. Produits garantis: Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la mise en march de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les missions sapplique tous les nouveaux moteurs portant le nom Komatsu, installs dans ces produits et utiliss au Canada dans des machines conues pour utilisation industrielle non-routire. Cette garantie sapplique seulement sur les moteurs produits partir du 1er Janvier 2000. Cette garantie sera administre par la distribution de Komatsu au Canada. 2. Couverture: Komatsu garantit lacheteur ultime et chaque acheteur subsquent que le moteur est conu, construit et quip en toute conformit, au moment de la vente par Komatsu, avec toutes les Rglementations fdrales amricaines sur les missions applicables au moment de la fabrication et quil est exempt de dfauts de construction ou de matriaux qui auraient pour effet de contrevenir ces rglementations en dedans de 5 ans ou 3000 heures dopration, mesur partir de la date de livraison du moteur au client ultime. 3. Limitations: Les bris, autres que ceux rsultant de dfauts de matriaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu nest pas responsable pour bris ou dommages rsultant de ce que Komatsu dtermine comme tant de labus ou ngligence, incluant mais ne se limitant pas : lopration sans lubrifiants ou agent refroidissants adquats; la suralimentation dessence; la survitesse; le manque dentretien des systmes de lubrification, de refroidissement ou dentre; de pratiques non-propices dentreposage, de mise en marche, de rchauffement, de conditionnement ou darrt; les modifications non-autorises du moteur. De plus, Komatsu nest pas responsable de bris causs par de lessence inadquate ou de leau, des salets ou autres contaminants dans lessence. Komatsu nest pas responsable des rparations non-relies au moteur, des dpenses encourues suite aux temps darrts, des dommages relatifs, amendes, et de tout autre cot daffaires ou autres pertes rsultant dun bris couvert par la garantie. KOMATSU NEST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSQUENTS. Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL NY A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIRE. INFORMATION IMPORTANTE SUR LE MOTEURCE MOTEUR EST CONFORME AUX NORMES AMRICAINES DELEPA (ANNE DU MODLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI-TION PAR COMPRESSION. CE MOTEUR EST CERTIFI POUR OPERATION ESSENCE DISEL.AVERTISSEMENTDES BLESSURES PEUVENT RSULTER ET LA GARANTIE SANNULER SI LES RPM DU TAUX DESSENCE OU LALTITUDE EXCDENT LES VALEURS MAXIMALES PUBLIES POUR CE MODLE ET SON APPLICATION.IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-FIED TO OPERATE ON DIESEL FUEL.MODLE DU MOTEURWARNINGINJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.NO. SRIEFAMILLE DU MOTEURENGINE MODEL SERIAL NO.DPLACEMENTSYSTME DE CONTROLE DES MISSIONS DCHAPPEMENTENGINE FAMILY DISPLACEMENT LITERSEXHAUST EMISSIONCONTROL SYSTEMFIRING ORDER 1 - 5 - 3 - 6 - 2 - 4 LITRESCHARGE DE SORTIE ADV.ADV. LOAD OUTPUT Kw ( HP) RPMSQUENCE DE MISE FEUPORTE DE VALVE FROID (mm)VALVE LASHCOLD (mm)IN. EX. FUEL RATE AT ADV.mm3/STROKEmm3/BATTEMENTTAUX DESSENCE ADV.VITESSE STATIQUEIDLE SPEED RPM FAMILY EMISSION LIMITINITIAL INJECTION TIMINGDEG. BTDC DATE OF MANUFACTURELIMITE DMISSION DELA FAMILLERGLAGE DE LALLUMAGE - INJECTION INITIALE_____________________________________________ KOMATSU LTD.MADE IN JAPANDATEDE FABRICATIONDEG. BTDCKOMATSU LTEFABRIQU AU JAPONENGINE DATAPLATE - ENGLISH / FRENCHA00004 7/95 Introduction A-1FOREWORDThis Service Manual is written for use by the service technician and is designed to help the technician become fullyknowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per-sonnel should read and understand the materials in this manual before performing maintenance and/or operationalchecks on the truck. All safety notices, warnings and cautions should be understood and followed when accom-plishing repairs on the truck.The first section covers component descriptions, truck specifications and safe work practices, as well as other gen-eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major ser-viceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiatorgroup is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entiremechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish neededrepairs.The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depicta specific model.This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to "Right","Left", "Front", or "Rear" are made with respect to the operators normal seated position, unless specifically statedotherwise.Standard torque requirements are shown in torque charts in the general information section and individual torquesare provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have 10%tolerance unless otherwise specified.A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig-nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.(Gross Vehicle Weight) rating. The HAULPAK Model designation consists of three numbers and one letter (i.e. 630E). The three numbers repre-sent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an Electricalpropulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original man-ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many serviceparts and/or warranty consideration.The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and othercompo-nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight(GVW) and this means the total weight: the Empty Vehicle Weight + the fuel &lubricants + the payload.To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners,tailgates, etc.) and then weigh truck.Record this value and subtract from the GVW rating. The result is the allowable payload.NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. Tomaximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as oftenas practical. Exceeding the allowable payload will reduce expected life of truck components. For Model 630E HAULPAK Trucks, optional heavy duty components may be required to utilize the630,000 lbs.(286 020 kg) GVW. Contact factory if clarification is needed.A-2 Introduction A00004 7/95 CAUTION is used for general reminders of proper safety practicesOR to direct the readers attention to avoid unsafe or improper practices which may result in damage to the equipment. WARNING identifies a specific potential hazard WHICH MAY RESULT in either INJURY OR DEATH if proper precautions are not taken. DANGER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken.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.A00004 7/95 Introduction A-3TABLE OF CONTENTSSUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTIONGENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASTRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BENGINE, FUEL, COOLING AND AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CELECTRIC SYSTEM (24 VDC. NON-PROPULSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DELECTRIC PROPULSION AND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDRIVE AXLE, SPINDLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GHYDRAIR II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HBRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JAIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KHYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOPERATORS CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NLUBRICATION AND SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QSYSTEM SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RA-4 Introduction A00004 7/95KOMATSU 630E HAULPAK TRUCKA01001 02/94 Index A1-1SECTION AGENERAL INFORMATIONINDEXMAJOR COMPONENTS & SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1GENERAL SAFETY AND TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1STANDARD TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-1A1-2 Index 02/94 A01001NOTESA2-1 Major Component Description A02028MAJOR COMPONENT DESCRIPTIONENGINEThe 630E HAULPAK is powered by a Detroit Diesel16V-149TIB engine rated at 1800 HP (1342 kW) or aCummins KTTA 50-C engine rated at 1800HP (1342kW). Other engines may be specified as optionalequipment.ALTERNATORThe diesel engine drives an alternator mounted in-line with the engine. The alternating current (AC) out-put of the alternator is rectified to direct current (DC)and sent to the DC drive wheel motors.WHEEL MOTORS (GE 776)The output of the alternator supplies electrical energyto the two wheel motors attached to the rear axlehousing. The two wheel motors convert electricalenergy back to mechanical energy through built-ingear trains within the wheel motor assembly. Thedirection of the wheel motors is controlled by a for-ward or reverse hand selector switch located on aconsole to the right side of the operator. The GE788wheel motor may be specified as optional equip-ment.BLOWERThe blower supplies cooling air for the alternator, rec-tifiers, and both wheel motors. The air is thenexhausted to the atmosphere through the wheelmotors.OPERATOR'S CABThe HAULPAK Operator's Cab has been engi-neered for operator comfort and to allow for efficientand safe operation of the truck. The cab is rubbermounted to reduce noise and vibration. It includes atinted safety-glass windshield and sliding side win-dows for excellent visibility, a deluxe interior, controlsmounted within easy reach of the operator, and aninstrument panel which provides the operator with allinstruments and gauges which are necessary to con-trol and monitor the truck's operating systems.POWER STEERINGThe HAULPAK truck is equipped with a full timepower steering system which provides positive steer-ing control with a minimum of effort by the operator.The system includes nitrogen-charged accumulatorswhich automatically provide emergency power if thesteering hydraulic pressure is reduced below anestablished minimum.DYNAMIC RETARDINGThe dynamic retarding is used to slow the truck dur-ing normal operation or control speed coming down agrade. The dynamic retarding ability of the DC elec-tric system is controlled by the operator through theactivation of the retarder pedal in the operators caband by setting the RSC (Retarder Speed Control).Dynamic Retarding is automatically activated if truckgoes to a preset overspeed setting.BRAKE SYSTEMThe braking system consists of an all hydraulic actu-ation system. Depressing the brake pedal actuateswheel-speed single disc front brakes and armature-speed dual disc rear brakes. The brakes can also beactivated by operating a switch on the instrumentpanel as described later in this manual. The brakeswill be applied automatically if system pressuredecreases below a preset minimum.SUSPENSIONHYDRAIR II suspension cylinders located at eachwheel provide a smooth and comfortable ride for theoperator and dampens shock loads to the chassisduring loading and operation.A2-2 Major Component Description A02028A2-3 Major Component Description A02028SPECIFICATIONSENGINES (Standard Options)Cummins KTTA 50-CNumber of Cylinders . . . . . . . . . . . . . . . . . . 16Operating Cycle . . . . . . . . . . . . . . . . 4-StrokeRated Brake HP 1800 HP (1342 kW) @ 1900 RPMFlywheel HP 1704 HP (1271 kW) @ 1900 RPMWeight (Dry) . . . . . . . . . 10,895 lbs. (4942 kg)Detroit Diesel 16V-149TIBNumber of Cylinders . . . . . . . . . . . . . . . . . . 16Operating Cycle . . . . . . . . . . . . . . . . 2-StrokeRated Brake HP . 1800 HP (1342 kW) @ 1900 RPMFlywheel HP 1704 HP (1271 kW) @ 1900 RPMWeight (Dry) . . . . . . . . . 11,210 lbs. (5085 kg)ELECTRIC DRIVE SYSTEMSTATEX III AC/DC CurrentAlternator. . . . . . . . . General Electric GTA - 22Motorized Wheels . . . . . . . . . General Electric776 Gear Ratio . . . . . . . . . . . . . . . . . . 28.85:1Maximum Speed . . . . . 34.0 MPH (54.7 km/h)788 (Optional) Gear Ratio. . . . . . . . . . 26.14:1Maximum Speed . . . . . 34.4 MPH (55.4 km/h)DYNAMIC RETARDINGElectric Dynamic Retarding. . . . . . . . StandardMaximum Retarding . . . . 2677 HP (1996 kW)Optional. . . . . . . . . . . . . . . 3700 HP(2759 kW)With. . . . . . . . Continuous Rated Blown Grids . . . . . . . . . . . . . . . Extended Range Retarding . . . . . . . . . . . . . . . . . . . . . Reverse RetardingBATTERY ELECTRIC SYSTEMBatteries. . . . . Two 12 Volt Batteries in Series. . . . . . . . . . . . . . . 140 Ampere-Hour CapacityWith Disconnect SwitchAlternator . . . . . . 24 Volt, 140 Ampere OutputLighting . . . . . . . . . . . . . . . . . . . . . . . . 24 VoltSERVICE CAPACITIESU.S. Gallons .LitersCrankcase (Includes lube oil filters)Detroit Diesel . . . . . . . . . . 52.5 . . . . . . . . . 199Cummins . . . . . . . . . . . . . 56.6 . . . . . . . . . 214Cooling System . . . . . . . . 83 . . . . . . . . . . 314Fuel . . . . . . . . . . . . . . . . . 850 . . . . . . . . 3217Hydraulic System. . . . . . . 134 . . . . . . . . . 507Whl. Motor Gear Box . . . . 4.5/Whl. . . . 17/Whl.AIR SYSTEMCompressor Bendix-Westinghouse TU-FLO 501Capacity. . . . . . . . . 12 ft/min. (0.34 m/min.)Starter with Interlock . . . . . Ingersol Rand 815. . . . . . . . . . . . . . . . . . . Optional, Electric StartAir Tank Capacity. . . 15 cubic feet (425 liters)HYDRAULIC SYSTEMPump 145 GPM (549 liters/min.) @ 1900 RPMRelief Pressure- Hoist . . 2500 psi (17.2 MPa)Relief Pressure- Steering 3000 psi (20.7 MPa)Hoist. . . . . . 3-Stage Hydraulic Twin CylindersTank . . . . . . . . . . . . . . . . . . . Non-Pressurized0Service Capacity . 134 U.S. Gal. (507 Liters)Filtration . Accessible, Replaceable, ElementsSuction. . . . . . . . Single, Full Flow, 100 MeshReturn . . . . . . . . . . . . . . . . . . . . . . . . Full FlowOptional Hoist & Steering High Pressure Filter . . . . . . . . . . . . . . . . . . . . . Full Flow, 7 MicronThe SPECIFICATIONS listed on these pages cover standard production. When Optional equipment is selected,some of these specifications and/or capacities may change.A2-4 Major Component Description A02028SERVICE BRAKESActuation . . . . . . . . . . . . . . . . . . All Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . (Front)(Rear)Type . . . . . . . . . . . . . . . . Single DiscDual Disc. . . . . . . . . . . . . Wheel SpeedArmature SpeedSTEERINGTurning Circle (SAE) . . . . . . . . . 80 ft. (24.4 m)Emergency Power Steering With AccumulatorsDUMP BODYCapacity:Struck . . . . . . . . . . . . . . . . . . . . 101 yds77 mHeaped @ 2:1 (SAE) . . . . . . .135 yds 103 mWidth (Inside) . . . . . . . . . . 20 ft. 7 in. (6.27 m)Depth . . . . . . . . . . . . . . . . . 7 ft. 8 in. (2.35 m)Loading Height . . . . . . . . . . 18 ft. 9 in. (5.71 m)Dumping Angle . . . . . . . . . . . . . . . . . . . . . 45TIRESRadial Tires (standard) . . . . . . . . . . 36.00 R51Rock Service, Deep Tread . . . . . . . . TubelessTire Rims. . . . . . . . . . . . . . . . . . . . . SeparableTires and Rims . . . . . . . . . . . InterchangeableWEIGHT DISTRIBUTIONEMPTY . . . . . . . . . . . . . . . . . . . Pounds . . KilogramsFront Axle . . . . . . . . . . . 117,150 . . . . . 53 138Rear Axle . . . . . . . . . . . 122,650. . . . . 55 633Total . . . . . . . . . . . . . . . 239,800. . . . 108 771LOADEDFront Axle . . . . . . . . . . . 206,600. . . . . 93 712Rear Axle . . . . . . . . . . . 413,200 . . . . 187 424Total * . . . . . . . . . . . . . . 619,800 . . . . 281 136* Not to exceed 630,000 lbs. (285 763 kg) includingoptions, fuel and payload.Optional heavy duty components may be required toutilize this Gross Vehicle Weight limit. Contact Haul-pak Division if clarification is required.OVERALL TRUCK DIMENSIONSAll dimensions are with 101/135 cu.yd. (77/103 m3 body, 36.00 R51 tires, and 776 wheel motors.A03004 7/95 General Safety & Operation A3-1GENERAL SAFETY AND OPERATIONSafety records of most organizations will show thatthe greatest percentage of accidents are caused byunsafe acts of persons. The remainder are causedby unsafe mechanical or physical conditions. Reportall unsafe conditions to the proper authority.The following safety rules are provided as a guide forthe HAULPAK operator. However, local conditionsand regulations may add many more to this list. SAFETY IS THINKING AHEAD Prevention is the best safety program. Potentialaccidents can be prevented by knowing theemployer's safety requirements, all necessary jobsite regulations, as well as use and care of the safetyequipment on the HAULPAK truck. Only qualifiedoperators or technicians should attempt to operatethe HAULPAK. Safe practices start before the operator gets tothe equipment! 1. Wear the proper clothing. Loose fitting clothing,unbuttoned sleeves and jackets, jewelry, etc.,can catch on a protrusion and cause a potentialhazard.2. Always use the personal safety equipment pro-vided for the operator such as hard hat, safetyshoes, safety glasses or goggles. There aresome conditions when protective hearingdevices should also be worn for operator safety.PREPARING FOR OPERATIONThe safest trucks are those which have been prop-erly prepared for operation. At the beginning of eachshift, a careful check of the truck should be madebefore the operator attempts engine start-up. 1. When walking to and from the truck, BE ALERT,remain a safe distance from all other machineseven if the operator is visible.2. Check for any oil or coolant leaks. When check-ing coolant in radiator, use coolant level sightgauge (if equipped). If necessary to removeradiator cap, shut down engine, and relievecoolant pressure SLOWLY before removingradiator cap.If engine has been running, allow coolant to cool,before removing the fill cap or draining radiator.Serious burns may result if coolant is not allowedto cool.Any operating fluid, such as hydraulic oil, orengine coolant escaping under pressure, canhave sufficient force to enter a person's body bypenetrating the skin and cause serious injury andpossibly death, if proper medical treatment by aphysician who is familiar with this type of injuryis not received immediately.3. Check tires for cuts, damage or "bubbles". Checktires for proper inflation before beginning shift andperiodically during shift. If tire is warm from opera-tion, allow tire to cool before adjusting tirepressure. If inflation is needed, use an air chuckwith extension hose clipped on the tire inflationvalve to allow service from behind the tread of thetire and away from front of wheel.Do not stand in front of rim and locking ringwhen inflating tire.4. Visually inspect all headlights, worklights andtaillights and safety equipment for external dam-age from rocks or misuse. Make sure lensesare clean.5. Always use hand rails and ladder when mountingor dismounting from the truck. Clean your shoes,ladder, and hand rails of all accumulations, suchas ice, snow, oil, or mud before climbing.Always mount and dismount the truck facing thetruck. Never attempt to mount or dismount thetruck while it is in motion.6. Check the deck areas for debris, loose hard-ware or tools. Become familiar with all protec-tive equipment devices on the truck and insurethat these items (anti-skid material, grab bars,seat belts, etc.) are securely in place.A3-2 General Safety & Operation A03004 7/957. Read and understand the contents of the Oper-ator's Handbook. Give particular attention tosafety material and operating instructions. Read and understand CAUTION and WARN-ING decals in the operator's cab.8. Become thoroughly acquainted with all gauges,instruments and controls. Be familiar with allbrake and steering system controls and warningdevices, road speeds, and loading capabilities,before operating the truck.9. Keep all unauthorized reading material out oftruck cab.10. Dirt or trash buildup, specifically in the opera-tor's cab, should be cleared. Do not carry toolsor supplies in cab of truck or on the deck.11. Insure steering wheel, controls and pedals arefree of any oil, grease or mud.12. Insure headlights, worklights and taillights are inproper working order.13. Insure windshield and all cab windows are cleanand unbroken. Good visibility may prevent anaccident.14. Check operation of windshield wiper, conditionof wiper blades, and windshield washer reser-voir for fluid level.15. Insure adequate ventilation before start-up if thetruck is in an enclosure. Exhaust fumes are dangerous! ENGINE START-UP SAFETY PRACTICES1. Insure all personnel are clear of truck beforestarting engine. Always sound the horn as awarning before actuating any operational con-trols.2. Check and insure Selector Switch is in "Neutral"before starting.3. If truck is equipped with auxiliary cold weatherheater system(s), do not attempt to start enginewhile heaters are in operation. Damage to coolant heaters will result.NOTE: If truck is equipped with HMS control system,refer to Operator Handbook for starting procedures4. The keyswitch is a three position (Off, Run,Start) switch. When switch is rotated one posi-tion clockwise, it is in the "Run" position and allelectrical circuits (except "Start") are activated.With Selector Switch in "Neutral", rotate key-switch fully clockwise to "Start" position andhold this position until engine starts. "Start" posi-tion is spring loaded to return to "Run" when keyis released.NOTE: If truck is equipped with the CumminsEngine Prelube System, a noticeable time delaywill occur (while engine lube oil passages arebeing filled) before starter engagement andengine cranking will begin. The colder theengine oil temperature, the longer the timedelay will be. In addition, if truck is alsoequipped with Engine Starting Aid for coldweather starting, the Engine Prelube Systemshould be engaged FIRST for 5-10 seconds, oruntil starter is engaged, BEFORE activating theEngine Starting Aid. Starting fluid is extremely volatile and flammable!Use with extreme care. If truck is equipped with optional Engine Starting Aidand ambient temperature is below 50F (10C), turnthe keyswitch to the "Start" position, and while crank-ing engine, move the Engine Starting Aid switch tothe "On" position for three (3) seconds MAXIMUM;then release Engine Starting Aid. If engine does notstart, wait at least fifteen (15) seconds before repeat-ing the procedure. Do not crank an electric starter for more than 30seconds. Allow at least two minutes for starter cooling beforeattempting to start engine again. Severe damage to starter motor can result from over-heating.A03004 7/95 General Safety & Operation A3-3AFTER ENGINE HAS STARTED1. Become thoroughly familiar with steering andemergency controls. After engine has startedand low pressure and warning systems are nor-mal, test the truck steering in extreme right andleft directions. If the steering system is not oper-ating properly, shut engine down immediately.Determine the steering system problem andhave repairs made before resuming operation.2. Operate each of the truck's brake circuits atleast twice prior to operating and moving thetruck. These circuits include individual activa-tion from the operator's cab of the servicebrake, parking brake, and brake lock (alsoemergency brake, if equipped). With the enginerunning and with the hydraulic circuit fullycharged, activate each circuit individually. If anyapplication or release of any brake circuitappears sluggish or improper, or if warningalarms are activated on application or release,shut the engine down and notify maintenancepersonnel. Do not operate truck until brakecircuit in question is fully operational.3. Check gauges, warning lights and instrumentsbefore moving the truck to insure proper systemoperation and proper instrument functioning.Give special attention to braking and steeringcircuit hydraulic warning lights. If warning lightscome on, shut down the engine immediatelyand determine the cause.4. Insure headlights, worklights and taillights are inproper working order. Good visibility may pre-vent an accident. Check operation of windshieldwiper.5. When truck body is in dump position, do notallow anyone beneath it unless body-up retain-ing pin or cable is in place.6. Do not use the fire extinguisher for any purposeother than putting out a fire! If extinguisher isdischarged, report the occurrence, so the usedunit can be refilled or replaced.7. Do not leave truck unattended while engine isrunning. Shut down engine before getting out ofcab.SAFETY PRECAUTIONS DURING TRUCK OPERATION After the truck engine is started and all systems arefunctioning properly, the operator must follow all localsafety rules to insure safe machine operation.If any of the red warning lights come " On" or ifany gauge reads in the red area during truckoperation, a malfunction is indicated. Stop truckas soon as safety permits, shut down engine ifproblem indicates and have problem correctedbefore resuming truck operation.Operating truck with stalled or free spinningwheel motors may cause serious damage towheel motors! If truck does not begin to movewithin 10 seconds after depressing throttle pedal(Selector Switch in a drive position), releasethrottle pedal and allow wheels to regain tractionbefore accelerating engine again.At the beginning of each shift, check the automaticemergency steering for proper operation. This can beaccomplished as follows: With engine running and steering system fullycharged, no red warning lights or buzzer shouldbe "on" (HMS trucks should have no warningsdisplayed.). Shut down engine and leave keyswitch in "Run"position (leave HMS "On"). Turn steering wheel one full turn left and right; iffront wheels turn, system is operating properly.Restart engine.NOTE: Automatic Emergency Steering ability is lim-ited by the capacity of the steering accumulators.This function is intended to allow the operator onlyenough time to steer the HAULPAK to a safe stopduring an emergency situation. 1. WEAR SEAT BELTS AT ALL TIMES! Operatethe truck only while properly seated with seatbelt fastened. Keep hands and feet inside thecab compartment while truck is in operation.2. Do not allow unauthorized personnel to ride inthe truck. Only authorized persons are allowedto ride in truck cab, and they should have seatbelts fastened. Do not allow anyone to get on oroff truck while it is in motion, or to ride on thedeck or the ladder of the truck.A3-4 General Safety & Operation A03004 7/953. Do not move truck into or out of a building with-out a signal person present. Know and obey thehand signal communications between operatorand spotter. When other machines and person-nel are present, the operator should move inand out of buildings, loading areas and throughtraffic, under the direction of a signalman. Cour-tesy at all times is a safety precaution!Always look to the rear before backing thetruck. Watch for and obey ground spotter's handsignals before making any reverse movements.Sound the warning horn (3 blasts). Spottershould have a clear view of the total area at therear of the truck.4. Check gauges and instruments frequently dur-ing operation for proper readings.5. DO NOT leave truck unattended while engine isrunning. Do not allow engine to run at "Idle" forextended periods of time. When parking, alwaysapply parking brake, and park a safe distancefrom other vehicles, as determined by supervisor.6. Report immediately to supervisor any condi-tions on haul road, pit or dump area that maypresent an operating hazard.7. Observe all regulations pertaining to the jobsite's traffic pattern. Be alert to any unusual traf-fic pattern. Obey the spotter's signals.8. Match the truck speed to haul road conditionsand slow the truck in any congested area. Keepa firm grip on steering wheel at all times.9. Check parking brake periodically during shift.Use parking brake ONLY for parking. Do notuse park brake for loading / dumping. Do not attempt to apply parking brake whiletruck is moving! Do not use " Brake Lock" or " Emergency Brake"(if equipped) for parking. 10. Check brake lock performance periodically forsafe loading and dump operation.11. Proceed slowly on rough terrain to avoid deepruts or large obstacles. Avoid traveling close tosoft edges and the edge of fill area.12. Truck operation requires concentrated effort bythe driver. Avoid distractions of any kind whileoperating the truck.13. Keep serviceable fire fighting equipment at hand.If extinguisher is discharged, report the occur-rence, so the used unit can be refilled or replaced.In the event of fire in the tire and wheel area(including brake fires), stay away from the truckat least 8 hours until the tire and wheel are cool.Tire and rim assembly may explode if subjectedto excessive heat. Personnel should move to aremote or protected location if sensing exces-sively hot brakes, smell of burning rubber or evi-dence of fire near tire and wheel area.If the truck must be approached, such as to fighta fire, those personnel should do so only whilefacing the tread area of the tire (front or back),unless protected by use of large heavy equip-ment as a shield. Stay at least 50 ft. (15 m) fromthe tread of the tire.14. Stay alert at all times! In the event of an emer-gency, be prepared to react quickly and avoidaccidents. If an emergency arises, know whereto get prompt assistance.LOADING1. Pull into the loading area with caution. Remain ata safe distance while truck ahead is being loaded.2. Do not drive over unprotected power cables.3. When approaching or leaving a loading area,watch out for other vehicles and for personnelworking in the area.4. When pulling in under a loader or shovel, follow"Spotter" or "Shovel Operator" signals. Thetruck operator may speed up loading operationsby observing the location and loading cycle ofthe truck being loaded ahead, then follow a sim-ilar pattern.5. When being loaded, operator should stay intruck cab. Place Selector Switch in "Neutral"and apply brake lock with engine running.If operator must leave truck cab during loading,engine must be shut down and parking brakeapplied. DO NOT use brake lock or emergencybrake (if equipped) for parking. Remain far enough away from truck to avoidbeing struck by flying material.6. When loaded, pull away from shovel as quicklyas possible but with extreme caution.A03004 7/95 General Safety & Operation A3-5HAULING1. Always stay alert! If unfamiliar with the road,drive with extreme caution. Cab doors should remain closed at all times iftruck is in motion or unattended.2. Obey all road signs. Operate truck so it is undercontrol at all times. Govern truck speed by theroad conditions, weather and visibility. Reporthaul road conditions immediately. Muddy or icyroads, pot holes or other obstructions canpresent hazards.3. When backing the truck, give back-up signal(three blasts on the horn); when starting for-ward, two blasts on the horn. Sound thesealarms each time the truck is moved forward orbackward.4. Use extreme caution when approaching a haulroad intersection. Maintain a safe distance fromoncoming vehicles.5. Maintain a safe distance when followinganother vehicle. Never approach another vehi-cle from the rear, in the same lane, closer than50 ft. (15 m). When driving on a down grade,this distance should not be less than 100 ft. (30 m).6. Do not stop or park on a haul road unlessunavoidable. If you must stop, move truck to asafe place, apply parking brake, block wheelssecurely, shut down engine and notify mainte-nance personnel for assistance.7. Before starting up or down a grade, maintain aspeed that will insure safe driving and provideeffective retarding under all conditions. Refer toGrade/Speed decal in operator's cab.8. When operating truck in darkness, or when visi-bility is poor, do not move truck unless head-lights are on. Do not back truck if back-up hornor lights are inoperative. Always dim headlightswhen meeting oncoming vehicles.9. If the "Emergency Steering" light and/or "LowBrake Pressure Warning" light (if equipped) illu-minate during operation, steer the truck imme-diately to a safe stopping area, away fromother traffic, if possible. Refer to item 6 above.10. The Statex III w/Fuel Enhancement systemmonitors wheel motor, ambient, and staticexciter temperatures. If any one of these valuesis outside the limits established, the Statex IIIcontrols will cause the engine to increase to1650 RPM. (Normal engine RPM for haul road/retardingoperation is 1250 RPM.)11. When maximum truck speed is reached, haultrucks equipped with Statex III w/Fuel Enhance-ment system will experience a DECREASE inengine RPM. NOTE: This is different from trucks equippedwith Statex II or Statex III without Fuel Enhance-ment, which increase RPM upon reachingspeed limit.12. Check tires for proper inflation periodically dur-ing shift. If truck has been run on a "flat", orunder-inflated tire, it must not be parked in abuilding until the tire cools.PASSING1. Do not pass another truck on a hill or blindcurve!2. Before passing, make sure the road ahead isclear. If a disabled truck is blocking your lane,slow down and pass with extreme caution.3. Use only the areas designated for passing.DUMPING1. Pull into dump area with extreme caution. Makesure area is clear of persons and obstructions,including overhead utility lines. Carefullymaneuver truck into dump position. Obey sig-nals directed by the spotter, if present.2. Avoid unstable areas. Stay a safe distance fromedge of dump area. Position truck on a solid,level surface before dumping. As body raises, the truck Center of Gravity (CG)will move. Truck must be on level surface to pre-vent tipping / rolling! 3. When in dump position, apply Brake Lock andmove Selector Switch to the "Neutral" position.A3-6 General Safety & Operation A03004 7/95To Raise dump body:The dumping of very large rocks (10% of payload,or greater) or sticky material (loads that do notflow freely from the body) may allow the materialto move too fast and cause the body to moveRAPIDLY and SUDDENLY. This sudden move-ment may jolt the truck violently and cause pos-sible injury to the operator, and/or damage to thehoist cylinders, frame, and/or body hinge pins. Ifit is necessary to dump this kind of material, referto the CAUTION in the following procedure: 4. Pull the lever to the rear to actuate hoist circuit.(Releasing the lever anywhere during "hoist up"will place the body in "hold" at that position.)5. Raise engine RPM to accelerate hoist speed.Refer to the CAUTION below.If dumping very large rocks or sticky material asdescribed in WARNING above, slowly accelerateengine RPM to raise body. When the materialstarts to move, release hoist lever to " HOLD"position. If material does not continue movingand clear body, repeat this procedure until mate-rial has cleared body.6. Reduce engine RPM as last stage of hoist cylin-der begins to extend and let engine go to lowidle as last stage reaches half-extension.7. Release hoist lever as last stage of hoist cylin-der reaches full extension.8. After material being dumped clears body, lowerbody to frame.To Lower Body:Move hoist lever forward to "down" position andrelease. Releasing the lever places hoist controlvalve in the "float" position allowing the body toreturn to frame. NOTE: If dumped material builds up at the rear of thebody and the body cannot be lowered, shift SelectorSwitch to "Forward", release Brake Lock, depressOverride button and drive forward to clear material.Stop, shift Selector Switch to "Neutral", apply BrakeLock and lower body. The HAULPAK is not to be moved with the dumpbody raised except for emergency moves only.Failure to lower body before moving truck maycause damage to hoist cylinders, frame and/orbody hinge pins. 9. With body returned to frame, move SelectorSwitch to "Forward", release Brake Lock, andleave dump area carefully. TOWINGPrior to towing a truck, many factors must be care-fully considered. Serious personal injury and/or sig-nificant property damage may result if importantsafety practices, procedures and preparation formoving heavy equipment are not observed. Do not tow the truck any faster than 5 MPH (8 kph). A disabled machine may be towed after the followingMINIMUM precautions have been taken.1. Shut down engine.2. If truck is equipped, install hydraulic connec-tions for steering and dumping between towingand towed vehicles. Check towed vehicle forbraking system.3. Inspect tow bar for adequacy (approximately1.5 times the gross vehicle weight of truck beingtowed).4. Determine that towing vehicle has adequatecapacity to both move and stop the towed truckunder all conditions.5. Protect both operators in the event of tow barfailure.6. Block disabled truck to prevent movement whileattaching tow bar.7. Release disabled truck brakes and removeblocking.8. Sudden movement may cause tow bar failure.Smooth and gradual truck movement is pre-ferred.9. Minimize tow angle at all times - NEVEREXCEED 30. The towed truck must be steeredin the direction of the tow bar.A03004 7/95 General Safety & Operation A3-7WHEN REPAIRS ARE NECESSARY1. Only qualified maintenance personnel, whounderstand the systems being repaired, shouldaccomplish repairs.2. If truck is to be towed for any reason, use a rigidtow bar. Refer to TOWING procedure.3. DO NOT WORK under a suspended load. Donot work under raised body unless body safetycables, props, or pins are in place to hold thebody.4. Do not repair or service truck while engine isrunning, except when adjustments can only bemade under such conditions. Keep a safe dis-tance from moving parts. 5. When servicing air conditioning system withrefrigerant (Freon), wear a face shield and coldresistant gloves for protection against freezing.6. Follow package directions carefully when usingcleaning solvents.7. If an auxiliary battery assist is needed, hook uppositive (+) leads of the auxiliary battery cablesto the positive (+) posts of both truck batteries.Connect the negative (-) lead to the auxiliary bat-tery and then connect cable to a frame groundon the disabled truck away from the battery.8. Disconnect batteries (or battery disconnectswitch, if so equipped), battery charging alter-nator, and plug-in cards before making weldingrepairs. When welding, the ground connectionsmust be as close as possible to weld area.Welding current must not pass through anybearings.9. Many components on the HAULPAK are largeand heavy. Insure that lifting equipment (hoists,slings, chains, lifting eyes) are of adequatecapacity to handle the lift.10. Relieve pressure in lines or hoses by shuttingengine down, activating the system to relieveaccumulator pressure, and place all systemcontrols in neutral before making the discon-nects.Any operating fluid, such as hydraulic oil, escap-ing under pressure can have sufficient force toenter a person's body by penetrating the skin.Serious injury and possibly death may result ifproper medical treatment by a physician familiarwith this injury is not received immediately.11. Drain, clean and ventilate fuel tanks and/orhydraulic tanks before making any weldingrepairs on these structures.12. After adjustments or repairs, replace all shields,screens and clamps.13. Tire Care:Mounting and demounting a multi-piece tire andrim assembly can be extremely dangerous. Anincorrect assembly can blow apart leading toextensive property damage, severe injury, oreven death for anyone in its trajectory path.Before servicing tire and rim assemblies, readall available publications on proper tire handlingand safety instructions.Do not stand in front of rim and locking ringwhen inflating/deflating tire mounted on vehicle.Inflate ONLY to tire manufacturer's recommenda-tion. Use an air chuck with extension hose clipped onthe tire inflation valve to allow service frombehind the tread of the tire. DO NOT weld or apply heat on the rim assemblywith the tire mounted on the rim. Resulting gasesinside the tire may ignite, causing explosion oftire and rim. When jacking a vehicle, DO NOT rely entirely onvehicle braking system; use chocks to block thewheels on opposite side from jack. DO NOT remove any rim or wheel mountinghardware, such as nuts or clamps, beforeCOMPLETELY exhausting all air from the tire, orboth tires on a dual assembly. DO NOT reuse cracked, damaged, or worn rimparts. Replace with new parts. DO NOT mix/assemble rim parts of differentdesigns. If in doubt of compatibility, consult rimmanufacturer. DO NOT use a steel hammer to aid assembly.Use soft mallets only.14. Only a qualified operator or experienced main-tenance personnel who are also qualified inoperation should move the truck under its ownpower to the repair facility or in road testingafter repairs are complete.A3-8 General Safety & Operation A03004 7/95SAFE PARKING PROCEDURESThe operator must continue the use of safety precau-tions when preparing for parking and engine shut-down.In the event that the equipment is being worked inconsecutive shifts, any questionable truck perfor-mance the operator may have noticed must bechecked by maintenance personnel before the truckis released to another operator.1. The truck should be parked on level ground, ifat all possible. If parking must be done on agrade, the truck should be positioned at rightangles to the grade.2. The parking brake must be applied and/orchocks placed fore/aft of wheels so that thetruck cannot roll. Each truck should be parkedat a reasonable distance from another.3. Haul roads are not safe parking areas. In anemergency, pick the safest spot most visible toother machines in the area. If the truckbecomes disabled where traffic is heavy, markthe truck with warning flags in daylight or flaresat night. SHUTDOWN PROCEDUREThe following procedure (1. - 4.) should be followedat each engine shutdown.1. Stop truck. Reduce engine RPM to low idle.Place Selector Switch in "Neutral" and applyparking brake.2. Allow engine to cool gradually by running at lowidle for 3 to 5 minutes.NOTE: If truck is equipped with HMS controlsystem, refer to Operator Handbook for shut-down procedure.3. With truck stopped and engine cooled down,turn keyswitch counterclockwise to "Off" for nor-mal shutdown of engines equipped with elec-tronic engine controls (MTU, Detroit Diesel w/DDEC, or Cummins w/Centry Fuel Control). If engine does not shutdown with keyswitch,use engine shutdown switch (*) and hold switchdown until engine stops.* For 445E - 685E, this is the Engine ShutdownSwitch on center console (see "Operator Con-trols" in Operator Handbook).* For 830E, this is the instrument panel Emer-gency Engine Shutdown switch (see "Instru-ments and Indicators" in Operator Handbook).4. With keyswitch "Off", and engine stopped, waitat least 90 seconds. Insure steering circuit iscompletely bled down by turning steering wheelback and forth several times. No front wheelmovement will occur when hydraulic pressure isrelieved.NOTE: A switch is located at lower left front of truckfor ground level engine shutdown. 5. Close and lock all windows, remove key fromkeyswitch and lock cab to prevent possibleunauthorized truck operation. Dismount truckproperly.A04015 1/91 Warnings and Cautions A4-1WARNINGS AND CAUTIONSA plate is located on the front left corner by the lad-der. This plate indicates the location of the groundlevel engine shutdown switch. A warning plate is mounted around the key switch onthe instrument panel. The warning stresses theimportance of reading and understanding the opera-tor's manual before operation.A warning plate is mounted on top of the instrumentpanel above the voltmeter and ammeter.The voltmeter indicates the condition of the batteries.Normal indicated voltage at high RPM is 27 to 28volts with batteries in fully charged condition.The ammeter indicates the charging or dischargingrate of the batteries.A warning plate is mounted directly under the redwarning lights in the instrument panel and warns thatthe truck should not be operated if any red warninglights on. If any of the red warning lights come on,safely stop truck, shut down engine, notify mainte-nance. A warning plate is mounted on the instrument panelaround the Parking Brake switch and the WheelBrake Lock switch.The Parking Brake switch is for parking only. Truckmust be completely stopped before applying parkingbrake or damage may occur to parking brake. Park-ing brake is not designed to stop a moving truck.NOTE: Do not use parking brake at shovel or dump.The Wheel Brake Lock should be used only withengine running during dumping and loadingoperations, or when brake pedal is inoperative.Wheel Brake Lock must NOT be used for parkingtruck with engine shut down. Under these conditions,pressure will bleed down and wheel brakes will NOThold truck.The following paragraphs give an explanation of the Warning, Caution, and Service Instruction plates and decalsattached to the HAULPAK truck. The plates and decals listed are typical of this model HAULPAK, but becauseof customer options, individual trucks may have plates and decals that are different from those shown here.The plates and decals must be kept clean and legible. If any decal or plate can no longer be read because ofdeterioration or damage, it should be replaced with a new one. A4-2 Warnings and Cautions A04015 1/91A warning plate is mounted on the instrument panelaround the "Dry/Slippery Road" switch on the instru-ment panel. It warns that the slippery road positionreduces front wheel braking effort while maintainingfull braking of the rear wheels. Reduced braking ofthe front wheels assists in steering control on slip-pery roads but increases stopping distance.The Dry / Slippery road control switch permits theoperator to select either full braking capability at allwheels for "dry" road or reduced braking at the frontwheels for "slippery" road.A warning plate is located inside the operator's cab todefine maximum speed to be used when descendingvarious grades with a loaded truck. This chart willvary depending on tire size and wheel motors.Attached to the exterior of the battery compartment isa danger plate. This plate stresses the need to keepfrom making any sparks near the battery. Whenanother battery or 24VDC power source is used forauxiliary power, all switches must be Off prior to mak-ing any connections. When connecting auxiliarypower cables, positively maintain correct polarity;connect the positive (+) posts together and then con-nect the negative (-) lead of the auxiliary power cableto a good frame ground. Do not connect to the neg-ative posts of the truck battery or near the batterybox. This hookup completes the circuit but minimizesdanger of sparks near the batteries.Sulfuric acid is corrosive and toxic. Use proper safetygear, goggles, rubber gloves and rubber apron whenhandling and servicing batteries.A04015 1/91 Warnings and Cautions A4-3A danger plate and a warning plate are attached tothe hydraulic brake accumulators mounted on deckat rear of cab. The danger plate provides instructionson how to relieve hydraulic pressure prior to loosen-ing or disconnecting any hydraulic lines or compo-nents while accumulators are under pressure. Theseplates are also located on the cabinet behind cab.The warning plate is also located on the inside of thebox cover.The engine cooling system is controlled by thermo-stats which keep coolant temperature between 160-190F (71-89C) during operation. Unless the pres-sure is first released, removing the radiator cap afterengine has been running for a time will result in thehot coolant being expelled from the radiator. Seriousscalding and burning can result. The warning plate ismounted on top of the radiator grille near the radiatorcap.Warning plates are mounted on the frame just in frontof and to the rear of the front tires. Technicians mak-ing adjustments while the truck is being steered arewarned the clearances change when the truck issteered and could cause serious injury.An instruction plate is applied to the side of thehydraulic tank. This plate furnishes instructions forfilling of the hydraulic tank.Keep the system open to the atmosphere only as longas absolutely necessary to lessen chances of systemcontamination. Service the tank with clean Type C-4hydraulic oil. All oil being put into the hydraulic tankshould be filtered through 3 micron filters.A caution decal is attached under the hydraulic tankoil level sight gauge. With body down, enginestopped, and oil level below top of sight glass, add oilper filling instructions.A4-4 Warnings and Cautions A04015 1/91The dump procedure for a disabled truck is locatedon the left side of the torque tube near the hoistvalve. This decal provides the operator or technicianwith the proper hook-up procedure for dumping aloaded disabled truck.A warning plate is attached to the hydraulic tank toalert technicians that hydraulic oil becomes heatedduring operation and care must be taken to avoidburns when it is necessary to open the hydraulic sys-tem. There is always a chance of residual pressurebeing present. Open fittings slowly to allow any pres-sure to bleed off before removing any connections.Any operating fluid, such as hydraulic oil orbrake fluid escaping under pressure, can havesufficient force to enter a person's body by pene-trating the skin. Serious injury and possiblydeath may result if proper medical treatment by aphysician familiar with this injury is not receivedimmediately.Warning plates are attached to both the hydraulicand fuel tank to alert technicians not to work on thetruck with the body in the raised position unlessbody-up safety devices are in position.A steering procedure for a disabled truck is locatedon the left frame rail near the unloader valve. Thisdecal provides the operator or technician with theproper hookup procedure for steering on a disabledtruck. Quick disconnects are located at the bottom ofthe bleeddown manifold. A warning decal is located on the left top corner ofthe operator's cab. This decal states that the cabassembly must not be lifted by using the handrail.A04015 1/91 Warnings and Cautions A4-5High Voltage Danger Plates and Caution Plates areattached to both doors of the Electrical Control Cabi-net. The High Voltage Plate is also attached to theblown grid housing, extended range housing, rectifierhousing, inlet duct structure and rear hatch cover.A wheel motor oil level decal is attached to the gearcover on both electric wheel motors. This decalstresses the fact that the truck must be on a levelsurface and parked for 20 minutes prior to checkingthe oil level. This is necessary in order to get anaccurate reading.A warning plate is located near the HOT START con-nection which is attached to the back side of the frontbumper on the left side of the truck. This warningplate states that the engine should not be startedwhile the optional HOT START is in operation. Oper-ators should observe this area during Ground LevelInspection and be certain that this option is discon-nected from the truck before starting engine.A decal is attached to the frame rail near the hoistcylinder creep down valve which is located on thehydraulic tank. This decal states that the body maybe lowered in a controlled manner by opening thevalve and allowing the hoist cylinders to slowlyretract.A danger plate is attached to or near the steeringaccumulator mounting bracket. This plate alerts tech-nicians to read the warning label attached to the topof the steering accumulator prior to releasing internalnitrogen pressure or disconnecting any hydrauliclines or hardware.A4-6 Warnings and Cautions A04015 1/91A danger plate is attached to each suspension cylin-der and steering accumulator. The plate containsinstructions for releasing internal pressure prior todisconnecting any hydraulic lines or hardware.A Product Identification plate is located on the framein front of the right side front wheel and gives ModelNumber, Maximum G.V.W. and the Product Identifi-cation Number.The Lubrication Chart is located on the left hand side of the radiator grille. Refer to the Lubrication Sec-tion in this service manual for more complete lubrication instructions.A05001 12/99 Standard Torque Chart and Tables A5-1STANDARD CHARTS AND TABLESThis manual provides dual dimensioning for most spec-ifications. U.S. standard units are specified first, withmetric (SI) units in parentheses. References through-out the manual to standard torques or other standardvalues will be to one of the following Charts or Tables.For values not shown in any of the charts or tables,standard conversion factors for most commonly usedmeasurements are provided in TABLE XIII, page 1-14.INDEX OF TABLESTABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2TABLE III . . Standard Metric Assembly Torque . . A5-2TABLE IV. . . . . . JIC Swivel Nuts Torque Chart . . A5-3TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3TABLE VIII . Torque Conversions (ft.lbs. - N.m) . . A5-4TABLE IX. . Torque Conversions (ft.lbs. - kg.m) . . A5-4TABLE X . . . Pressure Conversions (psi - kPa) . . A5-4TABLE XI . . Pressure Conversions (psi - MPa) . . A5-5TABLE XII . . . . . . . .Temperature Conversions . . A5-5TABLE XIII . . . Common Conversion Multipliers . . A5-6EFFECT OF SPECIAL LUBRICANTSOn Fasteners and Standard Torque ValuesKOMATSU engineering department does NOT recom-mend the use of special friction-reducing lubricantssuch as, Copper Coat, Never Seize, and other simi-lar products on the threads of standard fastenerswhere standard torque values are applied. The use of special friction-reducing lubricants will sig-nificantly alter the clamping force being applied to fas-teners during the tightening process. If special friction-reducing lubricants are used with theStandard Torque values listed below in Table I (andin Komatsu shop manuals), excessive stress and pos-sible breakage of the fasteners may result. Where Torque Tables specify Lubricated Threads forthe Standard Torque values listed, these standardtorque values are to be used with simple lithiumbase chassis grease (multi-purpose EP NLGI) or arust- preventive grease (see list, page 1-10) on thethreads and seats, unless specified otherwise.NOTE: Always be sure threads of fasteners andtapped holes are free of burrs and other imperfec-tions before assembling.Standard torque values are not to be used whenTurn-of-the-Nut tightening procedures are rec-ommended.TABLE I. -STANDARD TORQUE CHARTSAE HEX HEAD CAPSCREW AND NUT ASSEMBLY(LUBRICATED THREADS) - TOLERANCES 10%Cap-screw Thread SizeTORQUE - GRADE 5TORQUE - GRADE 8Cap-screw Thread SizeTORQUE - GRADE 5TORQUE - GRADE 8ft. lbs. kg.m N.m ft. lbs. kg.m N.m ft. lbs. kg.m N.m ft. lbs. kg.m N.m1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 4541/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 6785/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 7195/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 10173/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 10713/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 10857/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 14247/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 15461/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 20071/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 21429/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 26309/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 28745/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 34715/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 37563/4-10 220 30.4 298 310 42.8 4201 ft. lbs. = 0.138 kg.m = 1.356 N.mGrade 5Grade 8A5-2 Standard Torque Chart and Tables 12/99 A05001Standard Assembly Torques For 12-Point, Grade 9, Capscrews (SAE)The following specifications apply to required assemblytorques for all 12-Point, Grade 9 (170,000 psi minimumtensile), Capscrews.Capscrew threads and seats SHALL be lubri-cated when assembled. Unless instructions specifically recommend other-wise, these standard torque values are to be usedwith simple lithium base chassis grease (multi-pur-pose EP NLGI) or a rust-preventive grease (see list,this page) on the threads. Torques are calculated to give a clamping force of approximately 75% of proof load.The maximum torque tolerance shall be 10% of the torque value shown. Standard Metric Assembly Torque For Class 10.9 Capscrews & Class 10 NutsThe following specifications apply to required assemblytorques for all metric Class 10.9 finished hexagon headcapscrews and Class 10 nuts.Capscrew threads and seats SHALL NOT be lubricated when assembled. These specifications are based on all capscrews, nuts, and hardened washers being phosphate and oil coated.NOTE: If zinc-plated hardware is used, each piece must be lubricated with a Rust Preventive Grease or Lithium-base grease to achieve the same clamp-ing forces provided below.Torques are calculated to give a clamping force of approximately 75% of proof load.The maximum torque tolerance shall be within 10% of the torque value shown.Suggested* Sources for Rust Preventive Grease:AMERICAN ANTI-RUST GREASE #3-X from Stan-dard Oil Company (also American Oil Co.)GULF NORUST #3 from Gulf Oil Company.MOBILARMA 355, Product No. 66705 from Mobil Oil Corporation.RUST BAN 326 from Humble Oil Company.RUSTOLENE B GREASE from Sinclair Oil Com-pany.RUST PREVENTIVE GREASE - CODE 312 from the Southwest Grease and Oil Company.* NOTE: This list represents the current Engineer-ing approved sources for use in Komatsu manufac-ture. It is not exclusive. Other products may meetthe same specifications of this list.TABLE II. - STANDARD ASSEMBLY TORQUEfor 12-Point, Grade 9 CapscrewsCAPSCREW SIZE*TORQUEft. lbs.TORQUEN.mTORQUEkg.m0.250 - 20 12 16 1.70.312 - 18 24 33 3.30.375 - 16 42 57 5.80.438 -14 70 95 9.70.500 -13 105 142 14.50.562 - 12 150 203 20.70.625 - 11 205 278 28.30.750 - 10 360 488 49.70.875 - 9 575 780 79.41.000 - 8 860 1166 1191.000 - 12 915 1240 1261.125 - 7 1230 1670 1701.125 - 12 1330 1800 1841.250 - 7 1715 2325 2371.250 - 12 1840 2495 2541.375 - 6 2270 3080 3131.375 - 12 2475 3355 3421.500 - 6 2980 4040 4111.500 - 12 3225 4375 445* Shank Diameter (in.) - Threads per inchThis table represents standard values only. Do not use these val-ues to replace torque values which are specified in assembly instructions.TABLE III. - STANDARD METRIC ASSEMBLY TORQUECAPSCREW SIZE*TORQUEN.mTORQUEft.lbs.TORQUEkg.mM6 x1 12 9 1.22M8 x 1.25 30 22 3.06M10 x 1.5 55 40 5.61M12 x 1.75 95 70 9.69M14 x 2 155 114 15.81M16 x 2 240 177 24.48M20 x 2.25 465 343 47.43M24 x 3 800 590 81.6M30 x 3.5 1600 1180 163.2M36 x 4 2750 2028 280.5* Shank Diameter (mm) - Threads per millimeterThis table represents standard values only. Do not use these val-ues to replace torque values which are specified in assembly instructions.A05001 12/99 Standard Torque Chart and Tables A5-3TABLE IV. TORQUE CHART FOR JIC 37SWIVEL NUTSWITH OR WITHOUT O-RING SEALSSIZECODETUBE SIZE (O.D.)THREADS UNF-2BTORQUE FT. LBS. 2 0.125 0.312 24 4 1 3 0.188 0.375 24 8 3 4 0.250 0.438 20 12 3 5 0.312 0.500 20 15 3 6 0.375 0.562 18 18 5 8 0.500 0.750 16 30 5 10 0.625 0.875 14 40 5 12 0.750 1.062 12 55 5 14 0.875 1.188 12 65 5 16 1.000 1.312 12 80 5 20 1.250 1.625 12 100 10 24 1.500 1.875 12 120 10 32 2.000 2.500 12 230 20TABLE V. TORQUE CHART FORPIPE THREAD FITTINGSSIZECODE PIPE THREADSIZEWITH SEALANTFT. LBS.WITHOUTSEALANT FT. LBS. 2 0.125 27 15 3 20 5 4 0.250 18 20 5 25 5 6 0.375 18 25 5 35 5 8 0.500 14 35 5 45 5 12 0.750 14 45 5 55 5 16 1.000 11.50 55 5 65 5 20 1.250 11.50 70 5 80 5 24 1.500 11.50 80 5 95 10 32 2.000 11.50 95 10 120 10TABLE VI. TORQUE CHART FOR O-RING BOSS FITTINGSSIZECODETUBE SIZE (O.D.)THREADS UNF-2BTORQUE FT. LBS. 2 0.125 0.312 24 4 2 3 0.188 0.375 24 5 2 4 0.250 0.438 20 8 3 5 0.312 0.500 20 10 3 6 0.375 0.562 18 13 3 8 0.500 0.750 16 24 5 10 0.625 0.875 14 32 5 12 0.750 1.062 12 48 5 14 0.875 1.188 12 54 5 16 1.000 1.312 12 72 5 20 1.250 1.625 12 80 5 24 1.500 1.875 12 80 5 32 2.000 2.500 12 96 10TABLE VII. TORQUE CHART FOR O-RING FACE SEAL FITTINGSSIZECODETUBE SIZE (O.D.)THREADS UNF-2BTORQUE FT. LBS. 4 0.250 0.438 20 11 1 6 0.375 0.562 18 18 2 8 0.500 0.750 16 35 4 10 0.625 0.875 14 51 5 12 0.750 1.062 12 71 7 16 1.000 1.312 12 98 6 20 1.250 1.625 12 132 7 24 1.500 1.875 12 165 15A5-4 Standard Torque Chart and Tables 12/99 A05001TABLE VIII. TORQUE CONVERSIONSFoot Pounds ft. lbs. To Newton-meters (N.m)FT. LBS. 0 1 2 3 4 5 6 7 8 90 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.2010 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.7620 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.3230 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.8740 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.4450 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.0060 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.5570 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.1180 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.6790 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23See NOTE on page A5-5 regarding Table usageTABLE IX. TORQUE CONVERSIONSFoot Pounds ft. lbs. To kilogram-meters (kg.m)FT. LBS. 0 1 2 3 4 5 6 7 8 90 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.24510 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.6320 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.0130 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.3940 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.7850 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.1660 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.5470 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.9380 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.3090 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69See NOTE on page A5-5 regarding Table usageTABLE X. PRESSURE CONVERSIONSPounds/square inch (psi) To Kilopascals (kPa)Formula: psi x 6.895 = kPaPSI 0 1 2 3 4 5 6 7 8 90 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.0510 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.020 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.030 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.940 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.950 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.860 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.870 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.780 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.790 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6See NOTE on page A5-5 regarding Table usageA05001 12/99 Standard Torque Chart and Tables A5-5TABLE XI. PRESSURE CONVERSIONSPounds/square inch (psi) To Megapascals (MPa)Formula: psi x 0.0069 = MPaPSI 0 10 20 30 40 50 60 70 80 900 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83See NOTE below regarding Table usageTABLE XII. TEMPERATURE CONVERSIONSFormula: F- 32 / 1.8 = Cor Cx 1.8 + 32 = FCELSIUSCFAHRENHEITFCELSIUSCFAHRENHEITFCELSIUSCFAHRENHEITF121 250 482 63 145 293 4 40 104118 245 473 60 140 284 2 35 95116 240 464 57 135 275 1 30 86113 235 455 54 130 266 4 25 77110 230 446 52 125 257 7 20 68107 225 437 49 120 248 9 15 59104 220 428 46 115 239 12 10 50102 215 419 43 110 230 15 5 4199 210 410 41 105 221 18 0 3296 205 401 38 100 212 21 5 2393 200 392 35 95 293 23 10 1491 195 383 32 90 194 26 15 588 190 374 29 85 185 29 20 485 185 365 27 80 176 32 25 1382 180 356 24 75 167 34 30 2279 175 347 21 70 158 37 35 3177 170 338 18 65 149 40 40 4074 165 329 15 60 140 43 45 4971 160 320 13 55 131 46 50 5868 155 311 10 50 122 48 55 6766 150 302 7 45 113 51 60 76NOTE: 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 Cor F), find that temperature in the marked column and read the converted temperature in the center, unmarked column. NOTE: Tables such as Table VIII, IX, X, and XI maybe used as in the following example:Example: Convert 975 psi to kilopascals (kPa).1. Select Table X.2. Go to PSI row 90, column 7; read 668.897 psi = 668.8 kPa.3. Multiply by 10:970 psi = 6688 kPa.4. Go to PSI row 0, column 5; read 34.475 psi = 34.47 kPa. Add to step 3.5. 970 + 5 psi = 6688 + 34 = 6722 kPa.A5-6 Standard Torque Chart and Tables 12/99 A05001TABLE XIIICOMMON CONVERSION MULTIPLIERSCOMMON CONVERSION MULTIPLIERSENGLISH To METRICTo Convert From TOMultiplyByinch in. millimeter (mm) 25.40inch in. centimeter (cm) 2.54foot ft. meter (m) 0.3048yard yd. meter (m) 0.914mile mi. kilometer (km) 1.61sq. in. in.2 sq. centimeters (cm2)6.45sq. ft. ft.2sq. centimeters (cm2)929cu. in. in.3cu. centimeters (cm3)16.39cu. in. in.3liters (l) 0.016cu. ft. ft.3cu. meters (m3)0.028cu. ft. ft.3liters (l) 28.3ounce oz. kilogram (kg) 0.028fluid ounce fl. oz. milliliter (ml) 29.573pound (mass) kilogram (kg) 0.454pound (force) lbs. Newton (N) 4.448in. lbs. (force) Newton.meters (N.m) 0.113ft. lbs. (force) Newton.meters (N.m) 1.356ft. lbs. (force) kilogram.meters (kg.m) 0.138kilogram.meters (kg.m)Newton.meters (N.m) 9.807psi (pressure) kilopascals (kPa) 6.895psi (pressure) megapascals (MPa) 0.007psi (pressure)kilograms/cm2 (kg/cm2)0.0704ton (short) kilogram (kg) 907.2ton (short) metric ton 0.0907quart qt. liters (l) 0.946gallon gal. liters (l) 3.785HP (horsepower) Watts 745.7HP (horsepower) kilowatts (kw) 0.745COMMON CONVERSION MULTIPLIERSMETRIC To ENGLISHTo Convert From TOMultiplyBymillimeter (mm) inch in. 0.0394centimeter (cm) inch in. 0.3937meter (m) foot ft. 3.2808meter (m) yard yd. 1.0936kilometer (km) mile mi. 0.6210sq. centimeters (cm2) sq. in. in.20.1550sq. centimeters (cm2) sq. ft. ft.20.001cu. centimeters (cm3) cu. in. in.30.061liters (l)cu. in. in.361.02cu. meters (m3) cu. ft. ft.335.314liters (l)cu. ft. ft.30.0353grams (g) ounce oz. 0.0353milliliter (ml) fluid ounce fl. oz. 0.0338kilogram (kg) pound (mass) 2.2046Newton (N) pound (force) lbs. 0.2248Newton.meters (N.m) kilogram.meters (kg.m) 0.102Newton.meters (N.m) ft. lbs. (force) 0.7376kilogram.meters (kg.m) ft. lbs. (force) 7.2329kilogram.meters (kg.m) Newton.meters (N.m) 9.807Kilopascals (kPa) psi (pressure) 0.1450megapascals (MPa) psi (pressure) 145.038kilograms/cm2 (kg/cm2)psi (pressure) 14.2231kilograms/cm2 (kg/cm2)kilopascals (kPa) 98.068kilogram (kg) ton (short) 0.0011metric ton ton (short) 1.1023liters (l) quart qt. 1.0567liters (l) gallon gal. 0.2642Watts HP (horsepower) 0.00134kilowatts (kw) HP (horsepower) 1.3410A07002 01/98 Storage Procedures A7-1STORAGE AND IDLE MACHINE PREPARATION There may be periods when it is necessary for amachine to be idle for an extended period of time.Properly prepared, a stored machine may promptlyand safely be put back into operational service.mproper preparation, or complete lack of prepara-tion, can make the job of getting the vehicle back tooperating status difficult.The following information outlines the essentialproper steps for preparing a unit for extended stor-age, and the necessary steps to bring it back to oper-ational status - these are the ideals. Additionalinformation is given to help restore those machineswhich were not put into storage, merely shut downand left idle for a long period of time. Much of this material is of a general nature since theenvironment, where the machine has been standingidle, will play a big part in its overall condition. Hot,humid climate will affect vehicle components muchdifferently than the dry desert atmosphere or a coldarctic environment. These climatic aspects must beconsidered, and appropriate actions taken whenrestoring a long term idle vehicle.These instructions are not intended to be all inclu-sive, but are furnished to provide the minimum guidelines. The final aim should always be to provide theoperator with a safe, fully productive vehicle, that hecan rely on.SHORT TERM IDLE PERIODSThere will be periods when a vehicle may be idlefrom 30-60 days, but must be ready for use at alltimes.The most effective handling of this type situation is tofollow the procedure given below to prevent anydeterioration from beginning.1. Keep the vehicle fully serviced.2. On a weekly schedule, perform a visual check ofthe vehicle, start and run the engine until boththe engine and transmission are up to operatingtemperature. Move the vehicle around the yardfor a few minutes to insure that all internal gearsand bearings are freshly lubricated.3. Operate all hydraulic functions through completerange to insure that cylinder rams and all sealsare fully lubricated.4. Check and operate all systems.5. After shutdown, drain air tank (if so equipped) toexpel any accumulated moisture.6. Once a month, perform the 10 hour serviceitems shown in the Operation and MaintenanceManuals. Keep batteries properly serviced.A7-2 Storage Procedures 01/98 A07002PREPARATION FOR STORAGEFor long term idle periods, proper preparation willpay large dividends in time and money when futureoperation of the vehicle is scheduled.1. Engine should be prepared for storage accord-ing to instructions found in the engine manufac-turers manual.2. Transmission should be prepared for storage.nstruction will be found in the transmission Ser-vice Manual. Several storage variations aregiven.3. The vehicle should be in top operating conditionwith all discrepancies corrected. Paint shouldbe in good condition, no rust or corrosion, allexposed, machined or unpainted surfacesshould be coated with a good rust preventativegrease.4. After the vehicle has been parked in its storagelocation, all hydraulic cylinders, including Hyd-rair suspensions (Trucks), should be retractedas much as possible (steering cylinders cen-tered). Wipe the exposed portion of all cylinderrams clean and, coat (including seals on endsof barrel) with good preservative grease.5. f long term storage is anticipated, the vehicleshould be blocked up with the tires clear of theground or floor to remove vehicle weight fromthe tires. Lower air pressure in the tires to 15-25psi (103-172 kPa). Completely cover the tireswith tarpolins to minimize rubber oxidation anddeterioration.6. (Trucks equipped with air-actuated park brake)With air tanks pressurized and parking brakevalve "Off", remove a clevis pin from the brakeactuator linkage. This will relieve spring pres-sure from applying the parking brake while thevehicle is idle. Replace clevis pin in link to pre-vent loss. Tag steering wheel with a parkingbrake disconnected tag. 7. Drain air tank(s) completely (if equipped). Whentank compartments are empty, fog the inside ofeach tank compartment with a light applicationof preservative oil to deter rust and corrosion.8. Clean the radiator; refer to Engine Service Man-ual and the Vehicle Service Manual for theproper cleaning instructions.9. The cooling system should be completelydrained, chemically flushed, and refilled with aconditioned water/antifreeze solution suitablefor the lowest temperature anticipated. Refer toSection "P", Fluid Specifications and Charts, ofthe Shop Manual for the proper anti-freeze andconditioner concentrations. After refilling thesystem, always operate the engine until thethermostats open to circulate the solutionthrough the cooling system.NOTE: NEVER store a vehicle with a dry coolingsystem.10. New hydraulic filters should be installed and thehydraulic tank fully serviced with Type C-4 oil asspecified in Section "P", Lubrication and Ser-vice, of the Shop Manual.Any operating fluid, such as hydraulic oil, escap-ing under pressure can have sufficient force toenter a person's body by penetrating the skin.Serious injury and possible death may result ifproper medical treatment by a physician familiarwith this injury is not received immediately.11. Disconnect batteries, f possible, batteriesshould be removed and stored in a battery shopor a cool dry location on wooden blocks. Do notstore batteries on a concrete floor. Clean bat-tery compartment, remove all corrosion andpaint compartment with acid proof paint.12. Wheel axle housings and final drives should befully serviced with prescribed lubricants. Seal allvents.A07002 01/98 Storage Procedures A7-313. Exhaust openings and air cleaners should becovered tightly with moisture barrier paper andsealing tape.14. All lubrication points (grease fittings) should beserviced with the prescribed lubricants.15. Relieve tension from all drive belts. The enginemanufacturer recommends insertion of heavykraft paper between belts and pulleys to preventsticking.16. All vandalism covers and locks should be inplace and secured.17. f so equipped, cab windows should be closed,locked and sealed and the cab door locked toprevent vandalism and weather effects.18. The vehicle fuel tanks should be completelydrained of fuel, fogged with preservative lubri-cant, ("NOX-RUST" MOTOR STOR., SAE10)and closed tightly. All fuel filters should bereplaced.19. f at all possible, to aid those who will eventuallyplace the unit back in operation, all availableservice publications (vehicle, engine and trans-mission) and a current parts catalog should bepackaged in a moisture proof package andplaced in the vehicle cab.20. Be certain water drain holes in body (trucks) areopen.REMOVAL FROM STORAGEf the foregoing preparations were conscientiouslyfollowed in placing the vehicle into storage, getting itback to operational status is a simple matter ofreversing these steps.NOTE: Before starting the job or restoring a vehicleto operation, obtain copies of the Operation andMaintenance Manual, Shop Manual, Engine andTransmission Manuals and/or the Parts Book andfollow ALL special instructions regarding servicingthe vehicle and its components.n addition to removing the storage materials, the fol-lowing actions should be taken.1. nspect the entire vehicle carefully for rust andcorrosion, correct as necessary.2. Service the engine according to the EngineManufacturer's Operation and MaintenanceManual.3. Clean the radiator; refer Engine Manufacturer'sOperation and Maintenance Manual.4. The cooling system should be completelydrained, chemically flushed, and refilled with aconditioned water/antifreeze solution suitablefor the lowest temperature anticipated. Refer toFluid Specifications in Section "P", Lubricationand Service, of the Shop Manual for the properanti-freeze and conditioner concentrations.After refilling the system, always operate theengine until the thermostats open to circulatethe solution through the cooling system.5. Refer to the proper transmission service manualfor returning the transmission to operation.6. Thoroughly inspect all drive belts, hydraulic, airand oil lines for evidence of damage, wear ordeterioration. Replace any suspected lines.Don't take chances on ruptures or blow-outs.7. New hydraulic filters should be installed and thehydraulic tank (reservoir) checked and servicedwith Type C-4 oil as specified in Section "P",Lubrication and Service, of the Shop Manual.8. Drain on fuel tank should be opened to removeany build up of moisture or sediment that mayhave accumulated while in storage. Close drainthen fill the fuel tank with approved diesel fuel.NEVER blend gasoline, gasohol and/or alcoholwith diesel fuel. This practice creates an extremeFIRE HAZARD and under certain conditions maycause an EXPLOSION. 9. Make certain that all hydraulic controls, steeringlinkage and throttle linkage points are lubricatedand operate freely before engine start up.10. All electrical connections must be clean andtight. Check security of all ground straps andcables.A7-4 Storage Procedures 01/98 A0700211. nstall fully charged batteries in unit. Clean con-nectors and connect battery cables. Compart-ment must be free of corrosion. Securebatteries with hold downs.12. Check all electrical cables for weathering, cracksand/or damage. Replace any defective cables.Air pressure must be released from tires with badcuts or wear that extends into the plies, beforeremoval from the vehicle. Also, do not allow per-sonnel to stand in removal path of tires.13. Check all tires carefully for serviceability andinflate to proper pressure.14. f disconnected, reconnect the parking brakelinkage.15. Completely service the vehicle as recommendedin Section "P", Lubrication and Service, of theShop Manual for both 10 and 100 hour inspec-tions.16. Adjust all drive belts to specified tension.17. Make certain that all hydraulic controls, steeringlinkage and throttle linkage points are freebefore engine start up.18. Use the Operation and Maintenance Manual forguidance on engine start and vehicle checkout.Make a thorough check of all hose and line con-nections for leakage when the engine is run-ning.19. Before moving the vehicle, cycle all hydrauliccontrols and steering to verify proper operation.Verify proper operation of service brakes, emer-gency braking system and parking brake.Check ALL system instruments to insure that allsystems are operational. (Trucks with air-over-hydraulic brakes.) Bleed air system down withbrake pedal applicatio