Professional Documents
Culture Documents
Operators and
maintenance personnel must read and understand this manual before operating
or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically
reviewed by all personnel who will come into contact with it.
This material is proprietary to Komatsu Mining Systems, Inc. and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Systems, Inc.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The Company
reserves the right to make changes or add improvements at any time without incurring any obligation to install
such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication. Customers
should contact their local distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and
lead compounds, chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
Wash hands after handling.
NOTES:
FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician
become fully knowledgeable of the truck and all its systems in order to keep it running and in
production. All maintenance personnel should read and understand the materials in this manual
before performing maintenance and/or operational checks on the truck. All safety notices, warnings
and cautions should be understood and followed when accomplishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well
as other general information. The major portion of the manual pertains to disassembly, service and
reassembly. Each major serviceable area is dealt with individually. For example: The disassembly,
service and reassembly of the radiator group is discussed as a unit. The same is true of the engine
and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly
should be carried only as far as necessary to accomplish needed repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not
necessarily depict a 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 stated otherwise.
Standard torque requirements are shown in torque charts in the general information section and
individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All
torque 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 designates the Truck Model Number, Product Identification Number (vehicle serial
number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The
three numbers represent the basic truck model. The letter M designates a Mechanical drive and the
letter E designates an Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the
original manufacturing bill of material for this unit. This complete number will be necessary for proper
ordering of many service parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other
components. 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. To maximize payload and to keep from exceeding the GVW rating, these accumulations
should be removed as often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
A00017 03/01
Introduction
A-1
A-2
Introduction
A00017 03/01
TABLE OF CONTENTS
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAIR II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATORS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A00017 03/01
Introduction
A-3
A-4
Introduction
A00017 03/01
SECTION A
GENERAL INFORMATION
INDEX
. . . . . . . . . . . . . . . . . . . . . . . . . A3-1
A01001 2/94
Index
A1-1
NOTES
A1-2
Index
A01001 2/94
Operators Cab
Alternator (GE-GTA34)
The diesel engine drives an in-line alternator at engine
speed. The alternator produces AC current which is
rectified to DC within the main control cabinet. The
rectified DC power is converted back to AC by groups
of devices called inverters, also within the main
control cabinet. Each inverter consists of six phase
modules under the control of a gate drive unit
(GDU). The GDU controls the operation of each phase
module.
Each phase module contains an air-cooled solid-state
switch referred to as a gate turn-off thyristor (GTO).
The GTO cycles on and off at varying frequencies to
create an AC power signal from the DC supply.
The AC power signal produced by each inverter is a
variable-voltage, variable-frequency signal (VVVF).
Frequency and voltage are changed to suit the operating conditions.
Blower
Both the inverters and the wheel motors produce heat
while in operation and must be cooled. Cooling air is
provided by a separate AC drive blower using rectified
DC as its power source. Cooling air flow volume is
modulated based on thermal requirements.
Suspension
A02055
Power Steering
The truck is equipped with a full time power steering
system which provides positive steering control with
minimum operator effort. The system includes nitrogen-charged accumulators which automatically provide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
Dynamic Retarding
The dynamic retarding is used to slow the truck during
normal operation or control speed coming down a
grade. The dynamic retarding ability of the electric
system is controlled by the operator through the activation of the retarder pedal (or by operating a lever on
the steering wheel) in the operators cab and by setting
the RSC (Retarder Speed Control). Dynamic Retarding is automatically activated, if the truck speed goes
to a preset overspeed setting.
Brake System
Service brakes at each wheel are oil-cooled multiple
disc brakes applied by an all-hydraulic actuation system. Depressing the brake pedal actuates both front
and rear brakes, after first appling the retarder. All
wheel brakes will be applied automatically, if system
pressure decreases below a preset minimum.
The parking brake is a dry disc type, mounted inboard
on each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
protection (will not apply with truck moving).
A2-1
A02055
SPECIFICATIONS
These specifications are for the standard 930E Truck. Customer Options may change this listing.
SERVICE CAPACITIES
ENGINE
Cummins QSK60
Number of Cylinders . . . . . . . . . . . . . . 16
Operating Cycle . . . . . . . . . . . . . 4-Stroke
Rated Brake HP 2700HP (2014 kW) @ 1900 RPM
Flywheel HP . . . . . . . . . 2550HP (1879 kW)
Weight (Dry)* . . . . . . . . 19,515 lbs. (8852 kg)
* Weight does not include Radiator, Sub-frame, or Alternator
. . . . . . . . . . U.S. Gallons .
Crankcase (Includes lube oil filters)
QSK60-C . . . . . . . . . . . 74 .
Cooling System . . . . . . . 157 .
Fuel . . . . . . . . . . . . 1200 .
Hydraulic System . . . . . . 350 .
Wheel Motor Gear Box 20/Wheel .
. . . . Liters
.
.
.
.
.
.
.
.
.
.
. . . 280
. . . 594
. . 4542
. . 1325
76/Wheel
HYDRAULIC SYSTEM
DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . Standard
Maximum Retarding . . . . . 5400 HP (4026 kW)
Continuous . . . . . . . . . 3300 HP (2460 kW)
Continuously Rated High-density Blown Grids
with Retard at Engine Idle and Retard in Reverse
Propulsion.
A02055
SERVICE BRAKES
All Hydraulic Actuation . . . with Traction System
. . . . . . . . . . . . . Wheel Slip/Slide Control
Front & Rear Oil-Cooled Multiple Discs
. . . . . . . . . . . . . . . . . . at Each Wheel.
Total Friction Area /Brake 15,038 in2 (97 019 cm2)
Maximum Apply Pressure . 2500 psi (17 238 kPa)
STEERING
Turning Circle (SAE) . . . . 97 ft. 4 in. (29.67 m)
Twin hydraulic cylinders with accumulator assist to
provide constant rate steering.
Emergency Power Steering automatically provided by
Accumulators
A2-3
WEIGHT DISTRIBUTION
TIRES
Radial Tires (standard) . . . . . . . . 53/80 R63
Rock Service, Deep Tread . . . . . . . Tubeless
Rims . (patented Phase II New Generation rims)
EMPTY . . . . . . .
Front Axle (49.3%)
Rear Axle (50.7%)
Total (50% Fuel) .
LOADED
Front Axle (33.9%)
Rear Axle (66.1%)
Total . . . . . . .
.
.
.
.
.
.
.
.
Pounds . .
. 219,913 . .
. 226,121 . .
. 446,034 . .
Kilograms
. . 99 751
. 102 567
. 202 318
. . . 372,727 . . .
. . . 727,273 . . .
. . 1,100,000 . . .
169 069
329 891
498 960
A2-4
A02055
GENERAL SAFETY
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority.
The following safety rules are provided as a guide for the operator. However, local conditions and regulations may
add many more to this list.
SAFETY RULES
ONLY trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
When working with another operator or a person on worksite traffic duty, be sure all personnel understand all
hand signals that are to be used.
SAFETY FEATURES
Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.
(See Walk-Around Inspection, Operating Instructions - Section 3)
Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
NEVER remove any safety features. ALWAYS keep them in good operating condition.
Improper use of safety features could result in serious bodily injury or death.
Avoid loose clothing, jewelry, and loose long hair. They can catch on
controls or in moving parts and cause serious injury or death. Also, do
not wear oily clothes because they are flammable.
Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine. Always wear safety goggles, hard
hat and heavy gloves if your job involves scattering metal chips or minute
materials this is so particularly when driving pins with a hammer and
when cleaning the air cleaner element with compressed air.
Check also that there is no one near the machine.
UNAUTHORIZED MODIFICATION
Any modification made to this vehichle without authorization from Komatsu Mining Systems, Inc. can possibly
create hazards.
Before making any modification, consult the authorized regional Komatsu Mining Systems, Inc. distributor.
Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.
A03017
A3-1
When preparing to leave the operators seat, do not touch any control lever that is not locked.
To prevent accidental operations from occurring , always carry out the following:
Move the shift control lever to the Neutral position (N) and set the parking lever/switch to the PARKING position.
Lower the dump body, set the dump lever to the FLOAT position.
Stop the engine. When leaving the machine, always lock everything. Always remember to take the key with you.
If the machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or
death.
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When getting on or off the machine, face the machine and use the handhold and steps.
Never hold any control levers when getting on or off the machine.
Always maintain three-point contact with the handholds and steps to ensure that you support yourself.
When bringing tools to the operators compartment, always pass them by hand or pull them up by rope.
If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
A3-2
A03017
Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature and
are under pressure. If the cap is removed, or the oil or water is drained, or the filters are replaced, there is danger
of serious burns. Always wait for the temperature to cool down, and carry out the operation according to the
specified procedure.
Operate the machine with the wind to your back, whenever possible.
Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead
to serious bodily injury or death.
Be sure fire extinguishers have been provided and know how to use them.
Be sure you know the phone numbers of persons you should contact in case of
an emergency.
A03017
A3-3
If ROPS is installed, the ROPS must never be removed when operating the machine.
The ROPS is installed to protect the operator if the machine should roll over. It is designed not only to support
the load if the machine should roll over, but also to absorb the impact energy.
The ROPS installed on equipment manufactured and designed by Komatsu Mining Systems, Inc. fulfills all of the
regulations and standards for all countries, but if it is modified or repaired without authorization from Komatsu
Mining Systems, Inc., or is damaged when the machine rolls over, the strength will drop and it will not be able to
fulfill its function properly. It can only display its performance if it is repaired or modified in the specified way.
When modifying or repairing the ROPS, always consult the authorized regional Komatsu Mining Systems, Inc.
distributor.
Even if the ROPS is installed, it cannot show its full effect if the operator does not fasten the seat belt properly.
Always fasten the seat belt when operating.
When installing and using optional equipment, read the instruction manual for the attachment and the information
related to attachments in this manual.
Do not use attachments that are not authorized by Komatsu Mining Systems, Inc., or the authorized regional
Komatsu Mining Systems, Inc. distributor. Use of unauthorized attachments could create a safety problem and
adversely affect the proper operation and useful life of the machine.
Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the
responsibility of Komatsu Mining Systems, Inc., or the authorized regional Komatsu Mining Systems, Inc.
distributor.
A3-4
A03017
When walking to and from the truck, maintain a safe distance from all machines even if the operator is visible.
Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
Examine the road surface in the jobsite and determine the best and safest method of operation.
Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty
or by installing fences around the worksite.
The operator must check personally the work position, roads to be used, and existence of obstacles before starting
operations.
Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines
to travel.
If travel through wet areas is necessary, check the depth and flow of water before crossing the shallow parts.
NEVER be in water which is in excess of the permissible water depth.
FIRE PREVENTION
Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compartment. These could cause a fire.
Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks
repaired.
Wipe up any excess oil, fuel or other flammable fluids.
Always mount and dismount facing the truck. Never attempt to mount or dismount the truck while it is in motion.
Always use handrails and ladder when mounting or dismounting from the truck.
Check the deck areas for debris, loose hardware or tools. Check for people and objects that might be in the way.
Become familiar with and use all protective equipment devices on the truck and insure that these items (anti-skid
material, grab bars, seat belts, etc.) are securely in place.
If it is necessary to start the engine within an enclosed area, provide adequate ventilation.
Exhaust fumes from the engine can KILL.
A03017
A3-5
Do not leave tools or spare parts lying around in the operators compartment or allow trash to accumulate in cab
of truck. Keep all unauthorized reading material out of truck cab.
Keep the cab floor, controls, steps, and handrails free of oil, grease, snow, and excess dirt.
Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use
seat belts when operating your machine.
Read and understand the contents of this manual. Read the Section 3 pertaining to safety and operating
instructions with special attention. Become thoroughly acquainted with all gauges, instruments and controls
before attempting operation of the truck.
Read and understand the WARNING and CAUTION decals in the operators cab.
Insure steering wheel, horn, controls and pedals are free of any oil, grease or mud.
Check operation of windshield wiper, condition of wiper blades, and check washer reservoir for fluid level.
Be familiar with all steering and brake system controls and warning devices, road speeds and loading capabilities,
before operating the truck.
Remove any dirt from the surface of the windshield and all cab windows and lights. Good visibility may prevent
an accident.
Adjust the rear view mirror to a position where the operator can see best from the operators seat, and keep the
surface of the mirror clean. If any glass or light should break, replace it with a new part.
Insure headlights, worklights and taillights are in proper working order. Check that the machine is equipped with
the head lamps and working lamps needed for the operating conditions.
NEVER start the engine if a warning tag has been attached to the control.
Do not allow any person other than the operator in the operators compartment or any other place on the machine.
Only authorized persons are allowed to ride in truck. Riders should be in cab only and belted in passenger seat.
Do not move truck into or out of a building without a signal person present.
Know and obey the hand signal communications between operator and spotter. When other machines and
personnel are present, the operator should move in and out of buildings, loading areas and through traffic, under
the direction of a signal person. Courtesy at all times is a safety precaution!
Report immediately to supervisor any conditions on haul road, pit or dump area that may cause an operating
hazard.
A3-6
A03017
Check for flat tires periodically during shift. If truck has been run on a flat, it must not be parked in a building
until the tire cools.
If tire must be changed, do not stand in front of rim and locking ring when inflating tire mounted on the machine.
Observers should not be permitted in the area and should be kept away from the side of such tires.
Tire and rim assembly may expode if subjected to excessive heat. Personnel should move to a remote or
protected location if sensing excessively hot brakes, smell of burning rubber or evidence of fire near tire and
wheel area.
If the truck must be approached, such as to fight a fire, those personnel should do so only while facing the
tread area of the tire (front or back), unless protected by use of large heavy equipment as a shield. Stay at
least 50 ft. (15 m) from the tread of the tire.
In the event of fire in the tire and wheel area (including brake fires), stay away from the truck at least 8 hours
or until the tire and wheel are cool.
Keep serviceable fire fighting equipment at hand. Report used extinguishers for replacement or refilling.
Always have parking brake applied when the truck is parked and unattended. DO NOT leave truck unattended
while engine is running.
Stay alert at all times! In the event of an emergency, be prepared to react quickly
and avoid accidents. If an emergency arises, know where to get prompt
assistance.
Sound the horn to warn people in the area. For machines equipped with a back-up alarm, check that the alarm
works properly.
Check that there is no one near the machine. Be particularly careful to check behind the machine.
If necessary, designate a person to check the safety. This is particularly necessary when traveling in reverse.
When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite
traffic.
Do not allow any one to enter the line of travel of the machine. This rule must be strictly observed even on
machines equipped with a back-up alarm or rear view mirror.
TRAVELING
When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
Lower the dump body and set the dump lever to the FLOAT position when traveling.
If the engine should stop when the machine is traveling, the emergency steering system will be activated.
Apply the brakes immediately and stop the machine as quickly and safely as possible, and off the haul road, if
possible.
A03017
A3-7
TRAVELING ON SLOPES
Do not change direction on slopes. To ensure safety, go down to level ground before turning.
Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Take all possible steps to avoid traveling sideways, and always keep the travel
speed low.
When traveling downhill, use the retarder to reduce speed. Do not turn the steering wheel suddenly. Do not use
the foot brake except in an emergency.
If the engine should stop on a slope, apply the brakes fully and apply the parking brake to stop the machine.
When working in dark places, install working lamps and head lamps, and set up lighting in the work area if
necessary.
Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a
condition that allows the operation to be carried out safely.
When working on snowy or icy roads, there is danger that the machine may slip to the side on even the slightest
slope, so always travel slowly and avoid sudden starting, turning, or stopping.
Be extremely careful when carrying out snow-clearing operations. The road shoulder and other objects are buried
in the snow and cannot be seen. When traveling on snow-covered roads, always install tire chains.
When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits, always drive extremely carefully and lower the dump body completely before driving
the machine.
Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below
Voltage
6.6 kV
3m
10 ft
33.0 kV
4m
14 ft
66.0 kV
5m
17 ft
154.0 kV
8m
27 ft
275.0 kV
10 m
33 ft
If the work equipment should touch the electric cable, the operator should not leave the operators compartment.
When carrying out operations near high voltage cables, do not let anyone come close to the machine.
Check with the electrical maintenance department about the voltage of the cables before starting operations.
A3-8
A03017
WHEN DUMPING
Before starting the dumping operation, check that there is no person or object behind the machine.
Stop the machine in the correct position, and check again that there is no person or object behind the machine.
Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position
a flagman.
When carrying out dumping operations on slopes, the machine stability will become poor and there is danger
that it may tip over. Always carry out such operations extremely carefully.
Avoid operating the machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse,
the machine could fall or tip over and result in serious injury or death. Remember that the soil after heavy rain or
blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight or vibration of the
machine. Avoid these areas, if possible.
WHEN LOADING
Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
Choose a horizontal road surface to park the machine. If the machine has to be parked on a slope, always put
blocks under all the wheels to prevent the machine from moving.
When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn
pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
Before leaving the machine, lower the dump body fully, set the parking lever to the PARKING position, stop the
engine, then lock everything. Always take the key with you.
TOWING
WHEN TOWING, FIX WIRE TO HOOK
Towing in the wrong way may lead to serious personal injury or damage.
When using another machine to tow this machine, use a towing device with ample strength for the weight of this
machine.
When connecting a machine that is to be towed, do not let any one come between the towing machine and the
machine that is being towed.
Set the coupling of the machine being towed in a straight line with the towing portion of the machine, and secure
it in position.
(For towing method, see Section 3, Operating Instructions, TOWING.)
A03017
A3-9
BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or
poison prevention center immediately.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark of
flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across
the terminals.
When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.
ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
When starting from another machine, do not allow the two machines to touch.
Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the ground or negative
(-) cable first when removing them.
If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. This is dangerous, so
be sure to work carefully.
When connecting the ground cable to the frame of the machine to be started, be sure to connect it as far as
possible from the battery.
A3-10
A03017
If others start the engine or operate the controls while you are performing service or lubrication, you could suffer
serious injury or death.
ALWAYS attach the WARNING TAG to the control lever in the operators cab to alert others that you are working
on the machine. Attach additional warning tags around the machine, if necessary.
These tags are available from your Komatsu distributor. (Part No. 09963-03000)
PROPER TOOLS
When carrying out inspection or maintenance, always stop the machine on firm flat ground, lower the dump body,
then stop the engine.
If the engine must be run during service, such as when cleaning the radiator, always move the shift control lever
to the Neutral (N) position and set the parking brake lever to the PARKING position. Always carry out the work
with two people. One person should sit on the operators seat to stop the engine if necessary.
NEVER move any controls not needed to operate.
When servicing the machine, be careful not to touch any moving part or get clothing caught.
When carrying out service with the dump body raised, always place the dump lever at the HOLD position, and
apply the lock (if equipped). Install the body-up safety pins (or cable) securely.
A03017
A3-11
DURING MAINTENANCE
PERSONNEL
Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.
ATTACHMENTS
Place attachments that have been removed from the machine in a safe place so
that they do not fall. If they fall on you or others, serious injury could result.
Always lower all movable work equipment to the ground or to their lowest position
before performing service or repairs under the machine.
Spilled oil or grease, or scattered tools or broken pieces are dangerous because
they may cause you to slip or trip.
Always keep your machine clean and tidy.
If water gets into the electrical system, there is danger that the machine may not
move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the
operators compartment.
Spilled fuel and oil may cause slipping. Always clean up spills immediately.
Always tighten the cap of the fuel and oil fillers securely.
A3-12
A03017
If it is necessary to add water to the radiator, stop the engine and allow the engine
and radiator to cool down before adding the water.
Slowly loosen the cap to relieve pressure before removing the cap.
USE OF LIGHTING
When checking fuel, oil, coolant, or battery electrolyte, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is
danger or explosion.
When repairing the electrical system or when carrying out electrical welding,
remove the negative (-) terminal of the battery to stop the flow of current.
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Do not forget that the work equipment circuits are always under pressure.
Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits the skin or
enters the eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of wood
to check for oil leakage.
If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
A03017
A3-13
Immediately after stopping operations, the engine cooling water and oil at all parts are at high temperature and
under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters
are replaced, it may result in burns or other injury. Wait for the temperature to go
down, then carry out the inspection and maintenance in accordance with the
procedures given in this manual.
Keep away from rotating parts and be careful not to let anything get caught in them.
If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying,
so never touch any rotating parts.
WASTE MATERIALS
Always put oil drained from your machine in containers. Never drain oil directly on
the ground.
Obey appropriate laws and regulations when disposing of harmful objects such as
oil, fuel, coolant, solvent, filters, batteries, and others.
A3-14
A03017
TIRES
HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones
on rough road surfaces. This may lead to serious injury or damage.
To maintain safety, always keep to the following conditions:
Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
The tire inflation pressure and permissible speeds are general values. The actual values may differ depending on
the type of tire and the condition under which they are used. For details, please consult the tire manufacturer.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly dangerous if the tires
become overheated when the tires are under pressure. If the gas generated inside the tire ignites, the internal pressure
will suddenly rise, and the tire will explode, and this may lead to serious personal injury. Explosions differ from
punctures or tire bursts, because the destructive force is extremely large. Therefore, the following operations are
strictly prohibited when the tire is under high internal pressure:
If the proper procedure for carrying out maintenance or replacement of the wheel or tire is not used, the wheel or tire
may burst and cause serious injury or damage. When carrying out such maintenance, please consult the authorized
regional Komatsu Mining Systems, Inc. distributor, or the tire manufacturer.
As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored
outside, always erect a fence around the tires and put up No Entry and other warning signs that even young
children can understand.
Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy,
so trying to hold the tire may lead to serious injury.
A03017
A3-15
Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions.
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A3-16
A03017
A03017
A3-17
A3-18
A03017
A03017
A3-19
TRUCK OPERATION
PREPARING FOR OPERATION
The safest trucks are those which have been properly
prepared for operation. At the beginning of each shift,
a careful check of the truck should be made by the
operator before attempting to start the engine.
A3-20
A03017
START HERE
A03017
A3-21
16. Move on around the right dual tires, inspect between the tires for rocks, and for condition of the
rock ejector, inspect the tires for cuts or damage,
and for correct inflation.
17. Perform the same inspection for wheel nuts/studs
and wheel leaks that was done on the left hand
dual wheels.
18. Move in front of right dual tires, and inspect the
hoist cylinder the same as was done on the left
side.
Check security and condition of body-up limit
switch. Remove any mud/dirt accumulation from
switch.
19. Move on around the fuel tank, inspect the fuel
quantity gauge, (this should agree with what will
show on the gauge in the cab). Inspect the attaching hardware for the fuel tank at the upper saddles, and then at the lower back of the tank for the
security and condition of the mounts. Check hoist
filters for leaks.
20. Move in behind the right front wheel, and inspect
the steering cylinder, suspension attaching hardware and suspension extension, as well as greasing and attaching hardware for the steering
cylinder. Inspect the hub and brakes for leaks and
any unusual condition. Be sure the suspension
protective boot is in good condition.
21. Move out and around the right front wheel, inspect
that all nuts/studs are in place and tight.
22. Move in behind the front of the right front wheel,
check hub and brakes for leaks and any unusual
condition. Inspect steering cylinder for security
and for proper greasing. Inspect the engine compartment for any leaks and unusual condition.
Inspect the fan guard, and belts also for any rags
or debris behind radiator. Turn work light off, if
used, and secure the ladder up and latched.
23. Inspect auto lube system. See Lincoln Auto Lube
in Section M, for specific details concerning
auto lube system.
24. Move on around to the right front of the truck, drop
the air cleaner pans to remove dirt, latch up and
secure. Inspect battery box cover for damage and
be sure it is in place and secure.
25. As you move in front of the radiator, inspect for
any debris that might be stuck in front of the
radiator and remove it. Check for any coolant
leaks. Inspect all head and fog lights.
A3-22
A03017
33. Adjust seat and steering wheel so that it is comfortable for use.
34. Read and understand the description of all Operator Controls in Section N, Cab, Instrument
Panel and Indicator Switches.
Be familiar with all control locations and functions
BEFORE operating truck.
A03017
A3-23
A3-24
A03017
A03017
A3-25
A3-26
A03017
A03017
PASSING
1. Do not pass another truck on a hill or blind curve!
2. Before passing, make sure the road ahead is
clear. If a disabled truck is blocking your lane,
slow down and pass with extreme caution.
3. Use only the areas designated for passing.
LOADING
1. Pull into the loading area with caution. Remain at
a 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 personnel
working in the area.
4. When pulling in under a loader or shovel, follow
Spotter or Shovel Operator signals. The truck
operator may speed up loading operations by
observing the location and loading cycle of the
truck being loaded ahead, then follow a similar
pattern.
5. When being loaded, operator should stay in truck
cab with engine running.
Place Selector Switch in Neutral and apply
Wheel Brake Lock.
6. When loaded, pull away from shovel as quickly as
possible but with extreme caution.
DUMPING
1. Pull into dump area with extreme caution. Make
sure area is clear of persons and obstructions,
including overhead utility lines. Obey signals directed by the spotter, if present.
Avoid unstable areas. Stay a safe distance from
edge of dump area.
Position truck on a solid, level surface before
dumping.
A3-27
To Lower Body
(When dumping over a berm or into a crusher):
A3-28
A03017
To Lower Body
(When dumping on flat ground):
It is very likely when dumping on flat ground that the
dumped material will build up enough to prevent the
body from lowering. In this case, the truck will have to
be driven forward a short distance (just enough to clear
the material) before the body can be lowered.
a. Shift Selector Switch to Forward, release
Brake Lock, depress Override button and drive
just far enough forward for body to clear material. Stop, shift Selector Switch to Neutral,
apply Brake Lock.
b. Move hoist lever forward to down position and
release. Releasing the lever places hoist control valve in the float position allowing the
body to return to frame.
TOWING
Prior to towing a truck, many factors must be carefully
considered. Serious personal injury and/or significant
property damage may result if important safety practices, procedures and preparation for moving heavy
equipment are not observed.
Do not tow the truck any faster than 5 MPH (8 kph).
Attachments for towing the 930E are available from the
Komatsu Distributor Parts Department as follows:
Front Bumper Modification Kit - MK3941: This kit
contains the parts necessary to modify the front
bumper for installation of towing bosses. One MK3941
kit is required for each truck in the fleet.
Tow Adaptor Structure - MK3945: This structure
must be ordered (or designed) to mate with the intended towing vehicle and is intended for towing an
unloaded vehicle only.
A03017
A3-29
A3-30
3. With engine cooled down, turn keyswitch counterclockwise to Off position for normal shutdown
of engine.
If engine does not shutdown with keyswitch, use
Engine Shutdown Switch on operator cab center
console, and hold this switch down until engine
stops.
4. With keyswitch Off, and engine stopped, wait at
least 90 seconds. Insure steering circuit is completely bled down by turning steering wheel back
and forth several times. No front wheel movement
will occur when hydraulic pressure is relieved. If
the vehicle continues to steer after shutdown,
notify maintenance personnel.
5. Verify all LINK VOLTAGE lights are OFF (one on
back interior wall of operator cab, two on electrical
cabinet, on deck), and notify maintenance personnel if remains illuminated longer than five
minutes after the engine is shut down.
6. Close and lock all windows, remove key from
keyswitch and lock cab to prevent possible unauthorized truck operation. Dismount truck properly. Put wheel chocks in place.
A03017
A03017
A3-31
NOTES:
A3-32
A03017
A04039
A4-1
A4-2
A04039
A04039
A4-3
Warning decals are applied to both brake accumulators located inside the brake system cabinet behind
the operator cab. These decals remind servicing technicians to be sure to close the accumulator drain
valves after they have been opened to bleed brake
pressure. It further warns not to over-tighten the drain
valves to prevent damage to the valve seat(s).
Any operating fluid, such as hydraulic oil, escaping under pressure can have sufficient force to
enter a persons body by penetrating the skin.
Serious injury and possibly death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
A4-4
A04039
This CAUTION decal is placed near the battery disconnect switches on the right side of the front bumper to
alert servicing technicians that before doing any welding on the truck, always disconnect the battery charging alternator lead wire and isolate electronic control
components before making welding repairs.
This CAUTION decal is also placed around the Retarding Grid Cabinet.
A04039
A4-5
A4-6
This decal is placed on the ground level engine shutdown switch which is mounted on the left side of the
front bumper structure. It specifies that this switch is
for emergency shutdown only.
A04039
A04039
A4-7
The Lubrication Chart is mounted on the right hand side of the radiator grille structure.
Refer to the Lubrication and Service section in this manual for more complete lubrication instructions.
A4-8
A04039
INDEX OF TABLES
I . . . . Standard Torque Chart (SAE)
A5-1
TABLE I
STANDARD TORQUE CHART
SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS)
TOLERANCES
10%
GRADE 5
CAPSCREW
THREAD
SIZE
1/420
1/428
5/1618
5/1624
3/816
3/824
7/1614
7/1620
1/213
1/220
9/1612
9/1618
5/811
5/818
3/410
GRADE 8
TORQUE GRADE 5
TORQUE GRADE 8
ft. lbs.
kg.m
N.m
ft. lbs.
7
8
15
16
25
30
40
45
65
70
90
95
125
135
220
0.97
1.11
2.07
2.21
3.46
4.15
5.5
6.2
9
9.7
12.4
13.1
17.3
18.7
30.4
9.5
10.8
20.3
22
34
41
54
61
88
95
122
129
169
183
298
10
11
21
22
35
40
58
62
90
95
125
135
175
190
310
A05001 03/01
kg.m
N.m
CAPSCREW
THREAD
SIZE
TORQUE GRADE 5
TORQUE GRADE 8
ft. lbs.
kg.m
N.m
ft. lbs.
kg.m
N.m
1.38
13.6
3/416
235
1.52
14.9
7/89
350
2.90
28
7/814
375
3.04
30
1.08
525
4.84
47
1.012
560
5.5
54
1.014
570
8.0
79
1 1/87
650
8.57
84
1 1/812
700
12.4
122
1 1/47
910
13.1
129
1 1/412
975
17.3
169
1 3/86
1200
18.7
183
1 3/812
1310
24.2
237
1 1/26
1580
26.2
258
1 1/212
1700
42.8
420
1 ft. lbs. = 0.138 kg.m = 1.356 N.m
32.5
48.4
51.9
72.6
77.4
78.8
89.9
96.8
125.9
134.8
166
181
219
235
319
475
508
712
759
773
881
949
1234
1322
1627
1776
2142
2305
335
500
530
750
790
800
1050
1140
1480
1580
1940
2120
2560
2770
46.3
69.2
73.3
103.7
109.3
110.6
145
158
205
219
268
293
354
383
454
678
719
1017
1071
1085
1424
1546
2007
2142
2630
2874
3471
3756
A5-1
A5-2
A05001 03/01
TABLE IV
TORQUE CHART FOR JIC 37 SWIVEL NUTS
WITH OR WITHOUT O-RING SEAL
SIZE
TUBE SIZE
THREADS
TORQUE
CODE
(O.D.)
UNF 2B
FT. LBS.
TABLE VI
TORQUE CHART FOR
O-RING BOSS FITTINGS
TUBE SIZE
THREADS
(O.D.)
UNF 2B
SIZE
CODE
TORQUE
FT. LBS.
0.125
0.31224
4 1
0.125
0.31224
0.188
0.37524
8 3
0.188
0.37524
4 2
5 2
0.250
0.43820
12 3
0.250
0.43820
8 3
0.312
0.50020
15 3
0.312
0.50020
10 3
0.375
0.56218
18 5
0.375
0.56218
13 3
0.500
0.75016
30 5
0.500
0.75016
24 5
10
0.625
0.87514
40 5
10
0.625
0.87514
32 5
12
0.750
1.06212
55 5
12
0.750
1.06212
48 5
14
0.875
1.18812
65 5
14
0.875
1.18812
54 5
16
1.000
1.31212
80 5
16
1.000
1.31212
72 5
20
1.250
1.62512
100 10
20
1.250
1.62512
80 5
24
1.500
1.87512
120 10
24
1.500
1.87512
80 5
32
2.000
2.50012
230 20
32
2.000
2.50012
96 10
SIZE
CODE
TABLE V
TORQUE CHART FOR
PIPE THREAD FITTINGS
WITH
PIPE THREAD
SEALANT
SIZE
FT. LBS.
WITHOUT
SEALANT
FT. LBS.
0.12527
15 3
20 5
0.25018
20 5
25 5
0.37518
25 5
35 5
0.50014
35 5
45 5
12
0.75014
45 5
55 5
16
1.00011.50
55 5
65 5
20
1.25011.50
70 5
80 5
24
1.50011.50
80 5
95 10
32
2.00011.50
95 10
120 10
A05001 03/01
SIZE
CODE
TABLE VII
TORQUE CHART FOR
O-RING FACE SEAL FITTINGS
TUBE SIZE
THREADS
(O.D.)
UNF 2B
TORQUE
FT. LBS.
0.250
0.43820
11 1
0.375
0.56218
18 2
0.500
0.75016
35 4
10
0.625
0.87514
51 5
12
0.750
1.06212
71 7
16
1.000
1.31212
98 6
20
1.250
1.62512
132 7
24
1.500
1.87512
165 15
A5-3
FT. LBS.
0
10
20
30
40
50
60
70
80
90
FT. LBS.
0
10
20
30
40
50
60
70
80
90
PSI
0
10
20
30
40
50
60
70
80
90
PSI
0
100
200
300
400
500
600
700
800
900
A5-4
0
(N.m)
13.56
27.12
40.67
54.23
67.79
81.35
94.91
108.47
122.03
0
(kg.m)
1.38
2.77
4.15
5.53
6.92
8.30
9.68
11.06
12.45
0
(kPa)
68.95
137.9
206.8
275.8
344.7
413.7
482.6
551.6
620.5
0
(MPa)
0.69
1.38
2.07
2.76
3.45
4.14
4.83
5.52
6.21
1
1.36
14.91
28.47
42.03
55.59
69.15
82.70
96.26
109.82
123.38
1
0.138
1.52
2.90
4.29
5.67
7.05
8.44
9.82
11.20
12.59
1
6.895
75.84
144.8
213.7
282.7
351.6
420.6
489.5
558.5
627.4
10
0.069
0.76
1.45
2.14
2.83
3.52
4.21
4.90
5.58
6.27
7
9.49
23.05
36.61
50.17
63.72
77.28
90.84
104.40
117.96
131.51
8
10.85
24.40
37.96
51.52
65.08
78.64
92.20
105.75
119.31
132.87
9
12.20
25.76
39.32
52.87
66.44
80.00
93.55
107.11
120.67
134.23
7
0.968
2.35
3.73
5.12
6.50
7.88
9.27
10.65
12.03
13.42
8
1.106
2.49
3.87
5.26
6.64
8.02
9.40
10.79
12.17
13.55
9
1.245
2.63
4.01
5.39
6.78
8.16
9.54
10.93
12.30
13.69
7
48.26
117.21
186.2
255.1
324.1
393.0
462.0
530.9
599.9
668.8
8
55.16
124.1
193.1
262.0
331.0
399.9
468.9
537.8
606.8
675.7
9
62.05
131.0
200.0
268.9
337.9
406.8
475.8
544.7
613.7
682.6
70
0.48
1.17
1.86
2.55
3.24
3.93
4.62
5.31
6.00
6.69
80
0.55
1.24
1.93
2.62
3.31
4.00
4.69
5.38
6.07
6.76
90
0.62
1.31
2.00
2.69
3.38
4.07
4.76
5.45
6.14
6.83
A05001 03/01
NOTE: Tables such as Table VIII, IX, X, and XI may be 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 668.8
97 psi = 668.8 kPa.
3. Multiply by 10:
970 psi = 6688 kPa.
4. Go to PSI row 0, column 5; read 34.47
5 psi = 34.47 kPa. Add to step 3.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
975 psi = 6722 kPa.
A05001 03/01
A5-5
TABLE XIII
COMMON CONVERSION MULTIPLIERS
COMMON CONVERSION MULTIPLIERS
ENGLISH to METRIC
TO CONVERT
MULTIPLY
FROM
TO
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
sq. in. in.2
sq. centimeters (cm2)
6.45
sq. ft. ft.2
sq. centimeters (cm2)
929
cu. in. in.3
cu. centimeters (cm3)
16.39
cu. in. in.3
liters (l)
0.016
cu. ft. ft.3
cu. meters (m3)
0.028
cu. ft. ft.3
liters (l)
28.3
ounce oz.
kilogram (kg)
0.028
fluid ounce fl. oz.
milliliter (ml)
29.573
pound (mass)
kilogram (kg)
0.454
pound (force) lbs.
Newton (N)
4.448
in. lbs. (force)
Newton.meters (N.m)
0.113
ft. lbs. (force)
Newton.meters (N.m)
1.356
ft. lbs. (force)
kilogram.meters (kg.m)
0.138
kilogram.meters (kg.m) Newton.meters (N.m)
9.807
psi (pressure)
kilopascals (kPa)
6.895
psi (pressure)
megapascals (MPa)
0.007
psi (pressure)
kilograms/cm2 (kg/cm2)
0.0704
ton (short)
kilogram (kg)
907.2
ton (short)
metric ton
0.907
quart qt.
liters (l)
0.946
gallon gal.
liters (l)
3.785
HP (horsepower)
Watts
745.7
HP (horsepower)
kilowatts (kW)
0.745
A5-6
A05001 03/01
A07003
Storage Procedures
A7-1
A7-2
Storage Procedures
A07003
A07003
10. Install fully charged batteries in unit. Clean connectors and connect battery cables. Compartment
must be free of corrosion. Secure batteries with
hold downs.
11. Check all electrical cables for weathering, cracks
and/or damage. Replace any defective cables.
Storage Procedures
A7-3
A7-4
Storage Procedures
A07003
A07003
Storage Procedures
A7-5
5. The vehicle engine should be inspected and serviced according to the Engine Manufacturers Operation And Maintenance Manuals.
a. Insure that exhaust is clear and clean, no foreign materials. If water entry is suspected, disconnect air tubes at the turbochargers to check
for water damage before attempting startup.
A7-6
Storage Procedures
A07003
d. Check exposed portions of all hydraulic cylinder rams for rust, pitting and corrosion. If plating is deteriorated, the cylinder should be
removed and overhauled or replaced; pitted or
scored plating will cause leakage at the cylinder
seals.
8. Check front wheel hub, final drive and wheel axle
lubricant. If contamination is suspected, oil should
be drained completely and the component serviced with clean prescribed lubricant. If major contamination is present, disassembly and overhaul
will be in order.
9. Check parking brake. Since it is spring applied, the
brake pads may be stuck tightly to the disc; it may
be necessary to remove and overhaul the parking
brake assembly.
10. Lubricate all grease fittings with prescribed lubricants which are not part of the automatic lubrication system. Pay particular attention to the steering
linkage connections. All pivot points must be free
of any binding.
11. Check battery charging alternator for corrosion or
deterioration. Alternator rotor must be free, with no
binding or roughness. Inspect, install and properly
tension the alternator drive belts.
12. Check security of steering cylinder ball joints link
and hydraulic connections.
13. Examine Hydrair suspensions for signs of damage.
a. Discharge nitrogen from suspensions as outlined in the service manual. Check conditon of
suspension oil and cylinder wipers. If wipers are
cracked or hardened, the suspension must be
rebuilt. Recharge suspension with new oil if old
oil is deteriorated.
b. Check exposed chrome portions of cylinder for
rust, pitting and corrosion. If plating is deteriorated the suspension should be removed and
overhauled or replaced; pitted or scored plating will rapidly cause leakage at the seals.
c. Recharge suspensions as outlined in the service manual.
14. If not previously done, install fully-charged batteries and insure that hook-up is correct.
A07003
Storage Procedures
A7-7
ENGINE OPERATION
When all reconditioning operations have been completed, a static check of engine operation along with
operation of systems as well as verification of braking
and steering must be done before the vehicle is moved.
A7-8
Storage Procedures
A07003
A07003
Storage Procedures
A7-9
ENGINE STORAGE
Therefore, it is recommended that the engine be processed for storage as soon as possible after removal
from operation.
The engine should be stored in a building which is dry
and can be heated during the winter months. Moisture
absorbing chemicals are available commercially for
use when excessive damage prevail in the storage
area.
2. Fill the crankcase to proper level with the recommended viscosity and grade of oil.
3. Fill the fuel tank with the recommended grade of
fuel oil. Operate the engine for two minutes at
1,200 rpm and no load. Shut down engine, do not
drain the fuel system or the crankcase after this
run.
4. Check the air cleaner and service it, if necessary.
5. If freezing weather is expected during the storage
period, add an ethylene glycol base antifreeze
solution in accordance with the manufacturers
recommendations.
A7-10
Storage Procedures
A07003
If engines in vehicle are stored where condensation of water in the fuel tank may be a problem, add
pure, waterless isopropyl alcohol (isopropanol) to
the fuel at a ratio of one pint to 125 gallons(473 L)
of fuel, or 0.010% by volume. Where biological
contamination of fuel may be a problem, add a
biocide such as Biobor JF, or equivalent to the fuel.
When using a biocide, follow the manufacturers
concentration recommendations, and observe all
cautions and warnings.
9. Drain and disassemble the fuel filter and strainer.
Discard the used elements and gaskets. Fill the
cavity between the element and shell with No. 1
diesel fuel or pure kerosene, and reinstall on the
engine. If spin-on fuel filters and strainers are
used, discard the used cartridges, fill the new
ones with No. 1 diesel fuel or pure kerosene, and
reinstall on the engine.
10. Operate the engine for five (5) minutes to circulate
the clean fuel oil throughout the fuel system.
11. Service the air cleaner.
12. Turbocharger bearings are pressure lubricated
through the external oil line leading from the engine cylinder block while the engine is operating.
However, the turbocharger air inlet and turbine
outlet connections should be sealed off with moisture resistant tape.
13. Apply a rust preventive compound to all exposed
non-painted surfaces.
A07003
Storage Procedures
A7-11
A7-12
Storage Procedures
A07003
This instruction provides the recommended procedures for protecting equipment from damage during
both short-term and long-term storage periods and for
maintaining adequate protection while in storage. Also
included are instructions for placing this equipment
into service after having been stored.
For the purposes of this instruction, a short-term storage period is considered to be less than three months;
a long-term storage period is considered to be three
months or longer.
General Electric recommends a maximum storage period of three years, with these storage procedures
being repeated after each year. After a storage period
of three years or more, the Motorized Wheels should
be removed and sent to an overhaul facility for teardown and inspection of seals and bearings. These
should be replaced if necessary.
Periodic (every three months) inspections should be
made to determine the lasting qualities of long-term
storage protection measures. Such inspections will
indicate the need for renewing protective measures
when necessary to prevent equipment deterioration.
Proper storage of this equipment is vital to equipment
life. Bearings, gears, and insulation may deteriorate
unless adequate protective measures are taken to protect against the elements. For example, bearings and
gears in the Motorized Wheel gear case are susceptible
to the formation of rust; insulation in rotating electrical
equipment can accumulate moisture; and bearings
may become pitted.
A07003
These three major categories are the basis for determining required protective measures.
NOTE: In addition to these instructions, refer to truck
storage instructions.
Storage Procedures
A7-13
A7-14
Storage Procedures
A07003
Periodic Inspections
It is important that periodic inspections (every three
months) of stored equipment be performed to insure
the continued serviceability of all protective measures
initially taken when the storage period began. Items
which should be checked at each inspection interval
are listed as follows:
1. Remove the weatherproof tape from the compartment doors and preform a Megger test as described in the Vehicle Test Instructions. Record
the test results and compare them with the recorded Megger readings taken when storage first
began, and those taken throughout the storage
period. Remove all test equipment and close up
the compartment. Reseal the compartment doors
with new weatherproof tape. If Megger readings
indicate a deterioration of insulation quality, to
below 2.0 megohms then consideration should be
given to providing more protection.
2. Check all other weatherproofing tape. Replace any
that has become loose or is missing completely.
3. Check all heat sources. Replace or repair any units
which have become inoperative.
4. Check all machine surfaces which were coated
with flushing compound when storage began. If
compound appears to be deteriorating, it must be
cleaned off and renewed.
A07003
Storage Procedures
A7-15
A7-16
Storage Procedures
A07003
SECTION B
STRUCTURES
INDEX
STRUCTURAL COMPONENTS . . . .
Preparation . . . . . . . . . . . .
Grille, Hood and Ladder . . . . .
Decks . . . . . . . . . . . . . . .
Right Deck and Components
Left Deck . . . . . . . . . . .
Center Deck . . . . . . . . .
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B2-1
B2-1
B2-2
B2-3
B2-3
B2-4
B2-4
DUMP BODY . . . . . . . . . . . . .
Removal . . . . . . . . . .
Installation . . . . . . . . .
BODY PADS . . . . . . . . . .
BODY GUIDE . . . . . . . . . .
HOIST LIMIT SWITCH . . . . .
BODY UP SWITCH . . . . . . .
BODY-UP RETENTION CABLE
ROCK EJECTORS . . . . . . .
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B3-1
B3-1
B3-2
B3-3
B3-4
B3-4
B3-4
B3-4
B3-5
FUEL TANK . . . . . . . . .
Removal . . . . . .
Installation . . . . .
Repair . . . . . . .
Cleaning . . . . . .
VENT . . . . . . . . . .
FUEL GAUGE SENDER
Removal . . . . . .
Installation . . . . .
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B4-1
B4-2
B4-2
B4-2
B4-2
B4-3
B4-3
B4-3
B4-3
B01016 03/01
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Index
B1-1
NOTES
B1-2
Index
B01016
STRUCTURAL COMPONENTS
The 930E deck components are removable in sections
as shown in Figure 2-1. The following removal and
installation instructions detail the steps to be taken
before the decks and hood can be removed. Additional
steps may be required before the deck or other major
structure is removed, depending on optional equipment installed on the truck at the factory or after delivery.
Prior to removal or repair procedures, it may be necessary to remove the body to provide clearance for
lifting equipment to be used. If body removal is not
required, the body should be raised and the safety
cables installed at the rear of the truck.
Read and observe the following instructions before
attempting any repairs!
All removal, repairs and installation of propulsion system electrical components, cables etc.
must be performed by an electrical maintenance technician properly trained to service
the system.
In the event of a propulsion system malfunction, a qualified technician should inspect the
truck and verify the propulsion system does
not have dangerous voltage levels present before repairs are started.
PREPARATION
1. Reduce the engine speed to idle. Place the selector switch in NEUTRAL and apply the parking
brake. Be certain the parking brake applied indicator lamp in the overhead panel is illuminated.
2. Place the drive system in the REST mode by
turning the Rest switch on the instrument panel
ON. Be certain the REST warning lamp is illuminated.
3. Shut down the engine using the keyswitch. If, for
some reason the engine does not shut down, use
the shutdown switch on the center console.
4. Verify the LINK VOLTAGE lights are OFF. If they
remain on longer than 5 minutes after shutdown,
notify the electrical department.
5. Verify the steering accumulators have bled down
by attempting to steer.
6. Bleed down the brake accumulators using the
manual bleed valves on the brake manifold.
7. Open the battery disconnect switches.
B02015
Structural Components
B2-1
The anti-slip material on the decks should be inspected and maintained for the safety of all personnel.
If weld repairs are necessary, disconnect all electrical harnesses and remove the ground strap from
the Engine Control System (governor) located in
the Auxillary Control Cabinet behind the cab.
All hoses and mating fittings should be capped as
they are removed to prevent possible system contamination.
It is important to tag and visually verify all cables,
harnesses, hoses etc. have been removed before
the structure is lifted off the truck.
For cab removal instructions, refer to Section N of
this manual.
Installation
2. Capscrews &
Lockwashers
4. Attach lifting device to the hood and grille assembly (1, Figure 2-2).
B2-2
Structural Components
B02015
5. Headlights
6. Retard Grid Mounting Location
7. Electrical Connector
DECKS
The right and left deck mounting pad locations are
nearly identical. The decks are mounted directly to the
frame support structures using hardened flatwashers.
Be certain to use hardened flatwashers during reassembly.
RIGHT DECK AND COMPONENTS
Removal
1. Shut down engine following all the procedures
listed on page 2-1 of this Section of the manual.
2. Remove access covers from retarding grid assembly. Tag and disconnect all electrical leads in
preparation for removal. Attach lifting device to
grid lifting eyes.
B02015
Structural Components
B2-3
Installation
Repeat above procedures in reverse order for installation of the deck and components. Tighten all attaching
hardware to standard torque specifications as listed in
Section A.
Clean all mount mating surfaces before installation.
Clean mounting area before installing ground
cables.
Be certain all electrical connections and harness
clamps are reinstalled and secure.
All propulsion system power cables must be properly secured in their wood or other non-ferrous
cable cleats. If clamps are cracked and broken, oil
soaked or otherwise damaged, replace them with
new parts. Inspect cable insulation and replace
cable if insulation is damaged.
LEFT DECK
NOTE: The left deck mounting arrangement is nearly
identical to the right deck. Refer to Section N for cab
removal and installation instructions.
1. Shut down engine following all the procedures
listed on page 2-1 of this Section of the manual.
2. Be certain the brake system accumulators have
been bled to release pressure.
3. Tag and disconnect all hydraulic lines and electrical cables which will interfere with deck removal.
Cap all lines to prevent entrance of foreign material.
CENTER DECK
Center deck removal only requires removal of any
attached hoses cables etc. before removing the mounting hardware and and lifting the deck structure off.
Be certain to follow proper shutdown procedures
as described on page 2-1.
If equipped with air conditioning and air conditioning system components are to be removed, refer
to Section M, Options for special instructions on
discharging the air conditioning system prior to
disconnecting any air conditioning lines.
B2-4
Structural Components
B02015
DUMP BODY
Removal
Slings, chains, and/or cables used for lifting components must be rated to supply a safety factor of
approximately 2X the weight being lifted.
When in doubt as to the weight of components or
any assembly procedure, contact the Komatsu
area representative for further information.
Lifting eyes and hooks should be fabricated from
the proper materials and rated to lift the load being
placed on them.
Never stand beneath a suspended load. Use of guy
ropes are recommended for guiding and positioning a suspended load.
Before raising or lifting the body, be sure there is
adequate clearance between the body and overhead structures or electric power lines.
Be sure that the lifting device is rated for at least a
45 ton capacity.
1. Park truck on a hard, level surface and block all
the wheels. Connect cables and lifting device to
the dump body and take up the slack as shown in
Figure 3-1.
90444
90909
B03013 03/01
Dump Body
B3-1
Installation
1. Park truck on a hard, level surface and block all
the wheels.
Inspect all lifting devices. Slings, chains, and/or
cables used for lifting components must be inspected daily for serviceable condition. Refer to
the manufacturers manual for correct capacities
and safety procedures when lifting components.
Replace any questionable items.
Slings, chains, and/or cables used for lifting components must be rated to supply a safety factor of
approximately 2X the weight being lifted.
When in doubt as to the weight of components or
any assembly procedure, contact the Komatsu
area representative for further information.
Lifting eyes and hooks should be fabricated from
the proper materials and rated to lift the load being
placed on them.
B3-2
Dump Body
B03013 03/01
BODY PADS
5. Install the mounting hardware and torque to 65
ft.lbs. (88.1 N-m)
3. A gap of approximately 0.06 in. (1.5 mm) is required at each rear pad. This can be accomplished by using one less shim at each rear pad.
! IMPORTANT !
Proper body pad to frame contact is required to
assure maximum pad life.
B03013 03/01
3. Frame
4. Body Pad
Dump Body
5. Shim
6. Mounting Pad
B3-3
BODY GUIDE
1. Body guide wear points should be inspected each
time a body pad inspection is performed. (Refer
to Figure 3-5) The body guide should be centered
between the wear plates (3), with a maximum gap
of 0.19 in. (4.8 mm) at each side when new.
2. If gap becomes excessive, replacement parts
should be installed. (Refer to the Parts Catalog)
Any time personnel are required to perform maintenance on the vehicle with the dump body in the
raised position, the body-up retention cable MUST
be installed.
1. To hold the dump body in the up position, raise the
body to its maximum height. Refer to Figure 3-6.
90440
BODY UP SWITCH
B3-4
Dump Body
B03013 03/01
ROCK EJECTORS
Rock Ejectors are placed between the rear dual wheels
to keep rocks or other material from lodging between
the tires. Failure to maintain the Rock Ejectors could
allow debris to build up between the dual wheels and
cause damage to the tires.
Inspection
1. The ejectors must be positioned on the center line
between the rear tires within 0.25 in. (6.35 mm).
2. With the truck parked on a level surface, the arm
structure should be approximately 4.33 in. (110
mm) from the wheel spacer ring (3). Refer to
Figure 3-7.
NOTE: With Rock Ejector Arm (1, Figure 3-8)
hanging vertical as shown in Figure 3-7, there
must be NO GAP at Stop Block (3, Figure 3-8).
3. If the arm (1) becomes bent, it must be removed
and straightened.
4. The wear plates (2) must be replaced if severely
worn.
5. Inspect the mounting brackets (4, Figure 3-8), pins
(2) and stops (3) at each shift change for wear
and/or damage, and repair as necessary.
91185
B03013 03/01
Dump Body
3. Stop Block
4. Mounting Bracket
B3-5
NOTES
B3-6
Dump Body
B03013 03/01
FUEL TANK
1. Fuel Tank
2. Capscrews & L/Ws
3. Mounting Cap
4. Lifting Brackets
5. Breather
6. Filler Cap
B04015
Fuel Tank
B4-1
Removal
Repair
Cleaning
The fuel tank is provided with a drain and a cleaning
port in the side that allows steam or solvent to be
utilized in cleaning tanks that have accumulated foreign material.
It is not necessary to remove the tank from the truck
for cleaning of sediment, however rust and scale on the
walls and baffles may require complete tank removal.
This allows cleaning solutions to be in contact with all
interior surfaces by rotating the tank in various positions, etc.
Prior to a cleaning procedure of this type, all vents, fuel
gauge, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material has been removed, the temporary plugs can
be removed.
A small amount of light oil should be sprayed into the
tank to prevent rust if the tank is to remain out of
service. All openings should be sealed for rust prevention.
B4-2
Fuel Tank
B04015
VENT
Removal
1. Drain fuel below level of gauge sender.
2. Disconnect wire from terminal.
3. Loosen the small screws holding the fuel gauge
sender unit and carefully remove.
Installation
1. Install new gasket.
2. Reinstall the sender unit in tank. Take care to
insure that float is oriented properly and works
freely in vertical plane during installation.
3. Reinstall four socket head capscrews and tighten
to standard torque. Reconnect wire to terminal.
4. Refill tank and check for leaks.
B04015
Fuel Tank
B4-3
NOTES
B4-4
Fuel Tank
B04015
SECTION C
ENGINE
INDEX
POWER MODULE . . .
Preparation . . . .
Removal .
Installation
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. C2
C2-1
C2-5
C2-7
COOLING SYSTEM . . . . . .
RADIATOR . . . . . . . .
Removal . . . . .
Installation . . . .
Radiator Fill Procedure
Troubleshooting . . .
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. C3
C3-1
C3-1
C3-3
C3-4
C3-4
POWER TRAIN . . . . . . . . . . . . . . . . .
ALTERNATOR REMOVAL PROCEDURE .
Removal . . . . . . . . . . . . .
ENGINE/ALTERNATOR MATING . . . .
Joining Alternator and Engine . . . .
ENGINE . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . .
Installation . . . . . . . . . . . .
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. C4
C4-1
C4-1
C4-3
C4-5
C4-6
C4-6
C4-6
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. C5
C5-1
C5-2
C5-3
C5-4
C5-4
C5-5
C01021 03/01
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Index
C1-1
NOTES
C1-2
Index
C01021 03/01
POWER MODULE
The radiator, engine and alternator assemblies are
mounted on a roller equipped subframe which is contained within the trucks main frame and is referred to
as a Power Module. This arrangement permits removal and installation of these components with a
minimum amount of disconnect and by utilizing the
unique Roll In/Roll Out feature.
Although the instructions in this section are primarily
based upon the Rollout method for major component
removal, the radiator and fan may be removed as
separate items. Instructions for radiator and fan removal are contained later in this section. Optional
equipment may be installed on the truck, requiring
additional removal and installation steps not listed.
The procedures outlined in this section of the manual
are general instructions for power module removal and
installation. It may be necessary to perform some
procedures in a different order or use different methods for component removal and installation, depending on the lifting equipment available at the mine site.
Prior to removal or repair procedures, it may be necessary to remove the body to provide clearance for
lifting equipment to be used. If body removal is not
required, the body should be raised and the safety
cables installed at the rear of the truck.
Read and observe the following instructions before
attempting any repairs!
C02017 03/01
Power Module
C2-1
C2-2
Power Module
C02017 03/01
C02017 03/01
7. Reducer Elbow
8. T-Bolt Clamp
9. Duct Support Rod
10. Right Front Intake Duct
11. Right Rear Intake Duct
Power Module
C2-3
C2-4
Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere. An
approved recovery/recycle station must be used
to remove the refrigerant from the air conditioning
system.
Power Module
C02017 03/01
C02017 03/01
Power Module
C2-5
3. Capscrews
4. Engine
5. Power Module Subframe
C2-6
Power Module
C02017 03/01
C02017 03/01
Power Module
C2-7
8. Connect the hydraulic pump drive shaft companion flange (4, Figure 2-1) to the alternator (5).
Tighten capscrews to standard torque. Install
driveshaft guard (2).
7. Inspect alternator/wheel motor cooling duct gaskets and replace if damaged. Install Alternator
inlet transistion structure (8, Figure 2-2) and
wheel motor duct transition structure (5).
C2-8
Power Module
C02017 03/01
COOLING SYSTEM
RADIATOR
Removal
1. Drain coolant from radiator and engine. Be prepared to catch approximately 200 gallons (757
liters) of coolant. If the coolant is to be reused, it
must be stored in clean containers.
2. If radiator is being removed without the removal
of the complete power module, remove grille and
hood according to Removal instructions in Section B.
Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere. An
approved recovery/recycle station must be used
to remove the refrigerant from the air conditioning
system.
C03023 03/01
Cooling System
4. Inlet Hose
5. Outlet Hose
C3-1
NOTE: The radiator and shroud assembly weigh approximately 5,730 Lbs. (2,600 Kg.).
C3-2
Cooling System
C03023 03/01
4. Install upper support rods (4) and mounting hardware at radiator brackets and front upright brackets. Do not tighten at this time.
5. Adjust the lower stabilizer support rods to position
the radiator perpendicular to the subframe within
0.12 in. (3.0 mm) measured at top of radiator.
When position is established, tighten locknuts to
525 ft. lbs (712 N.m) torque to lock adjustment.
6. Tighten upper support rod mounts and recheck
perpendicularity of radiator.
7. Tighten nuts on capscrews (2, Figure 3-5) at lower
radiator mounting brackets to standard torque.
8. Install the fan guard using capscrews and washers removed during disassembly.
9. Install upper radiator hoses and lines between
radiator and engine, seat hoses fully and tighten
clamps securely.
4. Battery Box
5. Outlet Elbow
Installation
1. Attach a hoist to the radiator assembly and lift into
position on the subframe.
2. Insert the capscrews, washers, and nuts (2, Figure 3-5) at the lower radiator mounting brackets
but do not tighten at this time.
3. Inspect rubber bushings for lower support rods (5,
Figure 3-1) and replace if worn or damaged.
Install flatwashers, rubber bushings and nuts on
the lower end of radiator support rods and insert
rods into the subframe mounting brackets. Insert
remaining bushings, flatwashers and locknuts but
do not tighten. Install rods at radiator brackets and
tighten to standard torque.
C03023 03/01
Cooling System
C3-3
C3-4
Cooling System
C03023 03/01
POWER TRAIN
ALTERNATOR REMOVAL PROCEDURE
Removal
The following instructions cover the removal of the
main alternator from the engine after the power module
has been removed from the truck. (Refer to Figure
4-1.)
4. Subframe
5. Gap
C04023 03/01
4. Flywheel Housing
5. Capscrews
Power Train
6. Engine
7. Sub Frame
8. Alternator Lift Eyes
C4-1
C4-2
Power Train
C04023 03/01
MEASURING PROCEDURE
ENGINE/ALTERNATOR MATING
General Instructions
Average
c. Record (a + b) as;
Measurement C:
T.I.R.
0.66 mm
0.25 mm
0.18 mm
0.25 mm
C04023 03/01
Power Train
A - Dimension A
B - Drive Shims
C - Dimension C
D - Housing Shims
C4-3
3. Steel Bar
4. Capscrew
5. Determining Shims:
Compare Measurement C (Step 3.c.)
with Measurement A (Step 4.f.).
b. If A is greater than C, subtract: (A - C) = D
Shim pack thickness
D=
to be installed at location D, Figure 4-4.
C4-4
Shim Thickness
0.004 inch
0.007 inch
Power Train
Shim Thickness
0.004 inch
0.007 inch
C04023 03/01
6. Tighten engine-to-cradle structure mounting capscrews (5, Figure 4-1) to 345 ft. lbs. (465 N.m)
torque.
C04023 03/01
Power Train
C4-5
Service
ENGINE
Removal
Refer to instructions in previous sections for removal
instructions for the Power Module, alternator, and radiator assembly.
Complete instructions covering the disassembly, assembly and maintenance of the engine and its components can be found in the engine manufacturers
service manual.
Installation
1. Align engine to subframe and install front mounting capscrews and lockwashers (5, Figure 4-7).
Align and install rear engine mounting capscrews
and lockwashers (2) through cradle structure, but
do not tighten at this time. Tighten front mount
capscrews to 345 ft. lbs. (465 N.m) torque.
2. Install alternator on engine following instructions
for Engine/Alternator Mating.
3. Tighten rear engine mounting capscrews (2) to
345 ft. lbs. (465 N.m) torque after alternator is
installed.
4. Adjust setscrew (3, Figure 4-2) to equalize gap (5)
between cradle structure (1) and subframe (4) at
left and right side. Lock setscrew with jam nut (2).
C4-6
3. Engine Subframe
4. Engine
Power Train
C04023 03/01
The truck engine must be shut down before servicing the air cleaner assemblies or opening the
engine air intake system.
Never start the engine with the filter elements removed. Engine operation with elements removed
can cause serious engine damage.
C05013 5/98
C5-1
5. Wing Nut
6. Wing Nut Gasket
7. Safety Element Indicator
8. End Cover
C5-2
C05013 5/98
After inspection, determine the condition of the element and choose either the washing or compressed
air method for cleaning the filter element. If the element
is clogged with carbon, soot, oil and/or dust, the complete washing procedure will produce the best results.
C05013 5/98
C5-3
Both the main and safety elements must be installed in the air cleaner while Steps 1 and 2 are
being accomplished to prevent any possibility of
dirt being forced into the engine intake area.
1. Dust can be removed with a stiff fiber brush. DO
NOT use a wire brush. Dust may also be removed
effectively using compressed air.
2. Heavy plugging of tubes may require soaking and
washing of complete precleaner section. The following instructions cover these procedures.
Precleaner Section
The tubes in the precleaner section of the air cleaner
assembly should be cleaned at least once annually and
at each engine overhaul. More frequent cleaning may
be necessary depending upon operating conditions
and local environment should tubes become clogged
with oil, sludge or dirt.
To inspect tubes in precleaner section, remove main
filter element. Do not remove the safety element.
Loosen clamps and remove dust collector cup. Use a
light to inspect the tubes, all tubes should be clear and
the light should be visible.
Clean the tubes as follows if clogging is evident.
C5-4
C05013 5/98
C05013 5/98
C5-5
NOTES
C5-6
C05013 5/98
SECTION D
ELECTRICAL SYSTEM (24 VDC NONPROPULSION)
INDEX
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D2-3
D2-3
D2-3
D2-3
D2-4
D2-4
D2-5
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. D3
D3-1
D3-1
D3-3
D3-6
D3-6
D3-8
D3-8
D3-9
D3-9
D3-13
D3-14
D3-15
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. . . . . . . . . . . . . . . . . . . . D2
. . . . . . . . . . . . . . . . . . . D2-1
. . . . . . . . . . . . . . . . . . . D2-1
NOTE: Electrical system wiring hookup and electrical schematics are located in Section R of
this Manual.
DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNING AND CONTINUE TO EXIST AFTER SHUTDOWN IF THE REQUIRED SHUTDOWN PROCEDURES ARE NOT
FOLLOWED.
Before attempting repairs or working near propulsion system components, the following
precautions and truck shutdown procedure must be followed:
D01033
DO NOT step on or use any power cable as a handhold when the engine is running.
Index
D1-1
NEVER open any electrical cabinet covers or touch the Retarding Grid elements.
Additional procedures are required before it is safe to do so. Refer to Section
E for additional propulsion system safety checks to be performed by a technician trained to service the system.
ALL removal, repairs and installation of propulsion system electrical components, cables etc. must be performed by an electrical maintenance technician
properly trained to service the system.
IN THE EVENT OF A PROPULSION SYSTEM MALFUNCTION, a qualified technician should inspect the truck and verify the propulsion system does not have
dangerous voltage levels present before repairs are started.
After the truck is parked in position for the repairs, the truck must be shut down properly to ensure
the safety of those working in the areas of the deck, electrical cabinet, traction motors, and retarding
grids. The following procedures will ensure the electrical system is properly discharged before repairs
are started.
D1-2
Index
D01033
Troubleshooting
BATTERIES
Maintenance and Service
The electrolyte level of each cell should be checked at
the interval specified in the Lubrication and Service
Section P, and water added if necessary. The proper
level to maintain is 38 12 in. (10-13 mm) above the
plates. To insure maximum battery life, use only distilled water or water recommended by the battery
manufacturer. After adding water in freezing weather,
operate the engine for at least 30 minutes to thoroughly
mix the electrolyte.
D02018
D2-1
SPECIFIC GRAVITY
Corrected to 80F (27C)
FREEZING
TEMPERATURE DEGREES
1.280
-90F (-70C)
1.250
-60F (-54C)
Idle batteries should not be allowed to stand unattended. If equipment is to stand unused for more than
two weeks, the batteries should be removed and
placed in a cool, dry place where they may be checked
periodically and charged when necessary. Remember,
all lead-acid batteries discharge slowly when not in use.
This self discharge takes place even though the battery
is not connected in a circuit and is more pronounced
in warm weather than in cold.
1.200
-16F (-27C)
1.150
+ 5F (-15C)
1.100
+ 19F (-7C)
D2-2
D02018
BATTERY BOX
The truck batteries are located in an enclosure (1,
Figure 2-1) in the center of the truck behind the front
bumper. For access to the batteries, remove the two
covers by turning the cover handles counterclockwise
until released. Lift eyes are attached to the ends of the
enclosure if the entire battery container must be removed.
Four Type 8D batteries (2) are installed in the battery
box and are used for the 24VDC engine cranking circuit
and the 12VDC circuits. Two Type 4D batteries (3) are
installed to provide 24VDC for the truck systems other
than engine starting. A System Battery Starter Disconnect Relay isolates these batteries from the engine
starter circuit during engine cranking.
D02018
D2-3
D2-4
5. Auxiliary Battery
Connectors
6. 12VDC Circuit Breaker
7. System Battery Starter
Disconnect Relay
8. Battery Equalizer
D02018
Battery Equalizer
The majority of the accessory and control circuits
operate at 24VDC. Several components however, require 12VDC (cab window regulator motors, cassette/radio, cigar lighter etc.).
A battery equalizer (8) system is utilized to obtain the
required 12VDC and ensure that all the truck batteries
are charged and discharged equally.
A 50 amp circuit breaker (6) mounted in the box protects the 12VDC circuits.
Troubleshooting
Normal battery maintenance procedures should be
followed according to the intervals specified in the
Lubrication and Service section of this manual. Refer
to the Battery information in this section for detailed
instructions regarding proper battery maintenance and
service procedures. Prior to troubleshooting the battery equalizer system, inspect all battery circuit connections for excessive corrosion, loose cables, ground
connections etc. Use the following procedure to check
the system if a problem occurs:
D02018
D2-5
NOTES
D2-6
D02018
COMPONENTS
D03019 04/01
D3-1
D3-2
D03019 04/01
1. With the key switch ON, press the Engine Shutdown switch firmly to the momentary position and
release (switch will return to the ON position).
Circuit 712 (to ground) remains 24 volts for approximately 5 minutes. After 5 minutes, the voltage
drops to 0.
The 5 minute idle indicator lamp on the overhead
display is ON when circuit 712 reads 24 volts.
3. Repeat step 1. While monitoring voltage at circuit
712, turn the key switch OFF. Push the engine
shutdown switch off.
Verify voltage at circuit 712 drops to 0 when the
shutdown switch is pushed to OFF.
INCLINOMETER
Coolant Level/Flasher
The inclinometer is used by the on-board load weighing system to determine whether the truck is on a level
surface or tilted fore or aft. The information provided
by the inclinometer is sent to the weighing system for
use in calculating the payload. Refer to Section M for
detailed information on the inclinometer and on board
load weighing system.
The Coolant Level and Flasher Card contains two separate circuits. The flasher circuit at the top of the card
has Q12 transistor biased to be saturated when no
malfunction is present, resulting in there being 24 volt
positive output on pin H of the card and on wire 12F.
When a indicating circuit is activated, the ground side
of the circuit connected to card pin K is grounded.
Q12 will turn off initially and then after a delay, adjusted
by R20, will turn on and off to give the intermittent 24
volt output.
D03019 04/01
D3-3
D3-4
D03019 04/01
Temperature
The Temperature Card (Optional) is used to turn on
the High Oil Temperature Indicator Light. The indicator
light tells the operator that the hydraulic tank oil temperature has exceeded acceptabale levels. Normal
temperature setting is 250oF (121oC). As the temperature goes up the resistance in the probe decreases
providing a ground path for the indicator light and
alarm horn.
Lamp Test
All of the card circuits are connected to the Lamp Test
Switch on the overhead display area. In normal operation, these circuits are open and not functional. When
the operator pushes the Lamp Test Switch, it activates
all the indicator circuits by grounding them. This is used
to verify that all lamps are functional.
D03019 04/01
D3-5
D3-6
D03019 04/01
D03019 04/01
D3-7
D3-8
D03019 04/01
RELAY BOARDS
Service
To replace a relay:
D03019 04/01
D3-9
D3-10
D03019 04/01
4 - Relays
4 - Relays
4 - Relays
D03019 04/01
D3-11
NC - Normally Closed
COM - Common
NO - Normally Open
> COM terminal is for the voltage source (protected by a circuit breaker) coming into the relay
which will supply the electrical power for the component being controlled.
> NC terminal is connected (through the relay) to
the COM terminal when the relay is not energized (when the control circuit terminals + & -)
are not activated).
> NO terminal is connected (through the relay) to
the COM terminal when the relay is energized
(by the control circuits + & -) being energized).
D3-12
D03019 04/01
BODY-UP SWITCH
Adjustment
Operation
When the body is resting on the frame, actuator arm
(4) causes the electrical contacts in the magnetically
operated switch to close. When the body is raised, the
arm moves away from the switch, opening the contacts. The electrical signal is sent to the control system
and the body-up relay.
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch assembly.
1. Loosen capscrews (2, Figure 3-8) and adjust proximity switch bracket (3) to achieve an air gap
(dimension A) between sensing area (crosshatched area as marked on switch) and actuator
arm (4), of between 0.50 in. (12.7 mm) minimum
and 0.62 in. (15.9 mm) maximum. Tighten capscrews after adjustment.
2. If necessary, loosen actuator arm mounting capscrews (5), and position arm until centered over
sensing area of switch. Vertical set up dimension
(B) should be 1.63 in. (41.5 mm). Tighten capscrews after adjustment.
Service
Keep sensing area clean, free of metallic dust and other
debris that may damage or inhibit operation of the
proximity switch. If the switch is not functioning or
damaged, the unit must be replaced.
D03019 04/01
3. Proximity Switch
4. Actuator Arm
5. Adjustment Capscrews
D3-13
Operation
When the hoist cylinders approach maximum stroke,
and the body pivots on the pins, actuator arm (3)
moves close enough to the magnetically operated
switch to close the electrical contacts. When the contacts close, an electrical signal is sent to the hoist-up
limit solenoid valve (located in the hydraulic components cabinet) to prevent further oil flow to the hoist
cylinders.
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch assembly.
Adjustment
With body raised and hoist cylinders within 6 in. (152
mm) of maximum travel, make the following adjustment.
1. Adjust limit switch to achieve an air gap (dimension A) of 0.50 to 0.56 in. (12.70 to 14.30 mm)
between sensing area and actuator arm (3).
Retighten capscrews.
Service
1. Body
2. Frame
3. Actuator Arm
D3-14
D03019 04/01
CIRCUIT BREAKERS
DEVICE(S) PROTECTED
AMPS
CIRCUIT
LOCATION
CB00
50
11B1
CB1
440
CB2
20
240M
CB3
20
241M
CB4
20
240R1
CB5
20
241R1
CB6
15
11SL
CB7
10
68
712H
CB8
10
CB9
10
Spare
CB10
10
Spare
CB11
15
Spare
CB12
Spare
CB13
15
Clearance Lights
CB14
15
Turn Signals
11Z
CB15
15
41T
CB16
15
44C
CB17
15
47B
CB18
15
Stop Lights
44A
CB19
15
Back-up Horn
79A
CB20
439E
CB21
15
11A
CB22
23D
CB23
15
11DL
CB24
15
11DR
CB25
15
11HL
CB26
15
11HR
CB27
15
Headlight Switch
11D
CB28
15
Payload Meter
39J
CB29
15
Payload Meter
39G
CB30
15
11L
CB31
15
12H
CB32
15
12M
CB33
Not Used
CB34
Not Used
CB35
Not Used
CB36
10
Cigar Lighter
11B2
CB37
10
712W
CB38
712D
CB39
Not Used
CB40A
12GE
CB40B
10
Radio/Cassette Player
11B4
CB41A
15
11B6
CB41B
15
11B7
CB42
15
Air Seat
712A
CB43
10
Start Signal
21S
CB50
20
Communications Radio
SPR42/SPR46
CB51
20
Dispatch Radio
SPR43/SPR47
CB52
10
Spare
SPR44
D03019 04/01
D3-15
NOTES
D3-16
D03019 04/01
SECTION E
ELECTRICAL PROPULSION SYSTEM
INDEX
ELECTRIC PROPULSION SYSTEM COMPONENTS
GENERAL SYSTEM DESCRIPTION . . . . . . .
System Components . . . . . . . . . . . . .
DID Panel Fault Codes . . . . . . . . . . . .
PSC Software Functions . . . . . . . . . . .
Propulsion System Component Abbreviations
Electronic Accelerator and Retard Pedals . .
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. . E2
. E2-1
. E2-3
. E2-5
. E2-30
. E2-41
. E2-51
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. . E3
. E3-1
. E3-1
. E3-2
. E3-3
. E3-4
. E3-4
. E3-7
. E3-10
. E3-10
. E3-11
. E3-11
. E3-12
. E3-18
. E3-26
. E3-30
. E3-35
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. E3-36
. E3-36
. E3-36
. E3-38
. E3-41
. E3-42
. E3-43
NOTE: Propulsion System electrical schematics are located in Section R of this Manual.
E01012 3/01
Index
E1-1
DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNING AND
CONTINUE TO EXIST AFTER SHUTDOWN IF THE REQUIRED SHUTDOWN PROCEDURES
ARE NOT FOLLOWED.
Before attempting repairs or working near propulsion system components, the following
precautions and truck shutdown procedure must be followed:
E1-2
DO NOT step on or use any power cable as a handhold when the engine is running.
NEVER open any electrical cabinet covers or touch the Retarding Grid elements. Additional procedures are required before it is safe to do so. Refer to
Truck Shutdown Procedures, this Section, for additional propulsion system
safety checks to be performed by a technician trained to service the system.
ALL removal, repairs and installation of propulsion system electrical components, cables etc. must be performed by an electrical maintenance technician
properly trained to service the system.
IN THE EVENT OF A PROPULSION SYSTEM MALFUNCTION, a qualified technician should inspect the truck and verify the propulsion system does not have
dangerous voltage levels present before repairs are started.
THE LINK VOLTAGE LIGHTS MUST NOT BE ILLUMINATED WHEN TEST OR REPAIRS ARE INITIATED. It requires approximately 5 minutes after the truck is
shut down before the Link Voltage has dissipated.
Index
3/01 E01012
E02014 3/01
E2-1
E2-2
E02014 3/01
SYSTEM COMPONENTS
AUXILIARY BLOWER SYSTEM
The Auxiliary Blower System, mounted behind the
main electrical cabinet, consists of the blower assembly and control electronics; power inverter/phase control rectifier, power filter capacitor bank, and power
filter inductor.
The control electronics provide a 3-phase, AC, variable voltage/variable frequency output to the blower
motor. Output frequency (blower motor speed) is controlled by the PSC.
E02014 3/01
E2-3
The 17FL349 TCI Panel contains the following internal, removable printed circuit boards:
*17FB127 Power Supply: Supplies regulated
+15VDC, -15VDC, and +5VDC from the filtered
battery supply (B+) input.
17FB144 CPU Card: Provides high speed
RS422 serial communications to PSC and
RS232 serial communication with the PTU.
17FB160 Analog I/O Card: Provides RS232
serial communications with Diagnostic Information Display and an optional Modular Mining
Dispatch System. Provides RS422 serial communication with the Auxiliary Blower System.
Receives signals for front wheel speed, motor
cooling and barometric air pressures, accelerator, retard speed setting, payload, ambient and
hydraulic oil temperature, and engine cranking
voltage. Outputs drive cab mounted temperature gauges etc.
17FB104 Digital I/O Card: Receives operator
control, engine and body-up signals. Provides
engine start controls, drives cab mounted indicator/warning lamps, etc.
*NOTE: The 17FL373 Panel does not contain the
17FB127 card.
E2-4
E02014 3/01
The panel has two display lines, each line 40 characters long. The top line is the message line and is used
by the TCI to inform service personnel of the truck
systems and components status.
The bottom display line provides information in addition to the top line or relates to the keypad, displaying
possible selection options and display functions. The
keypad, located below the display lines is used by
service personnel to direct the activity of the TCI.
The display provides service and status information on
the various truck systems and the propulsion system
by displaying system status information or fault codes
as well as a description of the system status or a
problem on the top display line. Information on the
second display line may change to indicate what functions are available by pressing the [F1] through [F5]
keys.
In addition, the DID panel can be used by to perform
the self-load test.
DEFINITION
No Power
No retarding Allowed
No propulsion allowed
No power on the link
No Propel
No propulsion allowed
Retarding allowed
Link power allowed
System Warning
If corrective action is
not taken, a more
restrictive event may
follow
No restrictions
TABLE I.
E02014 3/01
E2-5
EVENT
DESCRIPTION
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
000
NO FAULT
None
N/A
N/A
002
No power
N/A
003
FAILED DIODE
No power
N/A
004
No power
N/A
005
No Propel
N/A
:01
No Propel
:02
auxiliary inverter
No Propel
:03
afse
No Propel
:04
alternator
No Propel
:05
left stator
No Propel
:06
left rotor
No Propel
:07
right stator
No Propel
:08
right rotor
No Propel
:09
chopper GTO
No Propel
:10
chopper diode
No Propel
:11
No Propel
:12
left diode
No Propel
:13
No Propel
:14
right module
No Propel
:15
rectifier diode
No Propel
BOTH INVERTERS
COMMUNICATION FAILED
No power
NO
006
E2-6
E02014 3/01
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER COMMUNICATION
FAILED
No power
:01
inv 1
No power
:02
inv 2
No power
DC LINK OVERLOAD
No power
:01
not in retard
No power
:02
in retard
No power
:03
instantaneous
No power
No propel
:01
with persistence
No propel
:02
no persistence
No propel
No propel
No propel
007
008
009
011
:01
:02
No propel
No propel
:01
No propel
:02
No propel
No power
012
013
014
SENSOR FAULT
No propel
:01
No propel
:02
link amps
No propel
:03
No propel
:04
No propel
:05
No propel
:10
No propel
:11
No propel
:12
No propel
:21
blower 1 amps
No propel
:22
blower 2 amps
No propel
ANALOG CARD
No propel
:01
gnd fault
No propel
:02
gainchk
No propel
015
:03
No propel
:04
ATOC ma
No propel
E02014 3/01
Limp
Lockout
Possible Limit
Yes
N/A
N/A
N/A
N/A
N/A
E2-7
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
No power
:07
flash CRC
No power
:10
excess timeouts
No power
:11
invalid pointers
No power
:12
BRAM CRC
No power
017
No power
018
016
Limp
Lockout
Possible Limit
N/A
N/A
No power
N/A
No power
Card missing.
No power
Read timeout.
019
No propel
020
No propel
021
NO TCI COMM.
No propel
N/A
:01
message missing
No propel
:02
bad tick
No propel
03
bad CRC
No propel
:04
overflow
No propel
:05
No propel
:06
No propel
022
No power
N/A
023
TERTIARY OVERCURRENT
No propel
N/A
024
No power
N/A
025
No power
N/A
E2-8
:01
No power
:02
numerous shutdowns
No power
E02014 3/01
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
027
No power
N/A
028
CN1 CONNECTOR
No power
N/A
029
No propel
N/A
030
GF CONTACTOR
No propel
Yes (if
closed)
031
GFR CONTACTOR
No propel
Yes (if
closed
032
RP CONTACTOR
No propel
N/A
:01
RP1
No propel
:02
RP2
No propel
:03
RP3
No propel
:04
No propel
ESS INPUT
No propel
035
036
No power
:01
blower 1 stall
No power
:02
blower 2 stall
No power
:03
blower 1 open
No power
:04
blower 2 open
No power
:05
No power
037
VOLTS 5 POS
No propel
038
VOLTS 15 POS
No propel
039
VOLTS 15 NEG
No propel
040
VOLTS 24 POS
No propel
041
VOLTS 24 NEG
No propel
042
No propel
043
No propel
044
No propel
045
No propel
Yes
046
CHOPPER 1 FAILED
No propel
Yes
047
ENGINE STALL
No propel
E02014 3/01
E2-9
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
048
CHOPPER 2 FAILED
No propel
050
MOTOR STALL
No propel
N/A
051
None
Yes
:01
None
:02
None
None
Yes
:01
None
:02
None
No spin/slide on
M1
N/A
:01
No spin/slide on
M1
:02
No spin/slide on
M1
No spin/slide on
M2
N/A
:01
No spin/slide on
M2
:02
No spin/slide on
M2
061
MOTOR OVERSPEED
Speed Limit
N/A
063
None
N/A
below minimum
None
052
053
054
:01
:02
above maximum
None
:03
None
ANALOG INPUT
None
None
065
:01
E2-10
:02
None
:03
None
:04
alternator temp
None
:05
None
:06
None
:07
None
:08
None
N/A
E02014 3/01
EVENT
NUMBER
:09
EVENT
RESTRICTION
None
DETECTION
INFORMATION
Temp out of range.
:10
None
:11
None
:12
None
:13
None
:14
None
:15
Limp
Lockout
Possible Limit
None
070
None
071
Speed Limit
072
Speed Limit
084
None
N/A
085
AUX COOLING
None
N/A
:02
auxrpmfb input
None
:03
auxrpm feedback
None
086
None
087
HP LOW
None
N/A
10
088
HP LIMIT
No propel
N/A
10
None
None
None
None
:01
message missing
None
:02
bad tick
None
:03
bad CRC
None
:04
overflow
None
:05
None
:06
None
:01
089
:02
091
E02014 3/01
N/A
N/A
10
E2-11
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
092
None
094
None
inverter cutout
None
095
None
096
None
098
DATA STORE
None
N/A
099
SOFTWARE EVENT
None
Software error
N/A
:01
E2-12
N/A
10
N/A
E02014 3/01
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
:23
No power
:29
no extvi TIC
No power
:30
no vector TIC
No power
:31
no I TIC TIC
No power
:32
NMI occurred
No power
:34
no background TIC
No power
:35
No power
:38
No power
:39
PGA DP failed
No power
:40
No power
:41
multiple par
No power
:48
no cam TIC
No power
:49
No power
101/201
:01
No power
:02
No power
:03
No power
:04
No power
:05
No power
:06
No power
:07
No power
:08
No power
:09
No power
:10
No power
:11
No power
:12
No power
:13
no chopper TIC1
No power
:14
no chopper TIC2
No power
:16
No power
E02014 3/01
Limp
Lockout
Possible Limit
E2-13
EVENT
NUMBER
102/202
DETECTION
INFORMATION
:05
gnd not ok
No power
no IO card
No power
:09
No power
:10
DB no brake
No power
:11
ptf A signal
No power
:12
ptf B signal
No power
:13
ptf C signal
No power
:14
IC zero not ok
No power
:15
IC not ok
No power
:16
ptl not ok
No power
No power
:17
Limp
Lockout
Possible Limit
:08
103/203
E2-14
EVENT
RESTRICTION
:01
No power
:02
No power
:03
No power
:04
No power
:05
No power
:06
No power
:07
No power
:08
No power
:09
No power
:10
No power
:11
No power
:12
No power
:13
IA VCO hi
No power
:14
IB VCO hi
No power
:15
link V VCO hi
No power
:16
infilV VCO hi
No power
:17
IA too high
No power
:18
IA too low
No power
:19
IB too high
No power
:20
IB too low
No power
E02014 3/01
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
103/203 (cont.)
:21
link V too hi
No power
:22
infilV too hi
No power
:23
DB chop VCO hi
No power
:24
DB chopV too hi
No power
:25
VA VCO hi
No power
:26
VB VCO hi
No power
:27
VC VCO hi
No power
:28
VA volts too hi
No power
:29
VB volts too hi
No power
:30
No power
:31
VC volts too hi
No power
104/204
:01
fo ps low
No power
:02
fo card disable
No power
:03
fo card enable
No power
105/205
:01
P5V not ok
No power
:02
P15V not ok
No power
:03
N15V not ok
No power
:06
P24V not ok
No power
N24V not ok
No power
:07
106/206
DC WIRING
:01
No power
:02
No power
107/207
GDPS FAILURE
:01
gate dr ps off
No power
:02
gate dr ps off S
No power
:03
No power
No power
No power
109/209
:01
111/211
:01
E02014 3/01
E2-15
E2-16
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
INVERTER, GENERAL
:01
Aup cur hi
No power
:02
Adn cur hi
No power
:03
Bup cur hi
No power
:04
Bdn cur hi
No power
:05
Cup cur hi
No power
:06
Cdn cur hi
No power
:07
Aup cur lo
No power
:08
Adn cur lo
No power
:09
Bup cur lo
No power
:10
Bdn cur lo
No power
:11
Cup cur lo
No power
:12
Cdn cur lo
No power
:13
A zero cur hi
No power
:15
B zero cur hi
No power
:17
A volt hi Adn
No power
:18
A volt lo Aup
No power
:19
A volt hi Bdn
No power
:20
A volt lo Bup
No power
:21
A volt hi Cdn
No power
:22
A volt lo Cup
No power
:23
B volt hi Adn
No power
:24
B volt lo Aup
No power
:25
B volt hi Bdn
No power
:26
B volt lo Bup
No power
:27
B volt hi Cdn
No power
:28
B volt lo Cup
No power
E02014 3/01
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
113/213 (cont.)
:29
C volt hi Adn
No power
:30
C volt lo Aup
No power
:31
C volt hi Bdn
No power
:32
C volt lo Bup
No power
:33
C volt hi Cdn
No power
:34
C volt lo Cup
No power
:35
No power
:36
No power
:37
No power
:38
No power
:39
No power
:40
No power
:48
A volt hi off
No power
:49
A volt lo off
No power
:50
B volt hi off
No power
:51
B volt lo off
No power
:52
C volt hi off
No power
:53
C volt lo off
No power
:54
No power
:55
No power
:60
No power
:70
No power
:71
No power
E02014 3/01
E2-17
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
113/213 (cont.)
:72
No power
:73
Aph neg I hi
No power
:74
Bph neg I hi
No power
:75
Cph neg I hi
No power
:76
No power
:77
No power
:78
No power
:79
Aph pos I hi
No power
:80
Bph pos I hi
No power
:81
Cph pos I hi
No power
:82
no current w run
No power
114/214
E2-18
INVERTER, GENERAL
:22
IA VCO lo
No Propel
:24
IB VCO lo
No Propel
:26
linkV VCO lo
No Propel
:28
infilV VCO lo
No Propel
:38
LinkV too lo
No Propel
:40
infilV too lo
No Propel
:46
DB chop VCO lo
No Propel
:48
DB chopV too lo
No Propel
:50
VA VCO lo
No Propel
:52
VB VCO lo
No Propel
:54
VC VCO lo
No Propel
:56
VA volts too lo
No Propel
:58
VB volts too lo
No Propel
:61
VC volts too lo
No Propel
E02014 3/01
EVENT
NUMBER
115/215
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER SYSTEM
:01
no direction
No power
:02
No power
:03
No power
:04
No power
:05
No power
:06
no hi spd data
No power
:07
V line not ok
No power
:08
I line not ok
No power
:09
No power
:10
DB GTO jn hot
No power
:11
No power
:12
VI test incomplete
No power
VI test incomplete
No power
116/216
:01
:02
PTF A
No power
Overcurrent in phase A
:03
IGBT_SAT_AP
No power
IGBT saturated.
:04
IGBT_SAT_AN
No power
IGBT saturated.
alarm AP
No power
117/217
:01
INVERTER, PHASE A+
:02
No power
:03
No power
:04
hold AP
No power
:05
Aup fb not on
No power
:06
No power
:07
IGBT_PS_AP
No power
118/218
INVERTER, PHASE A+
:02
No Propel
:03
No Propel
:04
No Propel
:05
No Propel
:06
No Propel
E02014 3/01
Limp
Lockout
Possible Limit
E2-19
EVENT
NUMBER
119/219
DETECTION
INFORMATION
alarm AN
No power
:02
No power
:03
No power
:04
hold AN
No power
:05
Adn fb not on
No power
:06
No power
:07
IGBT_PS_AN
No power
No propel
:02
:03
No propel
:04
No propel
:05
No propel
:06
No propel
121/221
:01
I sensor ph A
No power
:02
IA zero not ok
No power
:03
IA not ok
No power
:04
I snsr ph A open
No power
:05
I snsr ph A short
No power
123/223
:01
V sensor phase A
No power
:02
VA not ok
No power
No power
125/225
:01
:02
PTF B
No power
Overcurrent on phase B
:03
IGBT_SAT_BP
No power
IGBT saturated
:04
IGBT_SAT_BP
No power
IGBT saturated
126/226
Limp
Lockout
Possible Limit
INVERTER, PHASE A-
:01
120/220
E2-20
EVENT
RESTRICTION
INVERTER, PHASE B+
:01
alarm BP
No power
:02
No power
:03
No power
:04
hold BP
No power
:05
Bup fb not on
No power
:06
No power
E02014 3/01
EVENT
NUMBER
127/227
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER, PHASE B+
:02
No Propel
:03
No Propel
:04
No Propel
:05
No Propel
:06
No Propel
128/228
INVERTER, PHASE B-
:01
alarm BN
No Power
:02
No Power
:03
No Power
:04
hold BN
No Power
:05
Bdn fb not on
No Power
:06
No Power
:07
IGBT_PS_BN
No Power
129/229
INVERTER, PHASE B-
:02
No Propel
:03
No Propel
:04
No Propel
:05
No Propel
:06
No Propel
130/230
:01
I sensor ph B
No Power
:02
IB zero not ok
No Power
:03
IB not ok
No Power
:04
I snsr ph B open
No Power
I sensr ph B short
No Power
:05
132/232
:01
V sensor phase B
No Power
:02
VB not ok
No Power
134/234
:01
alarm C
No Power
:02
PTF C
No Power
Overcurrent on phase C
:04
IGBT_SAT_CP
No Power
IGBT saturated
:05
IGBT_SAT_CN
No Power
IGBT saturated
E02014 3/01
Limp
Lockout
Possible Limit
E2-21
EVENT
NUMBER
135/235
DETECTION
INFORMATION
alarm CP
No power
:02
No power
:03
No power
:04
hold CP
No power
:05
Cup fb not on
No power
:06
No power
:07
IGBT_PS_CP
No power
No propel
:02
INVERTER, PHASE C+
Cup temp short
:03
No propel
:04
No propel
:05
No propel
:06
No propel
137/237
INVERTER, PHASE C-
:01
alarm CN
No power
:02
No power
:03
No power
:04
hold CN
No power
:05
Cdn fb not on
No power
:06
No power
:07
IGBT_PS_CN
No power
138/238
INVERTER, PHASE C-
:02
No propel
:03
No propel
:04
No propel
:05
No propel
:06
No propel
141/241
Limp
Lockout
Possible Limit
:01
136/236
E2-22
EVENT
RESTRICTION
:01
V sensor phase C
No power
:02
VC not ok
No power
E02014 3/01
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER, TACH 1
:01
tach1 rate hi
No power
:02
tach1 no input
No power
:03
TACH_INTERMIT
No power
144/244
:01
145/245
INVERTER, TACH 1
tach1 one channel
No propel
INVERTER, TACH 2
:01
No power
:02
tach2 no input
No power
No propel
146/246
:01
148/248
INVERTER, TACH 2
tach2 one channel
INVERTER, CHOPPER 1
:01
No power
:02
chop1 fb not on
No power
:03
No power
:04
No power
:05
No power
:06
No power
:07
No power
150/250
INVERTER, CHOPPER 2
:01
No power
:02
chop2 fb not on
No power
:03
No power
:04
No power
:05
No power
:06
No power
:07
No power
No power
151/251
:01
153/253
MISCELLANEOUS
tach differential
INVERTER, MOTOR
:01
motor open
No power
:02
motor short
No power
154/254
INVERTER FAULTS
:01
rotor temp hi
None
:02
stator temp hi
None
E02014 3/01
Limp
Lockout
Possible Limit
E2-23
EVENT
NUMBER
155/255
:01
175
E2-24
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
No power
None
E02014 3/01
EVENT
DESCRIPTION
EVENT
NUMBER
601
EVENT
RESTRICTION
DETECTION
INFORMATION
No propel
:01
No propel
:02
No propel
:03
No propel
:04
No propel
:05
No propel
:06
No propel
:07
flash CRC
No propel
:09
No propel
:10
excess timeouts
No propel
:11
invalid pointers
No propel
:12
BBRAM CRC
No propel
602
No propel
603
No propel
604
PSC FAULT
No propel
:01
missing message
No propel
:02
bad tick
No propel
:03
bad CRC
No propel
Limp
Lockout
Possible Limit
N/A
:04
FIFO overflow
No propel
:05
No propel
:06
No propel
605
None
N/A
607
POSITIVE 5 VOLTS
No propel
N/A
608
POSITIVE 15 VOLTS
No propel
609
NEGATIVE 15 VOLTS
No propel
610
POT REFERENCE
No propel
E02014 3/01
E2-25
EVENT
NUMBER
611
DETECTION
INFORMATION
FREQUENCY INPUT
None
:01
None
:02
None
ANALOG INPUT
None
:01
gnd
None
:02
gainchk
None
:03
baropress
None
:04
potref
None
:05
accelpedal
None
:06
retspd set
None
:07
payload
None
:08
ambts
None
:09
hydbrktemp
None
:10
motorpress
None
:11
grade
None
:12
cntrlbatt
None
:13
crankbatt
None
:14
+5
None
:15
+15
None
:16
-15
None
None
:01
None
:02
None
:03
None
613
614
E2-26
EVENT
RESTRICTION
Limp
Lockout
Possible Limit
N/A
N/A
E02014 3/01
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
616
DIRECTION MISMATCH
No propel
N/A
617
None
N/A
:01
None
:02
None
619
No propel
N/A
620
No propel
621
ACCEL PEDAL
No propel
:01
No propel
:02
No propel
No propel
:01
command/response failure
No propel
:02
No propel
623
None
N/A
624
No propel
N/A
625
None
N/A
626
None
N/A
:01
low
None
:02
high
None
None
:01
low
None
:02
high
None
622
627
E02014 3/01
E2-27
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
None
:01
None
:02
None
:03
None
:04
None
No propel
:01
low
No propel
:02
high
No propel
Speed Limit
:01
low
Speed Limit
:02
high
Speed Limit
AMBIENT TEMPERATURE
No propel
:01
low
No propel
:02
high
No propel
No propel
:01
GE config file
No propel
:02
No propel
:03
628
629
630
631
632
version incorrect
No propel
633
BBRAM CORRUPTED
None
634
No propel
635
None
636
AUX INVERTER
None
:01
None
:02
None
:03
overcurrent
None
:04
battery loss
None
E2-28
Limp
Lockout
Possible Limit
N/A
N/A
N/A
N/A
N/A
E02014 3/01
EVENT
NUMBER
EVENT
RESTRICTION
DETECTION
INFORMATION
Limp
Lockout
Possible Limit
:05
None
:06
None
:07
None
:08
None
:09
None
:10
current overload
None
:11
None
:12
None
:13
None
:14
no input voltage
None
637
None
N/A
691
None
N/A
:01
missing message
None
:02
bad tick
None
:03
bad CRC
None
:04
FIFO overflow
None
:05
None
:06
None
:07
message error
None
696
None
698
DATA STORE
None
699
SOFTWARE ERROR
None
E02014 3/01
10
E2-29
Test State:
INPUT PROCESSING
This function reads in all external inputs for use by the
PSC. The Input Processing function performs any
signal conditioning required and computes the required derived inputs.
Ready State:
STATE MANAGEMENT
State Machine
As part of the total software package, a particular
group of regulatory software commands is included
called a state machine. The state machine controls
the various functions of truck operation.
The software implements the state machine by keeping track of which state the truck is in, and which state
the truck is allowed to move into if the operator requests a different mode of operation. Each software
state is defined as follows:
Startup/Shutdown State:
The purpose of this state is to ensure the system is in
a desired known state upon startup or shutdown. This
is an unpowered state.
NOTE: Powered and unpowered refer to the state of
the DC link; 600 volts or more on the DC link equals
powered. 50 volts or less on the DC link equals
unpowered.
E2-30
Rest State:
Rest is an unpowered state whose purpose is to
conserve fuel while the truck idles for an extended
period of time. Rest state also provides an environment where maintenance personnel can control the
engine without causing power to be applied to the DC
link.
Propel State:
The purpose of this state is to provide the power
system configuration and overall environment for engine-powered propulsion. This is strictly a powered
state, i.e., the system will not be allowed to maintain
propel state without sufficient power on the DC link.
E02014 3/01
Retard State:
This transition will occur upon completion of any required testing if all of the following conditions are true:
1. The TCI rest request is not active.
2. There is sufficient voltage on the DC link.
E02014 3/01
E2-31
E2-32
E02014 3/01
DC LINK STATE
2. AFSE disabled,
3. GF open and GFR dropped out,
4. Chopper turn on voltage set below approximately
600 volts,
5. Close RP2 or RP3, alternating each time to provide even wear.
CONTROL FUNCTIONS
2. AFSE enabled,
3. Alternator field reference is commanded such that
the desired DC link voltage or three-phase voltage is maintained,
4. RP contactors open,
5. Chopper turn-on voltage is set above 600 volts.
Engine Control
This software function generates the engine speed
command. The engine electronic fuel control is responsible for maintaining that speed.
The desired engine speed is determined according to
the system state:
Propel State:
E02014 3/01
E2-33
Self-load
E2-34
E02014 3/01
This software function commands the appropriate motor torque to the inverters during propel. The torque
command is primarily a function of the accel pedal
position and is limited by the physical constraints of the
system.
Each wheel torque is computed independently because the wheels may be operating at different
speeds. Each torque command is adjusted to account
for the following constraints:
Speed Override
The propulsion system will attempt to limit truck
speed to the design envelope of the wheel motors.
As such, the torque command will be modulated as
the truck speed approaches the motor overspeed
limit so that this limit is not exceeded if possible.
Note, however, that steady state operation is kept
as close to the overspeed limit as possible without
exceeding it.
Motor Torque Limits
The torque command will be constrained to the
operating envelope of the inverters and the traction
motors. The maximum torque that can be commanded is dependent on motor speed and on DC
link voltage.
Gear Stress
The torque commanded will not exceed that which
will produce excess gear stress.
Horsepower Available
The horsepower available will be estimated from
the engine speed. Parasitic loads are taken into
account. The torque will be limited such that the
engine does not overload.
Jerk Limit
The torque command will be slew-rate limited to
prevent jerking motion.
Wheel Spin
In the event that the inverters detect a wheel spin
condition and reduce torque in the slipping wheel,
the motor torque in the other wheel may be increased within the above constraints such that as
much of the total desired torque as possible is
maintained.
E02014 3/01
E2-35
EVENT PROCESSING
The PSC contains very powerful troubleshooting software. The PSC software constantly monitors the AC
drive System for any abnormalities (events).
Automatic self-tests are performed periodically on various parts of the system to ensure its integrity. Additionally, there are some elaborate tests which may be run
by an electrician with the use of DID screens. Predictive analysis is used in some areas to report potential
problems before they occur.
Event Detection
This software function is responsible for verifying the
integrity of the PSC hardware and the systems to
which the PSC interfaces by detecting an event
(abnormal condition).
The events fall into three detection categories:
Power On Tests
Three power-on tests are executed once every time
power is applied to the PSC. They are as follows:
1. CPU Card Checks - Upon powerup, the PSC will
confirm the integrity of its CPU card hardware
before transferring execution control to the application program residing in its FLASH memory.
2. Battery-backed RAM (BBRAM) Test/Adjustable
Parameter Initialization - A battery backed RAM
(BBRAM) check will be performed to check for
BBRAM data integrity. If the check fails, all
TCI/PTU-adjustable parameters will be initialized
to their default values.
E2-36
E02014 3/01
E02014 3/01
Initiated Tests
These tests are performed when requested by maintenance personnel; the truck must be in test mode for
these tests to run:
1. Maintenance Tests - The purpose of these tests
is to facilitate verification of system installation
and wiring (particularly the digital interfaces relays, contactors, etc.).
2. Self-load Test - Self-load testing is a means by
which the truck diesel engine can be checked for
rated horsepower output.
Periodic Tests
These automatic tests are run continuously during the
operation of the truck to verify certain equipment.
Event Restrictions
The PSC software will not override an event restriction
as long as Limp Home mode is not active. Transitions
to restricted states will not be allowed. If the system is
in a state which becomes restricted, it will transition
down to the highest unrestricted state. The order from
lowest to highest state is Startup/Shutdown, Rest,
Test, Ready, Retard, Propel. Transitions to the Test
state or lower states in reaction to event restrictions
will not be allowed until the truck is not moving.
NOTE. Limp Home mode is a state which is entered
when the truck has suffered a failure and is not able to
continue normal operation but is still capable of limping (getting either back to the maintenance area or at
least out of the way of other trucks).
Event Restrictions associated with a given event are
defined below:
No Power
No retarding or propulsion effort allowed. No power
allowed on the DC link.
No Propel
No propulsion effort allowed. Retard effort and power
on DC link is allowed.
System Warning
An event has occurred which indicates that if corrective
action is not taken, a more restrictive event may soon
follow. No restrictions. The DID will display a warning.
None
No restrictions (nonrestrictive event).
E2-37
Data Packs
E2-38
E02014 3/01
Event Reset
This software function performs the processing necessary for the PSC (System CPU Card) to communicate
through an RS-232 serial link to the Portable Test Unit
(PTU).
OUTPUT PROCESSING
This software function processes all external outputs
from the PSC. Refer to the G.E. publication, System
Description for a listing of the PSC outputs.
E02014 3/01
E2-39
ABNORMAL CONDITIONS/OVERRIDING
FUNCTIONS
Software functions given up to this point assumed for
the most part that the truck is operating under more or
less normal circumstances. The following paragraphs
define system operation under abnormal or exceptional circumstances. In the event of conflict between
these functions and those given for normal operation,
the functions in this section will take precedence.
Fast Start
A fast start software function is provided to address the
case where the PSC is reset unexpectedly (power
supply glitch, etc.) while the system is running. Its
purpose will be to regain control of the truck as quickly
as possible.
Engine Shutdown/Engine Not Running
The engine must be running to enable the gate drives
and to maintain power on the DC link. Typically, the
PSC will be given advanced warning that the engine
is about to be shut off. However, if the engine stalls or
stops because of a mechanical malfunction, the system will most likely have no advance warning. The
system reaction to an engine not running condition will
be the same as to an event carrying a no power
restriction except that no event will be recorded, and
no external reset to clear the condition will be required
(the no power restriction will be automatically lifted as
soon as the engine starts running). If the system is
given warning of an impending engine shutdown, the
existing torque commands will be command to zero
over a long ramp time (2 to 10 seconds). If no warning
is given and the engine stops running, the existing
torque commands will be command to zero over a
short ramp time (0.1 to 0.5 second).
The PSC will exit limp home mode if any of the following conditions occur:
1. The TCI stops requesting limp home mode.
2. An event occurs for which limp home mode is not
possible.
E2-40
E02014 3/01
COMPONENT
FUNCTION
AFSE
36
AFVLT
21
ALT
Alternator (5GTA34)
ANALOG
I/O CARD
AUX BLOWER
MOTOR
AXCAP
11
AXFU1, 2
33
AXIND
30
29
ASYN
35
Alternator Synchronization
Transformer
A3PV
AXINV
E02014 3/01
E2-41
19
BATTSW
COMPONENT
FUNCTION
System Fuse
BDI
68
BFC
67
BLFP
10
BM1, 2
63
BM1I
65
BM2I
66
CCLR1, 2
20
CCL1, 2
61
40
41
CLSW
59
CMAF
27
CMT
28
CM1, 2
5, 6
CM1A, 1B
45
CM2A, 2B
44
CPR
53
CPRD
CPRS
CPS
E2-42
56
E02014 3/01
COMPONENT
FUNCTION
DC Bus
DID
CT
34
CTR
DC link
38
DIT1A, 1B, 1C
43
DI/DT Transformers
DIT2A, 2B, 2C
42
DI/DT Transformers
FDP
24
FDT
23
FIBER OPTIC
ASSEMBLY
31
FP
39
GDFU1, 2
GDPC1
17
GDPC2
16
GDPS
18
GF
49
GFCO
62
GFIP
22
GFM
E02014 3/01
E2-43
COMPONENT
52
GFR
GFRS
GRR
26
FUNCTION
I1CO
57
I2CO
58
Key Switch
KEYSW
LDBXI
48
LEDP
60
LINKI
LINKV
Cabinet Lights
L1, 2, 3
M1, 2
E2-44
E02014 3/01
COMPONENT
FUNCTION
PSC
32
13
12
15
14
RD
64
RP1, 2, 3
47
RP1S, 2S, 3S
55
Suppression Modules
RSN1, 2
Snubber Resistors
Snubber Resistors
R1
51
AUX SNUB
25
Snubber
SPS
37
SS1, 2
E02014 3/01
E2-45
COMPONENT
FUNCTION
TH1
54
VAM1
46
VAM2
46
E2-46
E02014 3/01
E02014 3/01
E2-47
E2-48
E02014 3/01
E02014 3/01
E2-49
E2-50
E02014 3/01
Removal
NOTE: Repair procedures for the retard and accelerator pedal are identical. The retard pedal is mounted on
the brake pedal. Refer to Section J for instructions
for removing and installing the electronic pedal on
brake actuator.
Note routing and clamp location of wire harness.
Proper wire routing is critical to prevent damage during
operation after reinstallation.
1. Disconnect pedal wire harness from truck harness
connector.
2. Remove mounting capscrews, lockwashers and
nuts and remove pedal assembly.
Installation
1. Cable Clamp
2. Electrical Harness
3. Grommet
4. Potentiometer
5. Adjustment Screw
6. Cover
Assembly
1. Position new potentiometer with the flat side
toward the potentiometer cover and install on
shaft as follows:
a. Align cutouts in shaft with the potentiometer
drive tangs.
b. Press potentiometer onto shaft until it bottoms
against the housing.
2. Install screws (5) and lockwashers but do not
tighten.
Disassembly
1. Remove screws on cable clamps (1, Figure 2-9)
and potentiometer cover (6).
E02014 3/01
E2-51
NOTES
E2-52
E02014 3/01
If a problem occurs in the AC drive system preventing NORMAL shutdown procedures, ADDITIONAL
PRECAUTIONS ARE NECESSARY to ensure dangerous drive system voltages are not present
when tests or repairs are performed.
E03015 3/01
E3-1
E3-2
3/01 E03015
4. After the engine has been off for at least five (5)
minutes, inspect the Link Voltage lights in the
Information Display Panel (6, Figure 3-1) on the
main control cabinet, the contactor box, and back
wall of the operator cab (next to the DID panel).
If all lights are off, the retard grids, wheel motors,
alternator, and power cables connecting these
devices are safe to work on.
5. The blower motors, control cabinet and power
cables connecting these devices may still be
unsafe. To establish these devices are safe, wait
approximately 15 minutes, open the top control
cabinet cover and inspect the red lights (6, Figure
3-2) on the Auxiliary Capacitor Panel (AXCAP)
(4). If these lights are off, the blower system,
blower power cables and remainder of the control
cabinet is safe to work on. The normal de-energization time is 10 to 15 minutes.
IF THE LINK VOLTAGE RED LIGHTS IN THE CONTROL CABINET INFORMATION DISPLAY PANEL,
AND/OR CONTACTOR BOX, AND/OR THE BACK
WALL OF THE OPERATOR CAB CONTINUE TO BE
ILLUMINATED AFTER FOLLOWING THE ABOVE
PROCEDURE, A FAULT HAS OCCURRED.
Leave all cabinet doors in place, do not
touch the retard grid elements,
Do not disconnect any power cables or
use them as hand or footholds.
Notify the Komatsu factory representative
or Distributor immediately.
E03015 3/01
E3-3
SYSTEM CHECKOUT
Test equipment needed to fully test A/C system
One PTU (Portable Test Unit; lap top computer)
(The test could be more efficiently conducted with
two PTU units).
One Digital Multi-Meter
Several jumper wires
E3-4
3/01 E03015
CIRCUIT LOCATION
11B1
11
15V
71GE
71TCI
439
10V
11SL
11ST
15PV
11S
TB21
TB22
TB23
TB25
TB28
TB28
TB28
TB29
TB30
120
120
11A
TB30
11T
TB30
>36
11FR
11HTR
712
71
11L
12M
12F
TB30
TB30
TB32
TB32
CB30
*
*
>10
>200
E03015 3/01
E3-5
DC Link Checks:
NOTE: Use an analog meter (VOM) to measure resistance in the following steps:
E3-6
3/01 E03015
AFSE P1 adjustment:
11. Connect an ohmmeter from the wiper of Pot P1
(cathode of ZD1) to Terminal E (GND) on the
Battery Boost Module.
E03015 3/01
E3-7
E3-8
11S (TB30)
11L (CB30)
11A (TB30)
11SL (TB28)
3/01 E03015
E03015 3/01
E3-9
TCI PROGRAMMING
NOTE: At the present time, GE or KMS PERSONNEL must be present to program the TCI.
BE SURE TO VERIFY LINK VOLTAGE IS DISCHARGED BEFORE PERFORMING THE FOLLOWING PROCEDURES.
E3-10
3/01 E03015
PSC PROGRAMMING
INVERTER PROGRAMMING
NOTE: At the present time, GE or KMS PERSONNEL must be present to program the PSC.
NOTE: At the present time, GE or KMS PERSONNEL must be present to program the PSC.
BE SURE TO VERIFY LINK VOLTAGE IS DISCHARGED BEFORE PERFORMING THE FOLLOWING PROCEDURES.
BE SURE TO VERIFY LINK VOLTAGE IS DISCHARGED AND ENGINE IS NOT RUNNING BEFO R E P E RFO R MI NG TH E FO LLOW ING
PROCEDURES.
E03015 3/01
E3-11
TCI CHECKOUT
BE SURE TO VERIFY LINK VOLTAGE IS DISCHARGED BEFORE PERFORMING THE FOLLWING PROCEDURES.
1. Disconnect Circuits 21SS and 21SR, and insulate
from engine starter if equipped with MTU 396
engine. If MTU/DDC 16V4000 or Komatsu engine
is installed, disconnect and insulate 21B circuits
at starter solenoids. Apply park brake and brake
lock.
Log on to the TCI panel:
{escape} {escape}
Check Modular Mining Communication Port:
E3-12
3/01 E03015
2. Press {enter} to display TCI SERIAL LINK DATA screen shown below:
E03015 3/01
E3-13
DO NAME
1
2
3
4
5
6
7
8
9
10
RESTLT
PSCNOTRDY
REDUCELT
LINKONLT
TEMPWARNLT
NORETARDLT
NOPROPELLT
PSCWARNLT
RTRDCONTLT
HYDBHOTLT
11
PKBRKON
12
13
RETARDLT
RETARDXLT
14
BATSEPC
15
16
17
SPEED1
SPEED2
REVERSELT
DESCRIPTION
Rest Light
Propel System Not Ready Light
Reduced Propulsion Level Light
Link ON light, DID Panel (Behind Operators Seat)
Propulsion System Temperature Warning Light
No Retard, No Propel Light
No Propel Light
PSC Warning Light
Reduced Retarding Light
Hydraulic Brake Fluid Hot Light
Verify park brake switch is applied:
Measure Circuit 52CS @ TB26 to ground: Verify 0.0 volts
Press {enter} to turn PKBRKON on:
Verify approx. 24 volts
Retard Light (on overhead display)
Retard light (on top of cab and rear of truck)
Battery Separate Relay
Measure Circuit 21BSR @ TB28 to ground
With BATSEPC highlighted, press {enter}: verify 0.0 VDC
not used
not used
Activates backup horn and backup lights
LOCATION
(FIG. 3-4)
B6
C6
D6
C5
A5
A6
B5
D6
D5
A3
D3
B4
Refer to TCI Digital Output Test procedure step 5. before performing the following test:
18
E3-14
ENGCRANK
3/01 E03015
Row /
E03015 3/01
Column
Indicator Description
Indicator Color
A1*
B1*
C1
D1
E1
A2*
B2*
C2*
D2*
E2*
A3*
B3*
C3*
D3*
E3
A4*
B4*
C4*
D4*
E4*
A5
B5
C5
D5
Spare
Low Steering Pressure
Red
Low Accumulator Precharge
Red
Spare
Low Brake Pressure
Red
Low Hydraulic Tank Level
Red
Autolube Low Pressure
Amber
Circuit Breaker Tripped
Amber
Hydraulic Oil Filter Restricted
Amber
Low Fuel
Amber
Park Brake Applied
Amber
Service Brake Applied
Amber
Body Up
Amber
Dynamic Retarding Applied
Amber
STOP ENGINE
Red
Spare
Manual Back-Up Lights
Amber
5 Min. Shutdown Timer
Amber
Retard Speed Control
Amber
CHECK ENGINE
Amber
No Propel/Retard
Red
Propulsion System Caution
Amber
Propulsion Sys. Temp. Caution
Amber
High Brake/Hydraulic Oil Temp.
Red
STOP ENGINE (Komatsu engine
E5*
Red
only)
A6
No Propel
Red
B6
Propulsion System at Rest
Amber
C6
Propulsion System Not Ready
Amber
D6
Propel System at Reduced Level
Amber
E6
Retard System at Reduced Level
Amber
NOTE: On later model trucks, lamps indicated * can be dimmed
using dimmer control on Overhead Display Panel
E3-15
DID Display:
1. Observe the DID display.
The cursor to the right of the event code
should appear to spin.
E3-16
3/01 E03015
STEP
DO NAME
LAMPTEST
ENGCAUTION
ENGWARN
4
5
6
7
8
9
10
11
RESET
RESTSW
REVREQ
FORREQ
ENGKILL
DATASTORE
BODYDWN
PRKBRKSW
12
PRKBRKFDBK
13
14
15
16
ENGSTRTREQ
RSC
OVERPAYLD
CONTROLON
Refer to procedure step 3. before performing the following checks (RB2 circuit breakers must be OFF):
17
18
MIDPAYLD
FULLPAYLD
E03015 3/01
E3-17
c:\>ACNMENU {enter}
Highlight PTU TCI and PSC {enter}
DO NAME
DESCRIPTION
DEVICE CHECKOUT
E3-18
GF
GF Contactor
3/01 E03015
E03015 3/01
E3-19
STEP
DI NAME
1
2
3
4
5
KEYSW
CPSFB
CNFB
CNIFB
CNXFB
Key Switch
Control Power Switch Feedback
Panel Connectors Status
CNI and CNENG Connector Status
Auxiliary Blower Connector Status
INV1CO
INV2CO
8
9
BRKON1
BRKON2
E3-20
With the Key Switch and Control Power Switch ON, digital inputs should
be highlighted.
3/01 E03015
c:\>ACNMENU {enter}
Highlight PTU TCI & PSC {enter}
Type your name {enter}
Type your password {enter}
Cursor to Normal Operation {enter}
Cursor to PSC Real Time Data {enter}
Verify LINKV is equal to battery volts
7. Remove the jumper wires. Reconnect the wires
to terminals A and C.
Thermistor Checks:
1. With the PTU connected to the PSC:
Cursor to Normal Operation {enter}
Cursor to PSC Real Time Data {enter}
Verify AUXPCT is showing ambient temperature
Verify AUXIT is showing ambient temperature
Verify AFSET is showing ambient temperature
LINKV Panel
E03015 3/01
E3-21
A: Retard Pedal:
Cursor to the box in the # column on channel
one {enter}
Type in: 359 {enter}
1. Parameter name will be rpinhi_ail5.
Record the parameter value with the retard
pedal fully released. (typical value; 1.50
volts).
Record the parameter value with the retard
pedal fully depressed. (typical value; 9.50
volts).
B: Retard Lever:
Cursor to the box in the # column on channel
two {enter}
Type in: 344 {enter}
1. Parameter name will be retlever_ail4.
Record the parameter value with the lever
up (typical value; 0.0 volts).
E3-22
3/01 E03015
E: Truck Speed:
F: Accelerator pedal:
E03015 3/01
H: Pot Reference:
Record value of POTREF (typical value;
10.86)
14. Press {escape} to return to TCI Normal Operation
Menu.
Cursor to Exit {enter}
On TCI Communication Menu, cursor to Exit {enter} {enter} to return to Main Menu.
E3-23
Use the following formulas to determine accelerator pedal, retard pedal, and retard lever percentages
to input on the Change/View Truck Specifics screen:
accel pedal value, from step F
100 = value For Truck Specifics screen
pot reference, from step H
retard pedal value, from step A
100 = value For Truck Specifics screen
pot reference, from step H
retard lever value, from step B
100 = value For Truck Specifics screen
pot reference, from step H
Example:
To determine accelerator pedal percentages using above formula:
1. Divide accelerator voltage with pedal released (1.61 volts, step F) by Pot Reference Voltage (10.86 volts, step H). Multiply
result by 100 to obtain percentage value to enter for percent accel pedal travel off request on Change/View Truck
Specifics screen.
2. Divide accelerator voltage with pedal applied (8.53 volts, step F) by Pot Reference Voltage (10.86 volts, step H). Multiply
result by 100 to obtain percentage value to enter for percent accel pedal travel full request on Change/View Truck
Specifics screen.
E3-24
3/01 E03015
I: Program TCI
J: Program PSC
(PTU connected to PSC port)
1. Turn keyswitch ON.
To program the 17FB147 CPU card:
From the Main Menu, highlight DOWNLOAD
PSC PANEL {enter}
Highlight SELECT PSC SETUP {enter}
Cursor to configuration desired {enter}
Highlight DOWNLOAD PSC PANEL {enter}
Highlight DOWNLOAD PSC {enter}
E03015 3/01
E3-25
LOAD TESTING
1. Reconnect wires 21SR and 21SS (MTU 396
engine) to the starter or 21B (MTU/DDC 16V4000
or Komatsu engine) to the starter solenoids.
C:\>ACNMENU {enter}
Highlight PTU TCI & PSC {enter}
5. Install locks on the three front doors of the electrical cabinet. Also secure the 3 top covers.
PRELOAD CHECKS
Alternator Speed Sensor Check:
1. Connect an AC voltmeter to circuits 74X (TB22)
and 74Z (TB22).
2. Place the GF Cutout Switch in the CUTOUT
position (down).
3. With Rest Switch in the REST position, start the
engine and operate at low idle.
Verify approximately 4 VAC on the meter.
Verify tach (in cab) reads approximately 700
RPM.
4. Shut down the engine. Remove voltmeter.
E3-26
3/01 E03015
E03015 3/01
E3-27
a. Short Circuit 33T to ground (brake lock degradation pressure switch located in brake cabinet). (There is a 5.0-second delay timer on this
circuit.)
b. Note that when the brake lock is applied, the
service brake lights on the truck are active and
the service brake light indicator on the overhead display illuminates.
E3-28
3/01 E03015
Final Checks:
1. Place the REST switch in the OFF position.
2. With the PTU still connected to the PSC port and
the PSC REAL TIME DATA screen displayed
and the engine running, compare the values displayed with the values shown on the sample
screen in Figure 3-8.
3. Verify AUXFB is about 1700 rpm and exhaust air
is flowing from the rear exhaust ports of the
control cabinet.
E03015 3/01
E3-29
Preparation:
1. Jumper fan clutch control circuit to lock fan in full
on condition.
a. If truck is equipped with DDEC engine, jumper
circuit 541M @ TB24 to ground.
b. If truck is equipped with Komatsu engine,
jumper circuit 22FO @ TB32 to ground.
Note: With release 17 software installed, load testing
can be activated through the DID panel if desired.
2. Connect a VOM from circuit 72E @ TB24 (+) to
circuit 72R @ TB24 (-). This is the 10 volt load
hand-shaking signal from the engine. (Value
should be 5.0 volts with just control power on.)
Refer to PVM Test at the end of this section for
additional information.
E3-30
3/01 E03015
E03015 3/01
E3-31
FIGURE 3-11. SELF LOAD TEST SCREEN, RP1 & RP2/3 PICKED UP
E3-32
3/01 E03015
Cursor to => 0 HP
Input a + or - offset but not greater than +300 {enter}
E03015 3/01
E3-33
E3-34
3/01 E03015
E03015 3/01
E3-35
E3-36
5. With a 15/16" inch socket, remove the four mounting nuts on each Phase Module.
6. Cut the tyrap by the capacitor on top of each
Phase Module.
7. Partially pull out each Phase Module. Using a
7/16" inch socket, remove the snubber wire behind the top capacitor.
8. Remove each Phase Module which weighs 65
pounds (29.5 Kg). Mark each Module so that it will
be put back in the same location that it was
removed from.
3/01 E03015
E03015 3/01
E3-37
Subcode 03:
Description: An overcurrent condition was detected
during operation.
1. Check Capacitor Bank and Controller connections.
Subcode 05:
Description: A high DC bus voltage was detected
during operation.
1. Check Capacitor Bank and Controller connections.
2. Check DC Sense connection (connector J13 to
IV+ (red wire) and IV- (black wire)).
3. Attempt to restart and check operation.
4. If problem still exists, replace controller.
E3-38
Subcode 06:
Description: A high DC bus voltage was detected
after the phase controller power up sequence.
1. Check Capacitor Bank and Controller connections.
2. Check DC Sense connection (connector J13 to
IV+ (red wire) and IV- (black wire)).
3. If problem still exists, replace controller.
3/01 E03015
Subcode 07:
Subcode 08:
2. If no problem was found in step 1, use an ohmmeter to check for short circuits between AM101,
AM201, and AM301 wires and between IV+ and
IV-.
E03015 3/01
6. Capacitor Fuses
7. Propulsion System Controller (PSC)
8. Cover
9. Input Fuses (F1 & F2)
10. 3- Pin Connector
E3-39
Subcode 09:
Subcode 12:
Subcode 13:
Description: IGBT protection circuit detected an overcurrent condition.
1. Disconnect AM101, AM201 and AM301 wires
connecting the Auxiliary Inverter to the blower
motor.
2. Using an ohmmeter, check for shorts between
blower motor cables and between blower motor
cables and chassis ground.
3. Using an ohmmeter, check for shorts between
AM101, AM201 and AM301 wires and between
IV+ and IV-.
Subcode 10:
Description: A sustained current overload exists that
is below component safe operating range.
Subcode 14:
Subcode 11:
Description: An overcurrent condition exists due to a
low DC bus voltage.
1. Check the 3-phase input connections and fuses
F1 and F2.
2. Check Capacitor Bank and Controller connections.
3. After performing checks in step 1 and 2, attempt
to restart.
4. If problem still exists, replace the controller.
E3-40
3/01 E03015
3. Check continuity from PH+ to INV+ and from PHto INV-. These circuits connect the Aux Phase
Control, Aux Inductor, Aux Capacitors, & Aux
Inverter. The resistance should be 0 ohms for
these two measurements to verify continuity
through the Aux Inductor.
4. Check the fuses on the Aux Capacitor panel. (The
fuses must be removed from the circuit to check.)
5. Check for loose connections on all wires associated with the Aux Inverter circuits.
6. Check Aux Inverter Phase Control SCRs (see
Table below). Measure between AC input terminals 1, 2, & 3 and DC output terminals PH+ & PH-.
A reading of less than 100 ohms indicates a
shorted SCR. Good SCRs will measure more
than 100K ohms. Replace at least the connected
pair of SCRs if one is shorted (preferably replace
all 6 SCRs).
Measurement Points
AC Input 1
AC Input 2
AC Input 3
Term 1 PH+ Term 2 PH+ Term 3 PH+
Term 1 PH- Term 2 PH- Term 3 PH-
E03015 3/01
E3-41
3. Terminals
Specified Value
From
To
Minimum
Maximum
1
1
2
3
C1-2
3
C1-4
C2-4
C3-4
C2-4
C1-4
C3-4
C2-2
R1-1
C3-2
C1-2
C2-2
C3-2
23.75
23.75
23.75
0
0
0
0.10 F
0.10 F
0.10 F
26.25
26.25
26.25
0
0
0
0.17 F
0.17 F
0.17 F
E3-42
3/01 E03015
IGBT Troubleshooting
7. After all circuits have been tested, reconnect all
cables to their proper terminals. Reconnect J1,
J2, J3, J4, J7 and J8.
The Auxiliary Capacitor Panel remains charged for
at least 15 minutes after engine shutdown. Be
certain LEDs D1 and D2 (6, Figure 3-12) are OFF
before working on Auxiliary Blower Control circuits.
J1
J2
J3
J4
J7
J8
E03015 3/01
From Pin
1
2
1
2
1
2
To
IV+
AM101
AM101
IVIV+
AM201
Measurement
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
AM201
Continuity
IV-
Continuity
IV+
Continuity
AM301
Continuity
AM301
Continuity
IV-
Continuity
1. Auxiliary Inverter
5. IV+, IV- Terminals
(Controller)
6. Blower Control System
2. Cover
Warning LEDs
3. 3-Pin Connectors
7. CNX Connector
4. AM101, AM201, AM301
Connection Studs
E3-43
NOTES
E3-44
3/01 E03015
SECTION G
REAR AXLE, SPINDLES AND WHEELS
INDEX
TIRES AND RIMS . . . . . . .
FRONT TIRES AND RIMS .
Removal . . . . . . . .
Installation . . . . . .
REAR TIRES AND RIMS .
Removal . . . . . . . .
Installation . . . . . .
RIM . . . . . . . . . . . .
Tire Removal . . . . .
Tire Installation . . . .
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. G2
G2-2
G2-2
G2-3
G2-3
G2-3
G2-4
G2-6
G2-6
G2-7
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. G3
G3-1
G3-1
G3-4
G3-5
G3-5
G3-7
G3-7
G3-9
G3-9
G3-10
G3-11
G3-11
G3-12
G01017
Index
G1-1
NOTES
G1-2
Index
G01017
Due to the size and weight of the tire and rim assemblies, special handling equipment such as a modified
fork lift (tire handler) as shown in Figure 2-1 is
desirable. Consult local tire vendors for sources of
equipment designed especially to remove, repair, and
install large off-highway truck tires.
G02015
G2-1
5. Rim
6. Bead Seat Band
7. Side Flange
8. Lock Ring
9. O-Ring
10. Clamp Bracket
11. Flanged Nut
G2-2
G02015
Installation
Removal
G02015
1. Tire Handler
2. Outer Rear Tire
G2-3
4. Extension
5. Wheel Hub
6. Flanged Nut
7. Inner Extension
8. Clamps
9. Adaptor Ring
10. Flanged Nut
11. Flanged Nut
Installation
Always keep personnel away from a wheel assembly when it is being removed and installed.
G2-4
G02015
G02015
G2-5
RIM
Tire Removal
G2-6
5. Rim
6. Bead Seat Band
7. Side Flange
8. Lock Ring
9. O-Ring
10. Clamp Bracket
11. Flanged Nut
G02015
Tire Installation
1. Before mounting tire to rim, remove all dirt and
rust from rim parts, particularly the O-ring groove
and bead seats. It is advisable to touch up all
metal parts with a good anti-rust paint to prevent
bare metal from being exposed to the weather.
NOTE: Do not allow paint, rust or other contamination
to cover mating faces of lockring (8, Figure 2-6) and
rim (5).
G02015
G2-7
NOTES
G2-8
G02015
PREPARATION
1. Reduce the engine speed to idle. Place the selector switch in NEUTRAL and apply the parking
brake. Be certain the parking brake applied indicator lamp in the overhead panel is illuminated.
2. Place the drive system in the REST mode by
turning the Rest switch on the instrument panel
ON. Be certain the REST warning lamp is illuminated.
3. Shut down the engine using the keyswitch. If, for
some reason the engine does not shut down, use
the shutdown switch on the center console.
4. Verify the LINK VOLTAGE lights are OFF. If they
remain on longer than 5 minutes after shutdown,
notify the electrical department.
5. Verify the steering accumulators have bled down
by attempting to steer.
6. Bleed down the brake accumulators using the
manual bleed valves on the brake manifold.
7. Open the battery disconnect switches.
Removal
Refer to the Front Tire and Rim Removal instructions
and remove front tire and rim assembly.
1. Close hydraulic pump shut-off valves.
2. Disconnect speed sensor cable(s) (5, Figure 3-1)
at connector. Tie cables back away from spindle
to prevent damage during spindle removal.
NOTE: The left brake assembly has two speed sensors installed.
3. Disconnect disc brake cooling oil hoses (4) at inlet
and outlet ports on brake housing. Also disconnect brake apply line. Cap hoses and ports to
prevent contamination. Remove the oil in the
brake housing and hub bearings by removing the
hex plug (2) and draining into a suitable container.
FIGURE 3-1. FRONT WHEEL & SPINDLE
INSTALLATION
1. Spindle
2. Brake Housing Drain
3. Disc Brake Housing
G03017 02/01
G3-1
G3-2
1. Capscrews
2. Retainer Plate
3. Spindle
4. Spindle Arm
5. Arm Retainer Capscrews
G03017 02/01
3. Removal Tool
4. Spindle Arm
5. Spindle
6. Suspension Piston
G03017 02/01
2. Tool Structure
G3-3
Installation
1. Clean spindle bore and suspension rod taper to
be certain they are free of rust, dirt, etc.
2. Lubricate spindle bore and suspension rod taper
with multi-purpose grease Number 2 with 5%
Molybdenum Disulphide.
3. Position spindle and wheel hub assembly on fork
lift or similar lifting device as shown in Figure 3-2.
4. Raise the spindle and wheel hub assembly into
position.
5. Secure spindle to suspension using retainer plate
(2, Figure 3-3) and capscrews (1). Tighten capscrews using the following procedure:
a. Tighten capscrews uniformly to 500 ft. lbs.
(678 N.m) torque.
b. Continue to tighten capscrews in increments of
250 ft. lbs. (339 N.m) to obtain a final torque
of 1995 100 ft. lbs. (2705 135 N.m).
6. If removed, install spindle arm. Tighten capscrews
to 1995 100 ft. lbs. (2705 135 N.m) torque.
7. Install steering cylinder into steering arm. Use
EH4638 sleeve alignment tool (included in tool
group) to position spacers and bearing during pin
insertion. Tighten pin retaining nut to 750 ft. lbs.
(1017 N.m) torque.
G3-4
G03017 02/01
Disassembly
1. Remove wheel hub and spindle as covered in
Removal before proceeding to Step 2. Clean
assembly to remove dirt accumulation.
12. Attach lifting eyes to brake assembly, attach overhead hoist and carefully lift off hub. Refer to Section J for brake assembly rebuild instructions.
G03017 02/01
G3-5
G3-6
15. Washer
16. Speed Sensor
17. Sensor Bracket
18. Disc Brake Assembly
19. Brake Adaptor
20. Capscrew
21. Hardened Washer
22. O-ring
23. Capscrew
24. Hardened Washer
25. O-ring
26. Spindle
27. Bearing Spacer
28. Inner Bearing Cone
G03017 02/01
Assembly
9. Install bearing retainer (13) onto the spindle without any shims. The thickness of the retainer is
etched on the surface of the retainer. This side
should be facing outward. Use 4, equally spaced
capscrews in order to secure the retainer. Two
capscrews must be positioned adjacent to the
0.50 in. (12.7 mm) diameter access holes in the
retainer.
c. After cups have warmed to ambient temperature, press the cups tight against hub shoulder
as follows:
1.) Inner Cup (29) - Apply 23 tons (20,860 kg)
force.
2.) Outer Cup (6) - Apply 21 tons (19,050 kg)
force.
G03017 02/01
G3-7
Socket head capscrews (34) are installed to position the seal carrier on the brake back plate after
assembly and prior to installation on the Hub/spindle. In the next step, it may be necessary to loosen
the socket head capscrews slightly to align the
brake assembly holes with the brake adaptor.
G3-8
G03017 02/01
4. Capscrews
5. Shims
6. Brake Back Plate
G03017 02/01
G3-9
Removal
1. With engine shut down and key switch Off, allow
at least 90 seconds for the accumulator to bleed
down. Turn the steering wheel to make sure no
hydraulic pressure is present. Block front and
back of rear wheels.
2. Disconnect hydraulic and lubrication lines at the
steering cylinders. Plug all line connections and
cylinder ports to prevent contamination of hydraulic system.
G3-10
9. Locknut
10. Retainer
11. Bearing
12. Spindle Arm
G03017 02/01
Installation
Bearing Replacement
1. Remove capscrews (2, Figure 3-9) and lockwashers (3). Remove bearing retainer (4).
2. Press bearing (1) out of bore in steering cylinder
or tie rod end.
3. Press new bearing into bore.
4. Install bearing retainers with capscrews and lockwashers. Tighten capscrews to standard torque.
G03017 02/01
4. Bearing Retainer
5. Rod End
G3-11
TOE-IN ADJUSTMENT
1. The steering system must first be centered in the
straight ahead position. Shut down engine and
turn key switch OFF. Allow at least 90 seconds
for the accumulators to bleed down. DO NOT turn
the steering wheel. Block front and back of rear
wheels.
2. Check toe-in by measuring the distance between
the centers of the front tires. These measurements should be taken on a horizontal centerline
at front and rear of tires. Refer to Figure 3-10.
3. Radial tires should have equal measurements
(zero toe-in).
4. Loosen clamp locknuts on tie rod and rotate tie
rod as necessary to obtain correct toe-in setting.
5. When adjustment is complete, tighten clamp
locknuts (7, Figure 3-8) on tie rod to 310 ft. lbs
(420 N.m) torque.
6. Remove blocks from rear wheels.
in. (cm)
144.37 (366.7)
G3-12
G03017 02/01
1. Truck Frame
2. Capscrew
3. Lockwasher
4. 12 Pt. Capscrew
5. Lock Plate
6. Sleeve
7. Pivot Pin
8. Spacer
9. Cover Ring
10. 12 Pt. Capscrew
11. Locknut
12. Puller Holes
13. Bearing
14. Bearing Retainer
15. Pivot Eye Structure
16. Bearing Carrier
17. Clamp
Installation
1. Raise pivot eye (15, Figure 4-1) into position.
2. Be certain spherical bearing inner race is aligned.
Install cover rings (9) and spacers (8). Install pin
(7).
3. Position lock plate (5) by lining up capscrews with
capscrew holes in pin. Install capscrews.
4. Rotate pin and lock plate to align capscrews (2)
with holes in frame mounting structure.
a. Install capscrews (2) and lockwashers (3).
NOTE: Placement of a pry bar or jack between mounting structure and pivot eye may be necessary to push
pivot eye down and away from mount structure. Spacers (8) and cover rings (9) will fall free.
G04014
G4-1
Assembly
1. Setup an appropriate tool to press spherical bearing (4, Figure 4-2) into bearing carrier (3). Be
certain bearing outer race is flush with bearing
carrier sides.
2. Install bearing retainers (2) with 12 point capscrews (5) and locknuts (6). Tighten capscrews
to 575 ft. lbs. (779 N.m) torque.
G4-2
4. Spherical Bearing
5. 12 Pt. Capscrew
6. Locknut
G04014
Assembly
Lubrication groove in bearing carrier outer diameter must align with lubrication fitting hole in pivot
eye structure.
Installation
1. Be certain mating surfaces of axle housing (1,
Figure 4-3), and pivot eye (4) are clean and not
damaged.
2. Lift pivot eye into position on front of axle housing.
Insert several capscrews (2) and flatwashers (3)
to align the parts. Remove the lifting device.
3. Install the remaining capscrews and flatwashers.
Tighten alternately until the pivot eye is properly
seated. Tighten capscrews to 1715 ft. lbs. (2325
N.m) final torque.
G04014
3. Flatwasher
4. Pivot Eye
G4-3
ANTI-SWAY BAR
NOTE: The anti-sway bar mounting arrangement is
identical at each end.
Removal
1. Position frame and rear axle housing to allow use
of a puller arrangement to remove anti-sway bar
pins (4, Figure 4-4) on the rear axle housing and
the frame.
2. Block securely between frame and axle housing.
3. Disconnect lubrication lines. Position a fork lift or
attach lifting device to anti-sway bar (11) for removal from truck.
4. Remove capscrews (9) and locknuts (10) at each
mount.
5. Attach puller and remove pin (4) from each end of
anti-sway bar.
6. Remove anti-sway bar from mounting brackets.
7. Remove bearing spacers (6).
FIGURE 4-4. ANTI-SWAY BAR ASSEMBLY
Installation
1. Start pin (4, Figure 4-4) in through the front of the
frame mount and one spacer (6). Rotate pin to
align retaining capscrew (9) hole with the hole in
the mounting structure (1).
2. Raise the anti-sway bar into position and push pin
through spherical bearing, insert second spacer
and continue pushing into other ear of bracket. If
necessary, realign pin with retainer capscrew
hole. Install capscrew (9) and locknut (10).
3. Repeat above procedure to install remaining pin,
spacers, capscrew and locknut at opposite end of
bar. Start the pin into the bore of the axle housing
mount from the rear of the truck.
4. Attach lubrication lines. Pump grease into bearing
to verify line and system is operational.
5. Remove blocking.
6. If necessary, recharge suspensions. Refer to
Section H for charging procedure.
1. Mounting Structure
2. Capscrew
3. Lockwasher
4. Pin
5. Sleeve
6. Bearing Spacer
7. Retainer Ring
8. Bearing
9. Capscrew
10. Locknut
11. Anti-Sway Bar
Disassembly
1. Remove retainer rings (7, Figure 4-4) from bores
of both ends of anti-sway bar (11).
2. Press out spherical bearings (8).
Cleaning and Inspection
1. Inspect bearing bores of anti-sway bar. If bores
are damaged, repair or replace anti-sway bar.
2. Inspect bearing spacers (6) for damage or wear.
Assembly
1. Press in new bearings.
2. Install retainer rings. Be certain rings are properly
seated in grooves.
G4-4
G04014
Removal
1. Remove the dump body as outlined in Section B.
Block up truck and remove rear tires as described
in this Section of the manual.
2. Loosen hose clamps and disconnect wheel motor
cooling air duct from connection on front center
of housing.
3. With the pump shut-off valves in the closed position, remove drain plugs at bottom of brake assemblies and drain oil from disc brakes.
4. Disconnect hydraulic hoses at manifold (4, Figure
5-1). Cap fittings and plug hoses to prevent contamination.
5. Remove covers from access holes (17).
6. Remove cable grips at right front corner from
wheel motor cables (7), air pressure sensor/rear
light (8) and speed sensor (9) harnesses. Slide
cable grips forward on cables.
7. Remove cable grip mounting cover and slide
forward for access to brake cooling line clamp
inside axle housing.
8. Disconnect brake system cooling lines (2 & 10) at
each brake back plate. Disconnect brake apply
lines (11). Cap and plug openings.
9. Remove clamps (3) securing brake hoses to spindles.
10. Open rear access cover and remove wing nuts
securing duct tube to axle housing. Remove tube.
G05015 9/99
G5-1
6. Relay Valve
7. Wheel Motor Power Cables
8. Air Sensor/Rear Light Harness
9. Speed Sensor Harness
10. Brake Cooling Oil Supply
11. Brake Apply Line
G5-2
9/99 G05015
G05015 9/99
G5-3
WHEEL MOTOR
Read and observe the following instructions before attempting removal of the wheel motors or any
repairs on the propulsion system components!
PREPARATION
1. Reduce the engine speed to idle. Place the selector switch in NEUTRAL and apply the parking
brake. Be certain the parking brake applied indicator lamp in the overhead panel is illuminated.
2. Place the drive system in the REST mode by
turning the Rest switch on the instrument panel
ON. Be certain the REST warning lamp is illuminated.
Removal
NOTE: If suitable equipment is available to lift wheel
motor assembly from the axle housing it is not necessary to remove the truck body. The equipment used
must be capable of lifting and supporting the weight of
the complete wheel motor assembly, 35,050 Lbs.
(15,913 kg.), must be mobile and must be capable of
aligning the wheel motor to the axle housing mounting
flange during installation.
If the wheel motor must be removed by use of a crane
or overhead hoist, refer to Section B for body removal
instructions.
G5-4
9/99 G05015
Installation
1. Install two guide pins 180 apart in the rear housing.
The complete wheel motor assembly weighs approximately 35,050 lbs. (15,913 kg). Be certain lifting device is capable of handling the load safely.
13. Attach lifting device to wheel motor assembly. DO
NOT allow lifting device to contact brake housing.
14. Remove capscrews (15) and hardened flatwashers (16) securing wheel motor to rear housing.
15. Move wheel motor assembly out of axle housing,
using care to prevent damage to brake hoses if
not removed previously.
16. Refer to appropriate GE service information for
wheel motor repair instructions.
Cleaning and Inspection
1. Thoroughly clean the capscrew holes and mounting faces of the rear housing and the wheel motor.
2. Re-tap holes if threads are damaged.
3. Check mounting faces of wheel motor and rear
housing for nicks, scratches or other damage.
The complete wheel motor assembly weighs approximately 35,050 lbs. (15,913 kg). Be certain lifting device is capable of handling the load safely.
All propulsion system power cables must be properly secured in their wood or other non-ferrous
cable cleats. If clamps are cracked or broken, replace them with new parts. Inspect cable insulation and replace entire cable if insulation is
damaged.
G05015 9/99
G5-5
MASTIC SEALANT
Vendor Product Name:
Uniseal 310S Sealant
Description:
2.00 in wide x .125 in. thick x 120 in. long roll
Vendor Source:
Uniseal
1800 W. Maryland Street
Evansville, IN 47712
Other sources may be available throughout
the world.
G5-6
9/99 G05015
SECTION H
HYDRAIR II SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . .
"TURN OF THE NUT" Tightening Procedure
Minor Repair (Lower Bearing and Seals) . .
Major Suspension Rebuild . . . . . . . . .
Disassembly . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . .
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. H2
H2-1
H2-2
H2-4
H2-5
H2-6
H2-6
H2-7
REAR SUSPENSION . .
Removal . . . . .
Installation . . .
Disassembly
Assembly . .
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. H3
H3-1
H3-3
H3-4
H3-4
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. H4
H4-1
H4-1
H4-2
H4-2
H4-3
H4-4
H4-4
H4-5
H01013 04/01
Index
H1-1
NOTES
H1-2
Index
H01013 04/01
FRONT SUSPENSION
The HYDRAIRII suspensions are hydro-pneumatic
components containing oil and nitrogen gas. The oil
and gas in the four suspensions carry the gross truck
weight less wheels, spindles and rear axle assembly.
The front suspension cylinders consist of two basic
components; a suspension housing attached to the
truck frame and a suspension rod attached to the front
spindle.
Check valves and orifice dampening holes control
suspension travel to provide good ride qualities on haul
roads under loaded and empty conditions.
The front suspension rods also act as kingpins for
steering the truck.
The HYDRAIRII suspension cylinder requires only
normal care when handling as a unit. However, after
being disassembled these parts must be handled carefully to prevent damage to the machined surfaces.
Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
Removal
1. Park unloaded truck on hard level surface. Block
wheels and set parking brake. Remove front
wheel and tire according to Removal instructions in Section G, Front Tire and Rim. Remove
front wheel hub and spindle as covered in Section
G.
2. Remove boot clamp and boot from around suspension.
3. Discharge nitrogen pressure from suspension by
removing cap from charging valve (5, Figure 2-1).
Turn the charging valve swivel nut (small hex) (2,
Figure 2-2) counterclockwise 3 full turns to unseat
valve seal (DO NOT turn more than three turns).
DO NOT TURN LARGE HEX (4) (see DANGER
below). Wearing face mask or goggles, depress
valve stem until all nitrogen pressure has been
relieved.
H02013 2/01
Front Suspensions
H2-1
5. Place a suitable container under suspension cylinder. Remove bottom drain plug (19, Figure 2-8)
and allow cylinder to drain completely.
NOTE: Front HYDRAIRII suspensions are equipped
with lower bearing retainer puller holes. If only rod
wiper, rod seals, bearing, O-ring and backup ring
replacement is required, it will not be necessary to
remove suspension from truck. Refer to Minor Repair
Only (Lower Bearing & Seals) for bearing retainer
removal and installation.
6. If major suspension rebuild is required, continue
removal procedure.
7. Attach fork truck or suitable lifting device to suspension. Secure suspension to lifting device.
The front HYDRAIRII suspension weighs approximately 6150 pounds (2790 kg). Be certain the lifting
device to be used is of sufficient capacity to handle
load.
8. Remove capscrews and washers (1, Figure 2-3)
and nuts and washers (2).
9. Remove capscrews and washers (8), and nuts
and washers (10).
10. Remove capscrews and washers (6), and spacers
(9).
When using a cleaning agent, follow the manufacturers instructions for use, proper ventilation
and/or use of breathing apparatus.
H2-2
Front Suspensions
H02013 2/01
High tightening force is required to load front suspension mounting capscrews. Repeated tightening operations will cause capscrew material to
fatigue and break. DO NOT reuse mounting hardware (capscrews, hardened washers, and nuts)
more than twice after original installation (3 total
see NOTE below). Replace capscrews, washers
and nuts after third use.
NOTE: The following method is suggested to control
the 3 - Use maximum:
H02013 2/01
Front Suspensions
H2-3
7. Charge suspension with dry nitrogen to fully extend suspension piston before installing front
wheel hub and spindle.
FIGURE 2-6. REFERENCE MARKS FOR 120
DEGREE ADVANCE
(14.0 in. (36 cm) Capscrews)
H2-4
Front Suspensions
H02013 2/01
1. Capscrew
2. Hardened Flatwasher
3. Capscrew
4. Hardened Flatwasher
5. Upper Bearing
Retainer
6. Housing
7. Piston
8. Mounting Holes
H02013 2/01
Front Suspensions
H2-5
H2-6
Front Suspensions
H02013 2/01
Assembly
NOTE: All parts must be completely dry and free of
foreign material. Lubricate all interior parts with clean
HYDRAIR suspension oil (see Oil Specification under Oiling and Charging Procedure).
Take care not to damage the machined or plated
surfaces, O-rings or seals when installing piston
assembly.
3. Bearing Retainer
3. Install lower bearing (18) into lubricated suspension housing. Install capscrews and hardened
lockwashers (20 & 21) through bearing flange and
into tapped holes in housing. Tighten to 500 ft.
lbs. (678 N.m) torque.
H02013 2/01
Front Suspensions
H2-7
NOTES
H2-8
Front Suspensions
H02013 2/01
REAR SUSPENSIONS
The HYDRAIR II suspensions are hydro-pneumatic
components containing oil and nitrogen gas. The oil an
gas in the four suspensions carry the gross truck
weight less wheels, spindles and final drive assembly.
The rear suspension cylinders consist of two basic
components; a suspension housing attached to the
rear axle housing, and a suspension rod attached to
the frame.
The HYDRAIR II suspension cylinder requires only
normal care when handling as a unit. However, after
being disassembled these parts must be handled carefully to prevent damage to the machined surfaces.
Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
Removal
1. Remove capscrews, washers, and metal shield
(2, Figure 3-1) from the suspension.
2. Remove charging valve cap, (1, Figure 3-2)
loosen small hex (4) on charging valve and turn
counterclockwise three full turns to unseat valve
seal. Connect suspension charging kit.
3. If necessary, charge the suspension to be removed with dry nitrogen until the rod is exposed
approximately 5.0 in. (127 mm).
4. Place stands or cribbing under the truck frame at
each hoist cylinder mount.
H03013
3. Suspension Cylinder
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
Rear Suspensions
6. Valve Body
7. O-ring
8. Valve Stem
9. O-ring
H3-1
The rear HYDRAIRII suspension weighs approximately 2,400 pounds (1088 kg.). Be certain the
capacity of the lifting device used is sufficient for
lifting this load.
6. Bearing
7. Capscrew
8. Washer
9. Sleeve
H3-2
Rear Suspensions
H03013
Installation
1. Inspect mounting bore sleeves (9, Figure 3-3) and
bearing spacers for damage or wear. Check fit of
pins in bores prior to installing suspension.
2. Secure suspension to fork lift and raise into position. (Suspension assembly should be retracted
as far as possible prior to installation.)
3. Position top suspension eye with its spherical
bearing, between the ears on the frame as shown
in Figure 3-3. Be certain the upper and lower
mounting eyes are aligned and the vent plugs are
positioned to the rear.
4. Lubricate the pin (1), align the retaining capscrew
hole with the hole in the mounting bore and drive
in far enough to hold pin in position.
5. Insert the spacer (4) and continue to drive the pin
in through the spherical bearing. Insert the remaining spacer and continue to drive the pin in
until the retaining capscrew hole is aligned with
the hole in the pin.
H03013
Rear Suspensions
H3-3
Disassembly
NOTE: The suspension should be placed in a fixture
which will allow it to be rotated 180 vertically.
1. Depress charging valve stem to insure all nitrogen
gas pressure has been released prior to removing
charging valve. Wear face mask or goggles while
relieving nitrogen gas.
2. Remove charging valve cover. Remove charging
valve (12, Figure 3-4). Remove and discard
charging valve O-ring. Remove vent plug (14).
3. Place the suspension in a vertical position (piston
rod down). Suspension will contain oil which will
drain through the vent port. Remove piston protection shields (8), if installed.
4. Rotate the suspension 180. Remove socket head
capscrews (18) and pull suspension piston assembly (5) from housing (1). The housing bearing
(21) will be removed with the piston assembly.
5. Remove capscrew and hardened washers (2 &
3). Remove piston bearing (4) from piston rod.
Remove ball checks (22) from piston. Slide the
housing bearing (21) off of the piston.
6. Remove and discard wiper seal (15), rod seal (16),
step seal (17), O-ring (20), and backup ring (19)
from housing bearing.
Assembly
Assembly must be accomplished in a clean, dust free
work area. All parts must be completely clean, dry and
free of rust or scale. Lubricate all interior parts and
bores with fresh suspension oil. (See Oil Specifications
under Oiling and Charging Procedure, this section).
1. Install the spherical bearing (6, Figure 3-3) in the
eye of the piston rod and of the cylinder housing.
2. Place the ring retainers (5) in position to secure
the bearings.
3. Install the piston rod vent plug (7, Figure 3-4).
4. Install the wiper seal (15), rod seal (16), and step
seal (17). When installing backup rings with
rod seal (16) and step seal (17), be certain
radius is positioned toward the seal and the
white dot is positioned away from the seal as
shown in Figure 3-4.
5. Install O-ring (20) and backup ring (19) on the
bearing (21). Backup rings must be positioned
toward the flange of the bearing.
6. Slide the bearing (21) onto the lubricated piston
rod (5).
H3-4
Rear Suspensions
H03013
FIGURE 3-4.
REAR SUSPENSION
ASSEMBLY
1. Housing
2. Capscrews
3. Hardened
Flatwashers
4. Piston Bearing
5. Piston Rod
6. Bleeder Screw
7. Vent Plug
8. Shield
9. Capscrew
10. Washers
11. Vent Plug
12. Charging Valve
13. Plug (Sensor)
14. Vent Plug
15. Wiper Seal
16. Rod Seal
17. Step Seal
18. Socket Head
Capscrew
19. Backup Ring (See
note)
20. O-Ring
21. Housing Bearing
22. Ball Check
H03013
Rear Suspensions
H3-5
NOTES
H3-6
Rear Suspensions
H03013
GENERAL
These procedures cove the Oiling and Charging of
HYDRAIRII suspensions on Komatsu Trucks.
Suspensions which have been properly charged will
provide improved handling and ride characteristics
while also extending the fatigue life of the truck frame
and improving tire wear.
NOTE: Inflation pressures and exposed piston lengths
are calculated for a normal truck gross vehicle weight
(GVW). Additions to truck weight by adding body liners, tailgates, water tanks, etc. should be considered
part of the payload. Keeping the truck GVW within the
specification shown on the Grade/Speed chart in the
operator cab will extend the service life of the truck
main frame and allow the HYDRAIRII suspensions to
produce a comfortable ride.
H04005 9/99
H4-1
FRONT SUSPENSION
1. Park unloaded truck on a hard level surface. Block
wheels, apply parking brake.
2. Thoroughly clean area around charging valve on
the suspensions. Remove protective covers from
charging valves.
H4-2
H04005 9/99
OILING
HEIGHT
in. (mm)
CHARGING
HEIGHT
in. (mm)
CHARGING
PRESSURE
psi (kPa)
730E*
1.5 (38.1)
830E*
1.0 (25.4)
830E**
1.0 (25.4)
930E*
1.0 (25.4)
930E-2*
1.0 (25.4)
H04005 9/99
6. Valve Body
7. O-Ring
8. Valve Stem
9. O-ring
H4-3
3. If removed, install charging valve with new Oring(9, Figure 4-3). Lubricate O-ring with clean
HYDRAIRoil.
4. Tighten valve body (large hex, 6) to 16.5 ft. lbs.
(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated counterclockwise three
full turns.
REAR SUSPENSION
1. Park unloaded truck on a hard, level surface.
Apply parking brake.
2. Thoroughly clean area around charging valve on
suspensions. Remove protective covers from
charging valves and metal covers from the suspension piston.
NOTE: If suspensions are collapsed, it will be necessary to raise the truck frame with a crane or jacks to
install oiling dimension blocks. Insure lifting apparatus
capacity is adequate to hold truck weight.
H4-4
H04005 9/99
3. Depress the charging valve core to release nitrogen pressure from the suspension. When nitrogen pressure has been vented to atmosphere,
loosen and remove the charging valve. The suspension should have collapsed slowly as gas
pressure was released. Truck weight is now supported by the support blocks.
4. Use a plastic tube to help bleed off trapped air
inside the piston. Remove vent plugs and the
bleeder screw. Service the suspension with clean
HYDRAIR Oil until clean oil comes out of the port
where the bleeder screw and plug were removed
from the side of the housing. Drip pans should be
used and all spillage cleaned from outside of
suspension. Allow suspension to stand for at least
15 minutes to clear any trapped nitrogen and/or
air bubbles from the oil. Add oil if necessary.
Loosely install charging valve.
OILING
HEIGHT
in. (mm)
CHARGING
HEIGHT
in. (mm)
CHARGING
PRESSURE
psi (kPa)
730E*
1.0 (25.4)
9.0 (229)
280 (1931)
830E*
1.0 (25.4)
9.5 (241)
250 (1724)
830E**
1.0 (25.4)
9.5 (241)
315 (2172)
930E*, E-2*
1.0 (25.4)
7.5 (190)
215 (1482)
H04005 9/99
2. Install charging valve, with a new lubricated sealing O-ring (9, Figure 4-2) (use fresh HYDRAIR
oil). Tighten valve body (large hex) (6) to 16.5 ft.
lbs. (22.4 N.m) torque. The valve swivel nut (4)
(small hex) must be unseated (counterclockwise)
about three full turns.
3. Install HYDRAIR Charging Kit and bottle of pure
dry nitrogen. Following previous instructions,
charge the suspensions with nitrogen gas to the
pressure shown in Figure 4-4 for the truck being
serviced. DO NOT use an overcharge of nitrogen
gas to lift the suspension off the blocks.
4. Shut off gas pressure and remove charging kit
components.
H4-5
VJ5925
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.
VJ3911 and VJ5925 oils are supplied in 5 gallon (19 Liter) cans.
NITROGEN GAS (N2) SPECIFICATIONS
Property
Nitrogen gas used in HYDRAIR II
Nitrogen
Suspension Cylinders must meet or
Water
exceed CGA specification G10.1 for
Dew Point
Type 1, Grade F Nitrogen Gas
Oxygen
Value
99.9% Minimum
32 PPM Maximum
-68F (-55C) Maximum
0.1% Maximum
H4-6
H04005 9/99
SECTION J
BRAKE SYSTEM
INDEX
BRAKE CIRCUIT . . . . . . . . . . . . . . . .
Service Brake Circuit . . . . . . . . . . .
Secondary Braking and Automatic Apply
Parking Brake Circuit . . . . . . . . . . .
Brake Lock Circuit . . . . . . . . . . . .
Warning Circuit . . . . . . . . . . . . . .
Brake Valve Cut-Away . . . . . . . . . .
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. J2
J2-1
J2-3
J2-3
J2-4
J2-4
J2-5
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. J3
J3-1
J3-2
J3-2
J3-3
J3-6
J3-6
J3-9
J3-10
J3-11
J3-13
J3-13
J3-15
J3-17
J3-17
J3-17
J3-18
J3-19
J3-21
J3-22
J3-22
J3-22
J3-22
J3-22
J3-22
J3-23
J3-24
J3-25
J3-26
J3-26
J3-26
J3-27
J3-27
J3-28
J3-29
J3-30
J3-30
J3-30
J3-31
J3-31
J3-31
J01027 03/01
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J1-1
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. J4
J4-3
J4-4
J4-5
J4-6
J1-2
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. . J5
. J5-1
. J5-2
. J5-2
. J5-4
. J5-4
. J5-7
. J5-8
. J510
J5-11
J5-14
PARKING BRAKE . . . . . . . . . . .
Operation . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . .
Inspection . . . . . . . . . . .
Removal . . . . . . . . . .
Installation . . . . . . . . .
Disassembly . . . . . . . .
Cleaning and Inspection .
Assembly . . . . . . . . .
Parking Brake Bleeding Procedure
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Index
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. J7
J7-1
J7-2
J7-2
J7-2
J7-3
J7-4
J7-4
J7-4
J7-6
J01027 03/01
BRAKE CIRCUIT
The Komatsu truck is equipped with an all-hydraulic
actuated wet disc service brake system. The brake
system utilizes Type C-4 hydraulic oil provided by the
brake/steering pump from the main hydraulic tank for
brake application. Brake disc cooling during truck operation is provided by the hoist circuit pump through
the hoist valve. A disc type parking brake, located in
the rear axle housing, is attached to each wheel motor.
The fundamental function of the brake system is to
provide an operator the control he needs to stop the
truck in either a slow modulating fashion or in as short
a distance as reasonably possible.
Outlined below are the functions that Komatsu Division
feels are necessary for safe truck operation:
Warn the operator as soon as practical of a serious or potentially serious loss of brake pressure
so proper action can be taken to stop the truck
before the secondary system is exhausted of
power.
Provide secondary brake circuits such that any
single failure leaves the truck with sufficient stopping power.
Automatically apply service brakes if low pressure warnings are ignored and pressures continue to decrease.
Wheel brake lock to relieve the operator from
holding the brake pedal while at the dump or
shovel.
Spring applied park brake for holding, not stopping, the truck during periods other than loading
or dumping.
Brake system that is easy to diagnose and perform necessary service.
J02027
Brake Circuit
J2-1
J2-2
Brake Circuit
J02027
J02027
Brake Circuit
J2-3
WARNING CIRCUIT
The brake warning circuit is equipped with a low brake
pressure warning light (on the overhead display panel)
and an audible alarm (in the cab) to alert the operator
of low brake pressures. Several electrical sensors, a
relay and delay timer are used to detect brake system
problems. (See Figure 2-1 for the following component
references.)
Pressure sensor, system supply pressure
Located on the pump pressure sensing manifold.
When system supply pressure drops below 2300
psi (15.8 MPa), the low steering pressure light, low
brake pressure light and buzzer will turn on.
Pressure sensor, low brake pressure (20)
Located on the brake manifold. When the accumulator with the lower pressure falls below 1850
psi (12.7 MPa), the low brake pressure light and
buzzer will turn on.
Differential pressure switches (8)
Located on the dual controller valve (foot treadle)
and on each dual relay valve. During brake application, if the difference in brake apply pressure
between the front and rear circuits is greater than
a preset level, the differential pressure switch located on the dual controller valve will turn on the
low brake pressure light and buzzer.
If the difference in brake apply pressure between
the left and right circuits of the front or rear wheel
brakes is greater than a preset level, the differential pressure switch located on the dual relay valve
at either the front or rear wheels will turn on the
low brake pressure light and buzzer.
The pressure differential switches complete a
path to ground in order to turn on the low brake
pressure light and buzzer. The differential pressure switches provide detection of faults such as
a brake line rupture, poor brake valve tracking,
line blockage, excessive brake displacement or
air trapped in the system.
J2-4
By turning on the dash mounted toggle switch, a solenoid valve (14, Figure 2-1) and pressure reducing valve
(13) will apply unmodulated pressure oil at 2000 psi
(13.8 MPa) to fully actuate the rear brakes. A shuttle
valve (11) in the rear brake line provides the independence from the brake treadle valve for brake application.
Brake Circuit
J02027
NOTE:
B1 - Rear Brakes
B2 - Front Brakes
J02027
Brake Circuit
J2-5
J2-6
Brake Circuit
J02027
J03019 1/99
J3-1
Removal
If the Brake Valve is to be removed from the vehicle
for repair or adjustment, additional equipment will be
required as outlined in disassembly, assembly.
NOTE: Minor repairs and service adjustment may not
require the removal of the brake valve.
J3-2
Installation
1. Place the brake valve assembly into position and
secure in place with capscrews and lockwashers.
Tighten capscrews to standard torque.
2. Remove plugs from brake valve assembly and
hydraulic lines. Install fittings and connect lines to
brake valve assembly and tighten. Connect differential pressure switch to harness.
NOTE: Prior to checking the brake valve operation, the
steering system must have the proper nitrogen precharge in the steering accumulators (refer to Section
L, Hydraulic System for steering accumulator precharge procedure). In addition, the brake system lines
must be bled of air and the brake accumulators must
also be precharged with nitrogen (refer to brake accumulator precharge procedures, this section).
J03019 1/99
Disassembly
NOTE: If not already removed, remove electronic retard pedal (16, Figure 3-2) from brake pedal by removing pivot shaft (8).
NOTE: During disassembly, precision machined parts
should be ink marked or tagged to ensure proper
reassembly and minimize adjustment time. All items
must be placed back into the bores from which they
were removed.
J03019 1/99
13. Pad
14. Nut
15. Capscrew
16. Electronic Retard Pedal Assembly
17. Brake Pedal Actuator
18. Spring Pivot (Lower)
19. Spring
20. Spring Pivot (Top)
21. Set Screw
22. Jam Nut
23. Differential Pressure Switch
J3-3
5. Capscrew
6. Actuator Base
7. Threaded Insert
7. Remove capscrews (36, Figure 3-4) and the differential pressure switch (35). Refer to Differential Pressure Switch for further switch repair
instructions.
8. Remove and discard the seals (27 & 28).
9. Loosen the plunger locknuts (2). Loosen the
socket head capscrew from the adjustment collars (1).
10. Unscrew and remove the adjustment collars.
11. Remove the two socket head capscrews (5, Figure 3-3) that retain the actuator base (6) to the
valve body.
12. Remove the actuator base from the valve body.
13. Remove controller from vice.
14. Remove the four capscrews (34, Figure 3-4) and
washers (33) from the base of the valve.
J3-4
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J03019 1/99
30. O-Ring
31. Retaining Plug
32. Base Plate
33. Washer
34. Capscrew
35. Differential Pressure Switch
36. Capscrew
J3-5
ASSEMBLY
Actuator Base Threaded Inserts
1. If any inserts (7, Figure 3-3) were removed from
the actuator base (6), position the actuator base
upside down on the work bench and support
directly under each of the four floor mounting
holes.
2. Install the threaded inserts into the actuator base
by tapping lightly with a small hammer until the
insert flanges become flush with the actuator
base. Be sure the base is supported to avoid
breaking the base.
3. Thoroughly clean the actuator base and set aside.
Boot and Cap
1. Examine the boot (2, Figure 3-3) for any cracks,
tears, or other damage. If damage is evident, the
boot must be replaced. To replace the boot, follow
the procedure below.
2. Remove the boot from the actuator cap (1) and
discard the old boot. Thoroughly clean the sides
of the cap by scraping the lip where the cap
contacts the boot. Use a knife or suitable scraper.
Clean thoroughly to remove all adhesive or particles of the old boot.
J3-6
4. Back-Up Ring
5. Wiper Seal
6. Actuator Base
J03019 1/99
4. Back-Up Ring
5. O-Ring
6. O-Ring
Assembly of Valve
NOTE: Start with either side (circuit) of the valve and
build that side complete through Step 4. before starting
on the other side (circuit). Be careful to assemble
components into the circuit from which they were
removed.
1. If removed, install stud (4, Figure 3-4) in plunger
(3). Tighten nut (2).
2. Install new packing (5) on staging seat (6) and
insert in plunger bore.
3. Lightly lubricate the actuation plunger Glyde ring
(7).
J03019 1/99
3. Glyde Ring
4. Sharp Edges
J3-7
19. Using new seals (27 & 28, Figure 3-4), install
pressure differential pressure switch assembly
(35) on valve body. Install socket head capscrews
(36). Tighten capscrews to 140 - 150 in. lbs. (15.8
- 16.9 N.m) torque.
20. Install the actuator base (6, Figure 3-3) on top of
the valve. Make sure to position properly for
correct port direction. Tighten the two socket
head capscrews (5) and tighten to 180 - 190 in.
lbs. (20.3 - 21.5 N.m) torque.
21. Screw the adjustment collars (1, Figure 3-4) onto
the top of the actuation plungers. Screw all the
way down until they bottom on the threads.
J3-8
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J3-9
5. Needle Valve
6. Brake Valve
7. Front Brake Pressure Gauge
8. Shut Off Valves
NOTE: Shut off valves (8) for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1, B2 Cylinders must be capable of a 10 cubic inch maximum displacement.
J3-10
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J3-11
Red
300 30 psi
(2 068 207 kPa)
300 30 psi
(2 068 207 kPa)
Green
600 50 psi
(4 137 345 kPa)
600 50 psi
(4 137 345 kPa)
14. Release plunger and depress again while observing B1 gauge and ohmmeter to verify switch
contacts close at the pressure in Table I.
If not, repeat step 13.
15. Insert pry bar under pivot pin to actuate the B2
section of valve.
16. Slowly depress plunger while observing ohmmeter; switch contacts should close at the pressure
in Table I on the B2 gauge. A slight adjustment
may be necessary.
17. Slowly depress both plungers equally from minimum to maximum application pressure. Switch
contacts must remain open.
18. Install plug (6) and tighten to 90 - 100 in. lbs. (10.2
- 11.3 N.m) torque.
19. Shut down the test bench and relieve all hydraulic
pressure from the lines.
J3-12
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J3-13
J3-14
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Removal
1. Securely block the wheels to prevent possible
roll-away.
2. Place selector switch in NEUTRAL, turn the rest
switch ON. Turn key switch OFF to shut down
engine and allow 90 seconds for steering system
accumulators to bleed down. Open valves (6 & 7,
Figure 3-1) to bleed down all four brake accumulators. Close valves after all pressure is released.
NOTE: Follow steps 3 & 4 below for the front valve or
steps 5 through 9 for rear valve removal.
Front Brake Circuit:
3. Tag and remove all hydraulic lines from dual relay
valve. Plug lines and ports to prevent possible
contamination. Disconnect wiring harness at differential pressure switch connector.
4. Remove two capscrews and washers securing
valve to rear wall of cabinet. Remove valve and
move to clean work area for disassembly.
Rear Brake Circuit:
5. Open rear access cover and remove wing nuts
securing duct tube to axle housing. Remove tube.
6. Open access covers inside axle housing.
7. Remove wheel motor cooling air exhaust duct
from between wheel motors.
8. Tag and remove all hydraulic lines from dual relay
valve. Plug lines and ports to prevent possible
contamination. Disconnect wiring harness at differential pressure switch connector.
9. Remove two capscrews and washers securing
valve to mounting bracket. Remove valve and
move to clean work area for disassembly.
Installation.
1. Install dual relay valve in hydraulic components
cabinet (front brake circuit) or rear axle housing
(rear brake circuit). Install the two mounting capscrews and lockwashers to secure valve. Tighten
capscrews to standard torque.
2. Remove hose and fitting caps and plugs and
attach hoses to the proper valve ports. Connect
differential pressure switch connector to wire harness.
3. Start engine and check for leaks and proper brake
operation. Shut down engine.
4. For the rear valve, reinstall the wheel motor cooling air duct between wheel motors. Close access
covers and reinstall tube in axle access opening.
J3-15
J3-16
9. Sleeve
10. Seal
11. Spool Spring
12. Regulator Spool
13. Lower Spring Seat
14. Regulator Spring
15. Upper Spring Seat
16. Plunger
17. Sleeve
18. O-Ring
19. Plug
20. Capscrew
21. Backup Ring
22. O-Ring
23. Backup Ring
24. O-Ring
25. O-Ring
26. Switch
27. Body
28. Plug
29. Screw Plug
30. Spring
31. Piston
32. Spool Assembly
J03019 1/99
Disassembly
The parts installed in the valve body for the B1 and
B2 bores are identical, however the parts must not
be interchanged between the two bores.
1. Thoroughly clean valve to remove dirt accumulation. Drain all oil from all ports of the valve by
rotating the valve over a suitable container.
2. Use a felt tip pen to mark manifold body (1, Figure
3-11) and valve body (2) to ensure correct reassembly.
NOTE: As the valve is disassembled, lay out parts in
order of disassembly, being certain to note the valve
body bore from which they are removed. Parts must
be reinstalled in the same bore from which they are
removed.
3. Secure valve in an upright position in a vice.
4. Remove capscrews securing the differential pressure switch (3) to the valve body. Remove and
discard seals behind differential pressure switch
ports. Refer to Differential Pressure Switch for
disassembly.
5. Remove the two socket head capscrews (20)
retaining the manifold body (1) to the valve body
(2). Remove manifold body and discard O-rings
(18).
6. Remove plungers (16) and sleeves (17).
7. Remove controller from vice.
8. Remove the four capscrews and washers (7) from
the base of the valve.
9. Remove the sleeve retainer (6).
10. With the valve upright, the plug (5) should fall out.
If not, tap lightly to dislodge.
11. Remove the spools (12), reaction plungers (8) and
spool return springs (11). Keep parts separate so
they may be installed in the same spool from
which they were removed.
12. Remove and discard the packing (4) from the
counterbore in the base of the valve body.
13. Turn the valve on its side on the work bench and
remove the sleeves (9) from the valve body.
14. Remove seal (10), O-rings (22 & 24), and backup
rings (21 & 23) and discard.
15. Remove spring seats (13 & 15) and regulator
springs (14).
Assembly
1. Install sleeves (17, Figure 3-11) in bores in top of
valve body (2).
2. Install plungers (16) in sleeves as shown in Figure
3-11.
3. Apply film of oil to O-rings (18) and position in
grooves on top of valve body.
4. Position manifold body (1) on valve body, aligning
marks made during disassembly.
5. Secure manifold to valve body with two socket
head capscrews (20). Only finger tighten capscrews.
6. Preassemble upper spring seat (15), spring (14)
and lower spring seat (13). Insert assembly into
bore from bottom of valve. Be certain upper spring
seat is positioned against plunger (16). Repeat
for other bore.
7. Install sleeve packing seal (10). Refer to Detail A
and B, Figure 3-11 and install O-rings (22 & 24)
and backup rings (21 & 23) in the sleeve (9)
grooves.
8. Apply a light film of oil to sleeve seals. Carefully
push sleeves (9) into their respective bores in the
valve body until flange at base of sleeves contact
valve body.
9. Preassemble regulator spool (12) as follows:
a. Insert spool springs (11) into spool bore.
b. Insert reaction plungers (8) into spool bores
and springs.
J03019 1/99
J3-17
10. Install regulator spool assemblies into their respective sleeve bores. The spherical end must be
inserted toward the spring seat. Push into bore
until contact is made with lower spring seat.
11. Install sleeve retainer plug packing (4) in valve
body.
12. Check to be certain spring seats (13 & 15) are
properly positioned into the regulator springs (14)
and the reaction plunger (8) slides smoothly in its
bore. Install retaining plug (5) in valve body counterbore.
13. Position sleeve retainer (6) on valve body. Install
the four capscrews and washers (7), tightening
capscrews evenly to properly seat plug (5) in
counterbore. Final tighten capscrews to 140 - 150
in. lbs. (15.8 - 16.9 N.m) torque.
14. Tighten the two capscrews (20) holding the manifold body (1) to the valve body (2) to 180 - 190 in.
lbs. (20.3 - 21.5 N.m) torque.
Assembly
1. Install one plug (28, Figure 3-11) in the spool
assembly bore. Tighten plug to 190 - 210 in. lbs.
(21.5 - 23.7 N.m) torque.
2. Lightly lubricate Glyde rings on spool assembly
(32) and carefully insert in valve body bore until
seated against the plug.
3. Install plug in other end of spool bore. Tighten to
190 - 210 in. lbs. (21.5 - 23.7 N.m) torque.
4. Using new O-ring (25), install switch (26). Tighten
to 55 - 60 in. lbs. (6.2 - 6.8 N.m) torque.
5. Turn valve over and install piston (31), spring (30)
and screw plug (29). Plug should be inserted
approximately 0.5 in. (13 mm) below edge of
valve body. Temporarily install plug in screw plug
port.
Disassembly
1. Remove the four socket head capscrews attaching the differential pressure switch body (3, Figure
3-11) to the dual relay valve body (2).
2. Remove switch assembly (26) and O-ring (25).
3. Remove plugs (28).
4. Remove screw plug (29).
5. Remove spring (30) and piston (31).
6. Carefully push spool assembly (32) out of its bore.
J3-18
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J3-19
J3-20
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J03019 1/99
Be certain all hydraulic pressure has been released prior to disconnecting hoses and valve.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
21. Remove hoses from valve and remove valve from
test stand.
J3-21
J3-22
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J3-23
J3-24
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Charging Procedure
1. Mount hose assembly gland nut on pressure
regulator.
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J3-25
3. Charging Valve
J3-26
3. Capscrews, Washers
& Nuts
4. Mounting Bands
5. Oil Line
J03019 1/99
Disassembly
1. Remove charging valve (3, Figure 3-27).
2. Remove gland (4).
Note: Figure 3-28 illustrates a tool that can be fabricated locally to aid in removing the gland.
3. Remove plugs and/or adaptor (10 & 11). Using a
round rod, push piston (6) out of accumulator.
4. Remove piston rings (7) and seal (8).
Cleaning and Inspection
1. Clean parts using fresh cleaning solvent, lint free
wiping cloth and filtered compressed air. All parts
must be absolutely free of any foreign matter
larger than 3 microns.
2. Inspect piston for damage. If scored or otherwise
damaged, replace with a new part.
3. Minor defects in the housing bore may be corrected by honing.
a. Measure the bore at several places along the
length of the housing. Make two measurements, 90 apart at each point to verify tube is
not out-of-round.
J03019 1/99
7. Bearing
8. T Ring Seal
9. Housing
10. Plug
11. Plug
J3-27
TESTING
Assembly
J3-28
J03019 1/99
ACCUMULATOR CHARGING
PROCEDURE
(Frame Mounted Brake Accumulators)
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
6. Valve Body
7. O-ring
8. Valve Stem
9. O-ring
If nitrogen pressure is present in the accumulators, make certain only the small swivel hex nut is
turned during the next step. Turning the complete
valve assembly may result in the valve assembly
being forced out of the accumulator by the nitrogen pressure inside.
4. Remove charging valve cap (1, Figure 3-28). Turn
small swivel hex nut (4) three complete turns
counterclockwise.
5. Depress the valve stem and hold down until all
nitrogen has been released.
6. If a loss in nitrogen pressure is the reason for
recharging, inspect the charging valve and accumulator for damage. Replace or repair items, as
necessary, before charging procedure.
J03019 1/99
J3-29
J3-30
5. Harness Connector
9. Locknut
13. Bracket
6. Capscrew, Socket Hd.
10. Washer, Tanged
14. Shaft
7. Lockwasher
11. Spring, Disc
15. Lever
8. Potentiometer (Switch Assy.) 12. Washer, Internal Tang 16. Handle
J03019 1/99
Assembly
1. If handle (16, Figure 3-30) or lever (15) has been
removed from shaft (14), assemble as follows:
a. Apply Loctite #271 to lever (15) and install
lever fully into shaft (14).
b. Apply Loctite #271 to opposite end of lever
(15) and install handle (16) onto lever.
Hand Tighten Only!
2. Inspect the shaft bore and interior friction faces of
bracket (13) and remove any scratches or burrs,
or replace bracket.
Lightly lubricate the surfaces with a Multi-Purpose
EP NLGI Consistency #2 grease.
3. Insert the lever, handle, and shaft assembly into
bracket (13), and install washer (12), new spring
(11) [with the outer spring diameter against
washer (12)], tang washer (10), and locknut (9)
onto shaft (14).
4. Tighten and secure locknut (9) as described in
step 3.b. "Disassembly and Adjustment".
5. Move lever to the "UP" position as far as travel
permits. Align slot in potentiometer (8) with key
on shaft (14) and rotate pot until capscrew holes
line up with bracket.
Install washers (7) and capscrews (6) to secure
pot to bracket.
Tighten the socket head capscrews to 36 in. lbs.
(4.1 N.m) torque.
6. Install lever assembly to steering column.
J03019 1/99
J3-31
NOTES
J3-32
J03019 1/99
J04025
J4-1
The steering accumulator can be bled down with engine shut down, turning key switch Off, and waiting
90 seconds. Confirm the steering pressure is released
by turning the steering wheel - No front wheel movement should occur. Open both bleed down valves on
brake manifold to bleed down all four brake accumulators.
J4-2
J04025
EQUIPMENT REQUIRED
AF2
AF1
AR2
AR1
BF
BL
BR
CP1
CV, CVR,
CVF
LS
LAP1
LAP2
NVF
NVR
PK1
PK2
PK3
PR
SP1
SV1
SV2
T1
J04025
DSV
Check Valve
PSV
Return To Tank
J4-3
J4-4
J04025
Verify park brake release pressure (gauge installed in PK2 port in hydraulic cabinet) is
2700 100 psi (18,615 690 kPa).
Record on data sheet.
Both pressures must remain above their minimum values for a minimum of 20 seconds.
Record on data sheet.
Verify brake indicator lamp and stop lights illuminate at 75 5 psi (517 34 kPa) rear brake
pressure.
Record on data sheet.
24. Very slowly, release the brake pedal while observing the B1 pressure gauge:
Both pressures must remain above their minimum values for a minimum of 20 seconds.
Record on data sheet.
J04025
J4-5
36. Turn key switch ON. Very slowly, open the rear
brake accumulator bleeddown valve a small
amount ([NVR] 19, Figure 4-1) while observing
LAP1 decreasing pressure.
Verify the brake pressures B1 and B2 begin to rise within 100 psi (690 kPa) of the auto
apply set point pressure recorded in step 33.
Record on data sheet.
31. Disable the steering pressure switch by unplugging the diode between circuits #33 and #33F on
diode board DB1 in the auxillary control box or by
disconnecting the wires at the steering pressure
switch.
32. Turn the key switch ON. After 2 minutes, record
the low accumulator pressure (LAP1) gauge reading.
J4-6
41. Turn the key switch OFF and allow the steering
accumulators to bleed down.
42. Open both accumulator bleeddown valves and
bleed down the entire brake system. Close valves
after all pressure is released.
43. Disconnect the hose (4, Figure 4-4) that supplies
oil to the brake valve (P2 port), front brake circuit,
by removing at the tee attached to the bottom of
the hydraulic cabinet (brake manifold port AF1).
Cap the tee fitting, but hose must be vented to
atmosphere.
44. Start engine and allow low brake accumulator
pressure (LAP1 gauge) to stabilize at or above
2700 psi (18,613 kPa).
J04025
45. Depress the brake pedal very slowly until the brake
differential pressure switch activates the low brake
pressure lamp and buzzer.
Verify fault indicators are activated at:
Red
300 30 psi
(2 068 207 kPa)
300 30 psi
(2 068 207 kPa)
Green
600 50 psi
(4 137 345 kPa)
600 50 psi
(4 137 345 kPa)
46. Shut down the engine and turn key switch OFF.
Allow steering accumulators to bleed down.
47. Open both accumulator bleeddown valves and
bleed entire brake system. Close valves after all
pressure is released.
48. Reconnect hose (4, Figure 4-4) to Tee at AF1
port, bottom of hydraulic cabinet
J04025
J4-7
52. Shut down the engine and turn key switch OFF.
Allow steering accumulators to bleed down.
Open both accumulator bleeddown valves and
bleed entire brake system.
Close valves after all pressure is released.
53. Reconnect hose (5, Figure 4-4) to Tee at AR1
port, bottom of hydraulic cabinet.
54. Remove all test equipment and verify all hoses
have been reconnected.
J4-8
J04025
Replace coil.
Remove restriction.
Remove obstruction.
Replace piston.
TROUBLE: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system.
Check wiring.
Replace relay.
J04025
J4-9
POSSIBLE CAUSES
TROUBLE: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released
Brake valve out of balance (not tracking).
Differential pressure switch is defective or improperly
adjusted.
Accumulator precharge/leak.
Bleed brakes.
Replace timer.
Replace bulb.
Electrical problem.
Replace relay.
J4-10
J04025
POSSIBLE CAUSES
Check wiring.
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open.
Recharge accumulator
Check plumbing.
Normal
TROUBLE: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected.
Check plumbing.
TROUBLE: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in brake valve assembly.
J04025
J4-11
POSSIBLE CAUSES
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component.
Correct plumbing.
J4-12
J04025
CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
MACHINE MODEL
I.
UNIT NUMBER
SERIAL NUMBER
Operate Hydraulic Steering System to obtain proper operating temperature. Refer to Check-out
Procedures.
STEP 2
STEP 7
STEP 8
II.
Refer to appropriate Service Manual procedures and Bleed brakes; Bleed park brakes.
STEP 9
STEP 14
STEP 15
STEP 18
J04025
J4-13
CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
STEP 24
STEP 27
STEP 33
STEP 36
STEP 40
STEP 45
STEP 51
J4-14
J04025
OPERATION
The ring gear (4, Figure 5-1) is internally splined to
retain the dampers (8) and separator plates (12). The
separator plates are alternately placed between the
friction faced discs (7) which are splined to the inner
gear (6). The inner gear mounts directly to the wheel
hub on the front wheel brakes. On the rear, the inner
gear requires an adapter hub which mounts on the
wheel hub on the wheel motor.
The inboard side of the assembly contains the piston
(9) which is activated by hydraulic pressure supplied
by the dual relay valves (controlled by the brake valve).
As hydraulic pressure is applied, the piston moves to
compress the rotating friction faced discs against the
stationary steel discs. The friction forces generated
resist the rotation of the wheels. As hydraulic pressure
increases, friction forces are increased and wheel
rotation is slowed until maximum force is reached and
the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The low pressure cooling circuit is completely
isolated from the high pressure, piston apply circuit.
Cooling oil flows from the hydraulic tank to the hoist
pump, through the hoist circuit high pressure filters,
through the hoist valve, and into the brake housings.
A parallel circuit from the hoist valve outlet is connected to relief valves at the hydraulic tank which limit
brake cooling circuit pressure to 35 psi (241 kPa). Oil
routed to the front brakes passes through the oil cooler
before entering the front brake housings. In addition,
the brake cooling oil provides lubrication for the front
wheel bearings. Oil exiting the brake housings returns
to the hydraulic tank.
J05018 03/01
6. Inner Gear
7. Friction Disc
8. Damper
9. Piston Assembly
10. Seal Carrier
11. Back Plate
J5-1
MAINTENANCE
Brake disc wear should be checked every 1000 hrs.
using the wear indicator tool (Part Number EF9302),
included in the tool group shipped with the truck. Refer
to Figure 5-2.
5. O-Ring
6. Tool Housing
7. O-Ring
8. Indicator Pin
Removal/Installation
1. Place the selector switch in NEUTRAL, apply the
park brake, turn the rest switch ON, turn the key
switch OFF and allow the steering accumulators
to bleed down completely. Block truck wheels.
2. Open the bleeddown valves on the brake manifold
(in the hydraulic components cabinet) and bleed
all pressure from the brake accumulators. Close
valves after pressure is released.
3. Thoroughly clean the brake assemblies, especially the area surrounding cooling oil lines.
4. Remove the hex head O-ring plug from the port
(5, Figure 5-3) next to the cooling line opposite
the cooling line (3) with the adjacent brake apply
line (2) port. Quickly insert the brake wear indicator tool and tighten securely.
NOTE: The front wheel brakes have a diagnostic
connector installed for measuring brake apply pressure. The rear brakes do not have a diagnostic connector installed on the brake backplate, but instead
have an O-ring plug installed. Do not attempt to install
the brake wear indicator in this port.
5. Start the engine and allow the steering system to
stabilize and the brake accumulators to fill.
J5-2
J05018 03/01
4. Diagnostic Coupler
5. Wear Indicator
Installation Port
J05018 03/01
J5-3
BRAKE REBUILD
The brake assembly should be disassembled
and reassembled on a clean, dry work surface.
The surface should be wooden or if metal, covered with padding to prevent damaged to machined surfaces.
Match mark individual parts for correct orientation prior to disassembly.
If a rear wheel brake is to be disassembled,
start with step 1 below. If a front wheel brake is
to be disassembled, start the disassembly procedure at step 5.
1. Ring Gear
2. Back Plate
3. Capscrew
Disassembly
Rear Wheel Brake Only:
Refer to Wheel Motor Rebuild instructions for rear
wheel brake assembly removal.
1. Verify socket head capscrews (3, Figure 5-1) are
installed at each of the six locations on the back
plate (11). These capscrews are required to retain
the seal carrier (10) to the back plate when the
brake assembly is not installed on the truck.
Shipping bars (4, Figure 5-4) must be installed.
2. Remove the 12-point capscrews and hardened
washers (5, Figure 5-1).
3. Remove capscrews and lockwashers (2) used to
retain the hub to the seal carrier.
4. Be certain hub and other parts are marked to
ensure proper orientation during reassembly. Lift
the hub adaptor (1) from brake assembly. Be
certain to note shim packs installed at six locations on between seal carrier and hub.
Both Front and Rear Wheel Brakes:
Remove the front wheel brake assembly according to
the instructions in Front Wheel Hub and Spindle,
Section G.
5. Position brake assembly on work surface with ring
gear retainer bars on bottom as shown in Figure
5-5.
J5-4
J05018 03/01
5. Hardened Washer
6. O-Ring
7. Ring Gear
8. Piston Housing
9. Separator Plate
10. Damper
11. Friction Disc
12. Inner Gear
1. Capscrew
2. Spring Guide
J05018 03/01
3. Hardened Washer
4. O-Ring
5. Ring Gear
6. Seal Assembly
7. Seal Assembly
J5-5
12. Attach a lift strap through bars and lift inner gear
(5) out of brake assembly. Remove shipping bars
and spacers.
13. Remove capscrews (2, Figure 5-6) and hardened
washers (3) from piston housing (1).
14. Insert a 7/8 UNC x 2.0 in. pusher bolt in each of
the three tapped holes in the piston housing.
Tighten bolts evenly to lift housing from ring gear
(5). Remove and discard O-ring (4).
J5-6
J05018 03/01
Free Height:
. . . . . . . . . . .
J05018 03/01
J5-7
Assembly
J5-8
J05018 03/01
17. Follow procedures in Floating Ring Seal Assembly/Installation to install seal assembly in cavities
in the back plate and seal carrier.
1. Damper
2. Friction Disc
J05018 03/01
5. Piston
J5-9
J5-10
J05018 03/01
J05018 03/01
J5-11
ALTERNATE PROCEDURE:
After positioning the seal squarely over the retaining lip, thoroughly lubricate the ring by spraying
with tri-chloroethane #111.
DO NOT USE Stanosol or any other liquid that
leaves an oily film or does not evaporate quickly.
4. With all surfaces of toric ring wet, use installation
tool to position seal ring and toric ring squarely
against the seal housing.
J5-12
J05018 03/01
Make certain
seals are square
and concentric
NOTE: Do not slam, bump or drop seals together. High
impact can damage the seal face and cause leakage.
J05018 03/01
J5-13
J5-14
J05018 03/01
PARKING BRAKE
The Model 930E truck is equipped with a dry disc type
parking brake assembly mounted on each wheel motor
rotor shaft. The parking brake assemblies are inboard
mounted and can be accessed through the rear axle
housing door.
The parking brake is intended to prevent truck movement after the vehicle has stopped, the engine is shut
down, and when the truck is left unattended. The
parking brake is not for use during truck loading or
dumping operations. Refer to the Operation and Maintenance Manual for additional brake system operation
instructions.
OPERATION
The parking brake is a spring applied, hydraulically
released, multiple disc type brake, actuated by the
parking brake switch mounted on the instrument panel
in the operators cab.
J07010 12/98
Parking Brake
J7-1
MAINTENANCE
Removal
Inspection
1. Apply the parking brake, put selector switch in
NEUTRAL, place the Rest switch in the ON position, turn the key switch OFF to shut down the
engine, and allow approximately 90 seconds for
the steering accumulators to bleed down. Confirm
the steering pressure is released by turning the
steering wheel - no movement should occur.
Block the truck wheels.
2. Open brake accumulator bleeddown valves located on brake manifold inside the hydrauilc components cabinet behind the cab. Allow adequate
time for the accumulators to bleed down completely.
3. Open the rear axle housing access door and
remove wing nuts retaining duct inside door. Remove duct tube and open access covers inside
axle housing.
4. Observe for signs of oil leakage or damage.
5. Measure amount of disc wear as follows:
a. With the parking brake applied, insert a depth
micrometer through one of the piston position
holes (18, Figure 7-2) and record the dimension.
b. Repeat step a., measuring through the other
two holes and recording the dimensions.
c. Add the three measurements and divide the
total by 3 to determine the average.
d. If the resulting average of the three measurements is greater than 0.969 in. (24 mm), the
parking brake assembly must be removed and
rebuilt.
6. Repeat step 5 for the other parking brake assembly.
7. After inspection is complete, close duct access
covers and reinstall duct outlet tube.
J7-2
Parking Brake
J07010 12/98
Gear Removal:
J07010 12/98
Parking Brake
J7-3
Disassembly
1.Match mark housing (3, Figure 7-2), piston housing
(4), and cap structure (5).
Assembly
1. If dowel pins (2, Figure 7-2) have been removed,
press new dowel pins into holes in housing until
fully seated against shoulder.
2. Install a separator disc (12) over dowel pins. Insert
a spring (1) over each dowel pin. Insert a friction
disc (13). Insert springs (1) over dowels.
3. Install another separator disc, the 2nd friction disc
and the remaining separator disc.
NOTE: The internal teeth of the two friction discs must
be aligned and must be concentric with the pilot
diameter machined on the rear of the housing to
enable the completed assembly to be installed properly. If available, a mating gear as installed on the
wheel motor rotor shaft (4, Figure 7-1) should be used
to simplify alignment.
4. Assemble the seals (8 & 9) on the piston.
a. Install O-ring seal in bottom of each groove. Be
certain O-rings are not twisted.
b. If available, use an expander to expand the O.D.
of each seal enough to allow it to slide onto
piston.
NOTE: If an expander tool is not available, the seals
may be heated to 400F (204C) MAXIMUM. This will
allow ring to be manually expanded until it will fit over
piston.
c. When each seal is over the groove, re-size by
compressing the seal ring. Use a full circle
clamp with any sharp edges or grooves covered to prevent damage to the seal surfaces.
Free Height:
. . . . . . . . . . . . . . . . . . 0.456 in. (11.58 mm)
J7-4
Parking Brake
J07010 12/98
7. Belleville Springs
8. Piston Seal Assembly
9. Piston Seal Assembly
10. Capscrew
11. Hardened Washer
12. Separator Disc
Pressure Test:
J07010 12/98
Parking Brake
J7-5
J7-6
Parking Brake
J07010 12/98
SECTION L
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . .
HOIST CIRCUIT OPERATION . .
STEERING CIRCUIT OPERATION
DISC BRAKE COOLING SYSTEM
L01033
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. L3
L3-1
L3-1
L3-3
L3-4
L3-8
L3-13
L3-14
L3-14
L3-14
L3-15
. L3-15
. L3-16
STEERING CIRCUIT . . . . . . . . . .
STEERING CIRCUIT OPERATION
COMPONENT DESCRIPTION . .
Steering Control Valve . . . .
Bleed Down Manifold Valve .
Accumulators . . . . . . . . .
Flow Amplifier . . . . . . . . .
Steering Pump . . . . . . . .
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. L4
L4-1
L4-2
L4-2
L4-3
L4-5
L4-6
L4-16
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. L5
L5-1
L5-1
L5-2
L5-2
L5-3
L5-5
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. L6
L6-1
L6-2
L6-5
L6-6
L6-10
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Index
. L2
L2-2
L2-4
L2-6
L1-1
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. . L7
. L7-1
. L7-2
. . L7-5
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. . L8
. L8-1
. L8-9
. L8-12
. L8-20
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.
HOIST CIRCUIT . . . . . . . . . .
HOIST CIRCUIT OPERATION
COMPONENT DESCRIPTION
HOIST CIRCUIT OPERATION
L1-2
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Index
L6-12
L6-12
L6-12
L6-14
L6-20
L6-23
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. L9
L9-1
L9-3
L9-4
. L10
L10-1
L10-2
L10-3
L10-5
L10-6
L10-6
L10-7
L10-8
L10-10
L10-13
L01033
HYDRAULIC SYSTEM
The following is a general description of the Model
930E hydraulic system. Additional information concerning individual component description and opera-
L02028
Hydraulic System
L2-1
L2-2
Hydraulic System
L02028
L02028
Hydraulic System
L2-3
L2-4
Hydraulic System
L02028
L02028
Hydraulic System
L2-5
L2-6
Hydraulic System
L02028
L02028
Hydraulic System
L2-7
NOTES:
L2-8
Hydraulic System
L02028
1. Turn keyswitch Off and allow ample time (approximately 90 seconds) for the accumulators to
bleed down.
2. If necessary, drain the hydraulic tank by use of the
drain valve located on the rear side of the tank.
NOTE: If oil in the hydraulic tank has not been contaminated, the shut-off valves can be closed and both
pump inlet lines can be drained, eliminating the need
to completely drain the tank.
Always maintain complete cleanliness when opening any hydraulic connection. Insure that all system lines and components are capped while the
component is removed from the truck.
L03027
6. Pump Driveshaft
7. Hoist Circuit Filters
8. Hydraulic Tank
9. Hoist Valve Pilot Circuit Hoses
L3-1
L3-2
6. Bearing Plate
7. O-ring
8. Transition Plate
9. Coupling
10. Capscrew
L03027
Installation
NOTE: The following assumes the steering pump is
already in position on the truck.
1. Install O-ring (16, Figure 3-3) to steering pump
(11). Install coupler (9) to hoist pump.
L03027
L3-3
Disassembly
NOTE: As parts are removed they should be laid out in
a group in the same order in which they are removed.
1. Clean the exterior of the pump assembly thoroughly. If the steering pump is attached, remove
capscrews (10, Figure 3-3) and pull the steering
pump free of transition plate (8). Remove O-ring
(16).
2. Remove coupling (9). Remove dowels (3) if damaged, or if replacement of the bearing plate is
necessary.
L3-4
19. Dowel
20. Bearing Plate
21. Dowel
22. Transition Plate
23. O-ring
24. (Not Used)
25. Coupler
26. O-ring
27. Drive Gear (Rear)
L03027
L03027
7. Stud
8. O-ring
9. Connector Plate
10. Steel Ring
11. Idler Gear
12. Drive Gear (Rear)
13. Bearings
14. Steel Ring
15. Backup Ring
16. O-ring & retainer
17. Isolation plate
18. Pressure Plate
L3-5
10. Remove bearing plate (10, Figure 3-6). If the bearing plate is stuck, tap lightly with a plastic hammer
to loosen it. Remove O-rings (9) and (11).
13. Remove steel rings, backup ring, O-ring and retainer. Remove drive gear (1) and idler (3) from
gear plate (7). Remove both pressure plates (18).
L3-6
8. O-ring
9. O-ring
10. Bearing Plate
11. O-ring
12. Thru Studs
13. Steel Rings
14. Backup Ring
L03027
3. Wooden Blocks
1. Flange
2. Punch
3. Bearings
L03027
L3-7
INSPECTION OF PARTS
1. Examine the gear bores in both gear plates, reference Figure 3-9. During the initial break-in, the
gears cut into the aluminum gear plates. The
nominal depth of this cut is 0.008 in (0.203 mm)
and should not exceed 0.015 in (0.381 mm). As
the gear teeth cut into the gear plates, metal is
rolled against the pressure plates. Using a knife or
sharp pointed scraper, remove the metal that was
rolled against the pressure plates. Remove all
metal chips that were broken loose.
2. The following seal installation procedures are outlined for use with a vise, but they can be adapted
for use with a press if one is available.
3. Open the vise jaws wide enough to accept the
combined thickness of the flange, wood blocks
and press ring.
L3-8
2. Gear Plate
3. Bearing Projection
L03027
L03027
8. Bearing
9. Bearing
10. Weep Hole
11. Plug
12. Dowel
13. Gear Plate
14. Thru Studs
1. Gear Plate
2. Drive Gear
3. Idler Gear
4. Bearing
5. Steel Ring
6. Retainer
7. O-ring
8. Backup Ring
9. Isolation Plate
10. Relief Area
11. Thru Studs
L3-9
3. Slot
L3-10
6. Connector Plate
7. O-ring
8. Snap Ring
9. Coupling
14. Dowel
15. Isolation Plate
16. Pressure Plate
17. Bearings
L03027
L03027
8. O-ring
9. O-ring
10. Gear Plate
11. Connector Plate
12. Stud
13. Idler Gear
14. Capscrew
21. O-ring
22. Dowel
23. Dowel
24. O-ring
25. Dowel
26. Bearings
L3-11
21. Install rear drive gear (1) and idler gear (13). The
rear drive gear must be timed with the front drive
gear. This is accomplished by lining up a tooth on
the rear drive gear with the valley of two teeth on
the front drive gear, as shown in Figure 3-16.
1. Wrench
24. Install dowel (22) if removed. Lubricate and position O-ring (17) in transition plate (16). Assemble
bearing plate (15) to transition plate and install
capscrews (14). Tighten capscrews to standard
torque.
L3-12
3. Pump
L03027
TROUBLESHOOTING GUIDE
(HOIST PUMP)
TROUBLE
POSSIBLE CAUSE
SUGGESTED CORRECTIVE
ACTION
3. Incorrect installation
4. Aeration-Cavitation
a. Restricted oil flow to pump inlet
b. Aerated Oil
5. Lack of oil
7. Excessive Heat
1. Broken shaft
2. Broken housing or flange
8. Over Pressure
L03027
L3-13
HYDRAULIC TANK
Filling Instructions
NOTE: If filling is required, use only type C-4 hydraulic
oil as specified on the truck Lubrication Chart. Filtering
of oil with a 3 micron filtering system is recommended.
NOTE: With engine running and oil at operating temperature, the oil should be visible in the lower sight
glass. If not, shut down engine and add oil per Filling
Instructions.
NOTE: Minor adjustments to oil level can be made by
using the drain cocks (5) next to filler neck.
Removal
1. Turn keyswitch Off and allow at least 90 seconds
for the steering accumulator to bleed down.
NOTE: Be prepared to contain approximately 250 gal.
(947 L) of hydraulic oil. If the oil is to be reused, clean
containers must be used with a filtering (3 micron)
system available for refill.
2. Thoroughly clean the outside of the hydraulic tank
and attached equipment.
3. Drain the hydraulic tank by use of the drain valve
located on the rear side of the tank.
4. Disconnect hydraulic lines. Plug lines to prevent
possible contamination to the system. Tag each
line at removal for proper identification during
installation.
L3-14
L03027
Installation
1. Install hydraulic tank and secure with capscrews
and lockwashers. Tighten to 459 ft. lbs. (622
N.m) torque.
4. Fill the hydraulic tank with clean, filtered C-4 hydraulic oil. Refer to Filling Instructions.
Removal
1. Clean the strainers with fresh cleaning solvent from
the inside out.
2. Inspect the strainers for cracks or wear. Replace,
if necessary.
Prior to opening the hydraulic tank, allow at least
90 seconds for the accumulators to bleed down
after engine shutdown with the key switch Off.
1. Shut down the engine and the key switch Off for
at least 90 seconds.
L03027
4. Shutoff Valve
5. Pump Suction
Hoses
L3-15
L3-16
L03027
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
The steering/brake pump (7, Figure 4-1) supplies oil to
the bleeddown manifold (4) after passing through a
high pressure filter (10). If the filter element becomes
L04031
Steering Circuit
L4-1
COMPONENT DESCRIPTION
If a loss of steering pressure occurs during operation, the truck must be stopped immediately. The
pressure in the accumulators allow the operator to
steer the truck for a short period. Do not attempt
further operation until the problem is located and
corrected.
L4-2
Steering Circuit
L04031
L04031
Steering Circuit
L4-3
L4-4
Steering Circuit
L04031
Relief Valves
The 4000 psi (28. MPa) relief valve limits maximum
steering circuit pressure by returning oil to the hydraulic tank through internal passages in the bleeddown
manifold.
The 600 psi (4.1 MPa) relief valve provides maximum
pressure protection for the oil returning to the hydraulic
tank.
ACCUMULATORS
The steering accumulators (5, Figure 4-1) are a floating
piston type. The top side of the accumulators are
charged to 1400 psi (9.7 MPa) with pure dry nitrogen
with the piston at the bottom.
Oil entering the accumulators pushes the piston upward compressing the nitrogen on the top side of the
piston. The nitrogen pressure increases directly with
steering circuit pressure. When steering circuit pressure reaches 3025 psi (20.9 MPa) the unloader valve
will unload the pump. The accumulators will contain a
quantity of oil under pressure and held by check valves
in the bleeddown manifold, available for steering the
truck. When system pressure drops to 2750 psi (19.0
MPa) the pump output will again increase, to refill the
accumulators and increase steering system pressure.
The accumulators also provide oil, for a limited period
of time, to be used in case the pump becomes inoperative.
If the filter element becomes restricted, a warning indicator is activated at 40 psi (276 kPa) and oil will bypass
the element at 50 psi (345 kPa).
Refer to Section L9 for further information regarding
the various system filters and maintenance procedures.
L04031
Steering Circuit
L4-5
FLOW AMPLIFIER
The flow amplifier (3, Figure 4-1, & Figure 4-5) is located
on the left frame rail forward of the bleed down manifold
valve and is used in the steering circuit to provide the
high volume of oil required for the steering cylinders.
L4-6
Steering Circuit
L04031
L04031
Steering Circuit
L4-7
No Steer
Refer to figures 4-6 through 4-9 for oil flow paths during
the following conditions:
Neutral
Steering Left
Steering Right
External shock load
L4-8
Steering Circuit
L04031
L04031
Steering Circuit
L4-9
Steering Left
(Refer to Figure 4-7):
When the operator turns the steering wheel left, the
steering control unit is opened to allow oil coming in
port P to pass to the gerotor section of the control
unit to turn the rotor. Oil in the other side of the gerotor
flows through other passages in the control unit valve
and out steering control unit port L. This oil enters
port L of the flow amplifier assembly and goes to a
closed area B in the directional valve.
As pressure in this area builds, it also passes into the
spool through orifice C to the spring area on the end
of the directional valve. The pressure then moves the
spool compressing the springs on the opposite end.
This movement allows the oil entering area B to pass
through the directional valve to area D of the amplifier
valve through sleeve E holes to a passage between
sleeve E and valve F, through hole G in sleeve E
where it initially is blocked by the valve body.
As pressure builds up in this area, oil also flows from
area D, around the outside of sleeve E, around pin
H, through orifice J to build pressure on the end of
the amplifier valve and opens hole G only enough to
allow the flow of oil coming from the steering control
unit to pass to the control area of the directional valve.
At the same time, the movement of sleeve E opened
the holes near the spring end to allow the oil from the
priority valve to flow into the center of sleeve E.
L4-10
Steering Circuit
L04031
L04031
Steering Circuit
L4-11
Steering Right
(Refer to Figure 4-8):
Only a few differences occur between steer left and
steer right. When the operator turns the steering wheel
right, oil is supplied out ports R and LS of the
steering control unit.
L4-12
Steering Circuit
L04031
L04031
Steering Circuit
L4-13
L4-14
Steering Circuit
L04031
L04031
Steering Circuit
L4-15
STEERING PUMP
Operation
The driveshaft (35, Figure 4-10) runs through the centerline of pump housing (37) and valve plate (48). The
cylinder barrel (45) is splined to the drive shaft.
L4-16
Steering Circuit
L04031
L04031
Steering Circuit
L4-17
PRINCIPLE OF OPERATION
Full Pump Volume:
Control piston (1, Figure 4-11) controls the angle of the
swashblock (4). When control piston moves to the full
right position, the pump is at maximum pumping capacity.
The driveshaft turns the splined housing (2) which
contains the pumping pistons (3). When the housing is
rotated, the pistons move in and out of their bores and
the piston shoes ride against the angled swashblock
(4).
As the cylinder rotates, the individual piston bores are
connected, alternately to the left (port A) and right
(port B) crescent shaped ports in the valve plate.
While connected to left side (suction) port A, each
piston moves outward, drawing fluid from port A into
the piston bore until its outermost stoke is reached. At
that point the piston bore passes from the left crescent
port to the right crescent port.
3. Piston
4. Swashblock
1. Control Piston
2. Housing
3. Piston
4. Swashblock
Neutral Position:
Neutral position (Figure 4-13) results when the control
piston (1) centers the swashblock (4). The swashblock
angle is now zero and swashblock face is now parallel
to cylinder face. Therefore, no inward or outward motion of the pump pistons exists as piston shoes rotate
around the swashblock face. The lack of inward and
outward motion results in no fluid being displaced from
the piston bores to the crescents in the valve plate and
subsequently no delivery from pump ports.
FIGURE 4-13. PUMP IN NEUTRAL POSITION
1. Control Piston
2. Housing
L4-18
Steering Circuit
3. Piston
4. Swashblock
L04031
Steering Pump
Figure 4-14 shows the steering pump and the location
of the pressure control adjustments and stroke (flow)
adjuster.
Note: The Stroke adjuster (3, Figure 4-14) is set at the
factory to provide maximum pump flow and adjustment is not normally required. If the truck is operated
at high elevations, 10,000 ft. (3,050 meters) above sea
level or more, it may be necessary to readjust the
stroke control to reduce pump flow to prevent pump
cavitation under certain conditions. If the truck is operating at high altitude and problems are experienced,
consult the Komatsu Factory Representative for adjustment procedures.
5. Compensator Press.
Adjust
6. 4-Way Valve
7. GPA Port
8. GP2 Port
L04031
Steering Circuit
5. Case Drain
6. GP2 Port
7. GP4 Port
8. GPA Port
L4-19
NOTES
L4-20
Steering Circuit
L04031
L05021
Serious personal injury to the Operator or to anyone positioned near the front wheels may occur if
a truck is operated with the hydraulic steering lines
improperly installed. Improperly installed lines
can result in uncontrolled steering and/or SUDDEN AND RAPID rotation of the steering wheel as
soon as the steering wheel is moved. It will turn
rapidly and cannot be stopped manually.
After servicing the steering control assembly, hydraulic steering lines should be checked for correct hook-up before starting the engine.
L5-1
5. T Port Hose
6. P Port Hose
7. R Port Hose
3. Capscrew With
Rolled Pin
4. End Cover
3. Remove end cover capscrews and washers. Remove capscrew with rolled pin (3, Figure 5-4).
Mark hole location of capscrew with rolled pin on
end cover to facilitate reassembly.
L5-2
L - Left Steering
R - Right Steering
LS - Load Sensing
L05021
2. O-ring
FIGURE 5-6. DUST SEAL REMOVAL
1. Screwdriver
2. Dust Seal
3. Housing
10. Remove O-ring (5), kin ring (6) and bearing assembly (7).
11. Remove ring (8) and pin (9) and carefully push
inner spool out of outer sleeve.
L05021
L5-3
L5-4
7. Bearing Assembly
8. Ring
9. Pin
10. Neutral Position Springs
11. Cardan Shaft
12. Spacer
13. Tube
14. O- ring
15. Distribution Plate
16. Gear Wheel Set
17. O-ring
18. O-ring
L05021
Assembly
NOTE: When assembling the spool and sleeve, only
one of the two possible matching positions of the
spring slots can be used. The reason is that in the other
end of the sleeve and spool (opposite end of the spring
slots) there are three slots in the spool and three holes
in the sleeve. These must be opposite each other on
assembly so that the holes are partly visible through
the slots in the spool, refer to Figure 5-8.
3. Push two curved neutral position springs in between one side of the screwdriver blade and a flat
spring. Repeat for the opposite side. Remove the
screwdriver.
1. Slots
2. Hole
3. Spool
4. Sleeve
L05021
L5-5
5. Thrust Bearing
6. Bearing race
7. Neutral Position
Springs
2. Spool Assembly
L5-6
L05021
L05021
3. O-Ring
4. Housing
L5-7
NOTES
L5-8
L05021
L06021
L6-1
ACCUMULATORS
Removal
1. Insure key switch has been Off for at least 90
seconds to allow accumulator oil to drain back to
tank. Move steering wheel to be certain all pressurized oil is released.
2. Remove charging valve guard (3, Figure 6-2) and
loosen small hex on charging valve (4) three
complete turns. Depress the valve core until all
nitrogen pressure has been relieved.
1. Accumulator
2. Pressure Switch Cover
L6-2
3. Mounting Band
L06021
Disassembly
1. Remove charging valve (3, Figure 6-4).
2. Remove gland (4).
Note: Figure 6-5 illustrates a tool that can be fabricated
locally to aid in removing the gland.
3. Remove plugs and/or adaptor (10 & 11). Using a
round rod, push piston (6) out of accumulator.
4. Remove piston rings (7) and seal (8).
Cleaning and Inspection
1. Clean parts using fresh cleaning solvent, lint free
wiping cloth and filtered compressed air. All parts
must be absolutely free of any foreign matter
larger than 3 microns.
2. Inspect piston for damage. If scored or otherwise
damaged, replace with a new part.
3. Minor defects in the housing bore may be corrected by honing.
a. Measure the bore at several places along the
length of the housing. Make two measurements, 90 apart at each point to verify tube is
not out-of-round.
L06021
7. Bearing
8. T Ring Seal
9. Housing
10. Plug (or Adaptor)
11. Plug
L6-3
TESTING
To carry out the testing required, it will be necessary
to check for internal and external leaks at high pressure. A source of 5000 psi (35 MPa) hydraulic pressure
and nitrogen pressure of 1400 psi (9.65 MPa) will be
required. A small water tank with the necessary safety
guards in place will be necessary for a portion of the
test.
Assembly
4. Pressurize gas end of accumulator with approximately 100 psi (690 kPa) nitrogen pressure to
move piston to bottom of housing.
5. Submerge oil end of assembly in water.
L6-4
L06021
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
6. Valve Body
7. O-ring
8. Valve Stem
9. O-ring
If nitrogen pressure is present in the accumulators, make certain only the small swivel hex nut is
turned during the next step. Turning the complete
valve assembly may result in the valve assembly
being forced out of the accumulator by the nitrogen pressure inside.
3. Remove charging valve cap (1, Figure 6-6). Turn
small swivel hex nut (4) three complete turns
counterclockwise.
4. Depress the valve stem and hold down until all
nitrogen has been released.
5. If a loss in nitrogen pressure is the reason for
recharging, inspect the charging valve and accumulator for damage. Replace or repair items, as
necessary, before charging procedure.
6. Connect the nitrogen charging kit to the charging
valves. Open the regulator and charge the accumulators simultaneously to 1400 psi (9.65 MPa).
NOTE: If a loss in nitrogen pressure occurred during
operation, oil may still be present in the accumulator
below the piston. This oil can be bled off during the
L06021
L6-5
FLOW AMPLIFIER
Removal
Installation
1. Support the flow amplifier and move into position.
2. Install mounting capscrews and tighten to standard torque.
3. Identify hydraulic line location, unplug lines and
connect at proper location. Tighten fittings securely. Use new O-rings on the flange fittings.
L6-6
L06021
L06021
L6-7
Disassembly
1. Remove counterpressure valve plug (17, Figure
6-7), and O-ring (16). Remove counterpressure
valve assembly (15).
2. Remove plug (18) and seal (19). Using an 8 mm
hex allen head wrench, remove the relief valve
assembly (54). Remove steel seal (55).
3. Remove capscrew (35) and capscrews (34) using
a 10 mm and 13 mm hex head allen wrench.
Remove lockwashers (36 & 37). Remove end
cover (39).
4. Remove spring stop (42) and spring (43). Remove
spring stop (32) and springs (30 & 31). Remove
O-rings (38 & 40).
5. Remove spring control (29) and main spool (27).
Remove priority valve spool (44). Remove spring
control (23), springs (21 & 22) and spring stop
(20).
6. Remove amplifier valve spool assembly (53). Set
amplifier valve spool assembly aside for further
disassembly, if required.
7. Remove shock and suction valve (26). Set shock
and suction valve aside for further disassembly, if
required.
8. Remove capscrews (1 & 3) using a 10 mm and 13
mm hex head allen wrench. Remove lockwashers
(2 & 4). Remove end cover (5).
9. Remove O-rings (6, 7 & 8). Remove spring (52).
10. Remove shock and suction valve assembly (12).
Set the shock and suction valve aside for further
disassembly, if required. Remove orifice screw
(13).
3. O-Ring
L6-8
7. Retaining Ring
8. Inner Spool
9. Spring
10. Plug
11. Orifice Plug
L06021
Assembly
1. Thoroughly lubricate each part prior to installation
using clean, type C-3 hydraulic oil.
2. Reassemble the Amplifier spool assembly in reverse order. Refer to steps 12 & 13, and Figure
6-9 under disassembly.
3. Install orifice screw (13, Figure 6-7). Tighten orifice
screw to 4 in. lbs. (.5 N.m) torque.
4. Install check valve (47). Tighten check valve to 8
in. lbs. (1 N.m) torque.
5. Install orifice screw (45). Tighten orifice screw to
8 in. lbs. (1 N.m) torque.
6. Install seal (55) and relief valve assembly (54).
Install seal (19), and plug (18). Tighten plug to 22
in. lbs. (2.5 N.m) torque.
7. Install counterpressure valve assembly (15). Install plug (17) using new O-ring (16).
8. Install both shock and suction valves (12 & 26) as
complete units. Install spring stop (20) springs (21
& 22) and spring control (23). Install orifice screws
(24 & 33) if removed from main spool (27). Install
main spool (27).
L06021
L6-9
STEERING CYLINDERS
Figure 6-10 illustrates details of the steering cylinder
mounting. Refer to Section G for removal and installation instructions.
L6-10
6. Capscrew
7. Lockwashers
8. Retainer
9. Mount Bracket (Frame)
10. Bearing Spacer
11. Bearing
12. Pin
13. Hardened Washer
L06021
1. Housing
2. Locknut
3. Piston
Disassembly
Cylinder Assembly
Test
After cylinder assembly rebuild, perform the following
tests to verify performance is within acceptable limits.
1. Piston leakage must not exceed 1 in3/min. (1.6
cm3/min.) at 2500 psi (17.5 MPa), port to port.
2. Rod seal leakage must not exceed 1 drop in 8
cycles of operation.
3. Piston break-away force should not exceed 100
psi. (69 kPa).
L06021
L6-11
Installation
1. Install a new O-ring on pump mounting flange.
2. Make certain the steering pump splined coupler is
in place (inside hoist pump) prior to steering pump
installation.
L6-12
5. Steering/Brake Pump
6. Pump Mount Bracket
7. Outlet To Filter
L06021
If trapped air is not bled from steering pump, possible pump damage and no output may result.
NOTE: Use only Komatsu filter elements, or elements that meet the Komatsu hydraulic filtration
specification of Beta 12 = 200.
10. Open shut-off valve in steering pump suction line
completely.
11. With the body down and the engine shut-off, fill the
hydraulic tank with clean C-4 hydraulic fluid (as
specified on the truck Lubrication Chart) to the
upper sight glass level.
12. With suction line shut-off valve open, loosen suction (inlet) hose capscrews (at the pump) to bleed
any trapped air. Tighten hose connection capscrews to standard torque.
L06021
L6-13
DISASSEMBLY
L6-14
L06021
L06021
8. Name Plate
9. Plug
10. O-Ring
11. Plate
12. O-Ring
13. Stem
14. O-Ring
15. Gland
16. Jam Nut
17. Pin
18. O-Ring
19. Pin
20. O-Ring
21. Housing
22. Seal Retainer
23. Elbow Fitting
24. Plug
25. O-Ring
26. Seal
L6-15
L6-16
L06021
Rotating Group
Driveshaft Group
28. Remove bearing retaining ring (3, Figure 6-13).
Use a mallet on the tail shaft and tap driveshaft (1)
out from the front of the pump housing.
L06021
L6-17
L6-18
6. O-Ring
7. Capscrew
8. Capscrew
9. Cover Plate
10. O-Ring
11. Valve Plate
12. Gasket
13. Bearing
L06021
Swashblock Group
11. Inspect swashblock (25, Figure 6-14) for
scratches, grooves, cracks or uneven surface.
Replace if defective.
NOTE: The wear face is coated with a gray colored
epoxy based dry film lubricant for break-in purposes.
Scratching or wear of this coating is not detrimental as
long as the metal surface underneath the coating is not
scored or picked-up.
L06021
7. Plug
8. O-Ring
9. Orifice (0.062 in.)
10. Compensator Control Block
11. 4-Way Valve
12. Screw
13. Plug
14. O-Ring
15. Orifice (0.032 in.)
16. Compensator
17. Screw
18. Unloader Module
19. O-Ring
L6-19
Driveshaft Group
ASSEMBLY
Swashblock Group
2. Press or tap roll pin (22, Figure 6-14) into pump
housing (18, Figure 6-13).
4. Press four roll pins (23) into saddle (20) until they
bottom, then press saddle bearing (24) onto the
pins to locate the bearing in the saddle.
Extreme care should be used not to damage saddle bearing surfaces while installing the saddle
into the pump housing.
5. Use a long brass bar and a mallet (or an arbor
press), to install saddle and bearing assembly into
pump housing. Tap or press ONLY on the area of
the saddle that is exposed between the saddle
bearings (DO NOT tap on bearing surfaces). Saddle is fully seated when a distinct metallic sound
is heard when installing saddle into pump housing.
6. Fasten control link (17, Figure 6-14) to swashblock
(25) using link pin (16) and two retaining rings
(14).
7. Be sure the two dowel pins (19), are pressed into
swashblock (25).
8. Insert swashblock into pump housing until it engages in saddle bearing and allow swashblock to
settle to its lowest natural position.
L6-20
3. Gland
4. Jam Nut
L06021
Driveshaft Group
NOTE: Be sure punch marks on cylinder bearing (26,
Figure 6-14) will face toward shaft end of pump.
10. Insert cylinder bearing (26) straight into pump
housing. Be sure bearing is positioned so bearing
retainer pins (14, Figure 6-13) can be inserted in
the case and into the bearing.
11. Install O-rings (18) on pins (17) and install pins.
12. An arbor press is required to install shaft bearing
(2, Figure 6-13) onto driveshaft (1). IMPORTANT
- press ONLY on the inner race of the bearing.
Press bearing until it contacts the shoulder on
driveshaft.
13. Use a long 6 in (153 mm) sleeve with an I.D. slightly
larger than the retaining ring I.D. and press retaining ring (4) towards bearing until it seats in the
groove.
14. Place seal retainer (22) over seal (26) inside the
pump housing (21). Lubricate shaft seal with clean
hydraulic oil.
15. Install entire driveshaft assembly through front of
pump housing. A mallet will be required to install
the driveshaft through shaft seal.
16. Once the driveshaft assembly is fully seated in the
pump housing, install snap ring (3).
Rotating Group
17. Mating surfaces should be greased. Place cylinder
assembly on clean table with the valve plate side
down.
18. During disassembly, shoe retainer springs were
referenced to individual bores. Assemble rotating
group by inserting shoe retainer springs (28, Figure 6-14) into the same spring bores located in
cylinder barrel (10) that they came from.
19. Slide fulcrum ball (12) over the nose of the cylinder
barrel (10).
20. Place shoe retainer (27) over fulcrum ball and align
holes in retainer with corresponding holes
(marked during disassembly) in the cylinder barrel. Once aligned, insert piston/shoe assemblies
(13) into corresponding (marked during disassembly) holes completing the rotating group.
L06021
The assembled rotating group weighs approximately (30 lbs.). Assistance from others and use
of proper lifting techniques is strongly recommended to prevent personal injury.
26. Install seal and piston ring (2 & 3, Figure 6-14) into
their respective grooves on control piston (11)
using care to assure they are in proper location.
27. Insert control piston assembly into sleeve (4).
28. While supporting the control piston, press or slip
in pin (8) and secure with cotter or roll pin (18).
29. Order of piston sleeve seal installation starts at
widest end of sleeve.
30. Install backup ring (1, Figure 6-18) and O-ring (2)
and back-up ring (3) in rear most groove on piston
sleeve. Install O-ring (4) and back-up ring (5) in
remaining groove.
31. Insert piston and sleeve assembly into valve plate
(11, Figure 6-15). Install O-ring (6) with back-up
ring (5) in seal groove of control cover cap (4).
L6-21
39. Carefully maneuver valve plate assembly, supported by overhead hoist, over driveshaft and into
pump housing so slot on control piston (11) engages control link (17).
40. With hole in control piston lined up with hole in the
link, carefully insert control link pin (16).
4. O-Ring
5. Back-Up Ring
L6-22
L06021
TROUBLESHOOTING CHART
(Steering Circuit)
POSSIBLE CAUSES
Replace pump.
Inspect and replace linkage if necessary. Check alignment or toe-in of the front wheels.
Repair or replace.
TROUBLE: Slip - a slow movement of steering wheel fails to steer front wheels
Leakage of steering cylinder piston seals
L06021
L6-23
POSSIBLE CAUSES
TROUBLE: Free wheeling - steering wheel turns freely with no back pressure. Front wheels do not steer.
Splines of steering column/steering control unit coupling may be disengaged or damaged
2. Ruptured hose
2. Replace hose.
L6-24
L06021
POSSIBLE CAUSES
TROUBLE: Steered wheels turn in opposite direction when operator turns steering wheel
Lines connected to wrong cylinder ports
(Steering Pump)
TROUBLE: No pump output
Air trapped inside steering pump
Restricted inlet
L06021
L6-25
POSSIBLE CAUSES
L6-26
L06021
(Flow Amplifier)
POSSIBLE CAUSES
Disassemble valve, check directional spool and orifices for damage or obstruction.
Disassemble valve, check and clean shock and suction valves. Replace valves if necessary.
L06021
L6-27
NOTES
L6-28
L06021
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
The following information describes the basic hoist
system circuit as shown in Figure 7-1. Detailed component operation is outlined under the individual component descriptions.
Hydraulic fluid is supplied by a tank (1) located on the
left frame rail. The tanks service capacity is approximately 250 gal. (947 l). Hydraulic oil is routed to a
tandem gear type pump (2). A second pump, coupled
to the rear of the hoist pump, supplies oil for the
steering and brake systems. The pumps are driven by
an accessory drive at the end of the traction alternator.
Hoist pump output is directed to a pair of high pressure
filters (3), mounted to the inboard side of the fuel tank.
1. Hydraulic Tank
2. Hoist Pump
3. High Pressure Filter
4. Hoist Pilot Valve
5. Hoist Limit Solenoid
L07023
Hoist Circuit
L7-1
COMPONENT DESCRIPTION
HYDRAULIC TANK
The hydraulic tank supplies hydraulic oil for the hoist,
steering and brake circuits. The tank is located on the
left hand frame rail forward of the rear wheels. The
service capacity of the tank is 250 gal. (947 l). Type
C-4 hydraulic oil is recommended for use in the hydraulic system. Oil used in the hoist circuit flows
through 100 mesh wire suction strainers to the inlet
hoses of the pump. Air drawn into the tank during
operation is filtered by air filters located on the top of
the tank. Oil level can be checked visually at sight
glasses located on the face of the tank.
HYDRAULIC PUMP
The hoist system hydraulic pump is a tandem, gear
type pump driven by a drive shaft on the end of the
traction alternator. The pump has a total output of 246
GPM (931 l/m) at 1900 RPM and 2500 psi (17, 235
kPa).
A smaller, piston type, pressure compensated pump
rated at 66 GPM (250 l/m) @ 1900 RPM, coupled to
the hoist pump, supplies oil to the steering system and
brake apply system.
Hoist pressure is limited to 2500 psi (17,235 kPa) by
internal relief valves located in the hoist control valve
inlet sections.
5. Inlet Port
6. Outlet Port
7. Spool Section Cover
8. Separator Plate
HOIST VALVE
The hoist valve (Figure 7-2) is mounted on a modular
assembly containing the hoist valve, overcenter manifold, and both hydraulic pumps. This assembly is
bolted to brackets attached to the frame rails behind
the main alternator.
The hoist valve is a split spool design. (The term split
spool describes the spool section of the valve.) The
hoist valve precisely follows differential pressure input
signals generated by the hoist pilot valve as the operator moves the hoist control lever while raising and
lowering the dump body.
Inlet Sections
Each of the front and rear inlet sections of the hoist
valve contains of the following components:
Flow control valve and main relief valve
Secondary Low pressure relief valve
Anti-void check valve
Load check valve
The flow control portion of the flow control and main
relief valves allow pump flow to the service brake
cooling circuit unless the body is being raised or lowered. The relief portion of the valve is direct acting and
has the capacity to limit the working pressure at full
pump flow.
L7-2
Hoist Circuit
L07023
Spool Sections
Work Ports (Rear) Spool Section
The rear spool section of the hoist valve consists of the
following components:
Pilot ports
Main spools
Work ports
Check poppets
The pilot ports are located in the spool section cover.
These ports provide connections for a pilot line to the
hoist pilot valve. Each work port has a corresponding
pilot port.
L07023
Hoist Circuit
L7-3
BLEEDDOWN MANIFOLD
OVERCENTER MANIFOLD
L7-4
Hoist Circuit
5. Quick Disconnects
6. Steering/Brake Pump
7. Hoist Pump
L07023
L07023
Hoist Circuit
L7-5
L7-6
Hoist Circuit
L07023
L07023
Hoist Circuit
L7-7
L7-8
Hoist Circuit
L07023
L07023
Hoist Circuit
L7-9
L7-10
Both pilot ports (14 & 15) in the pilot valve are closed
by the pilot valve spool. In this condition pressure is
equalized on each end of each main spool (7 & 8)
allowing the springs to center the spools and close all
ports to trap the oil in the cylinders and hold the body
in its current position.
Hoist Circuit
L07023
L07023
Hoist Circuit
L7-11
L7-12
Hoist Circuit
L07023
L07023
Hoist Circuit
L7-13
L7-14
Hoist Circuit
L07023
L07023
Hoist Circuit
L7-15
NOTES
L7-16
Hoist Circuit
L07023
4. Mark, disconnect and cap or plug all line connections to help prevent hydraulic oil contamination,
refer to Figure 8-1.
5. Remove capscrews and lockwashers securing
the hoist valve to its mounting bracket.
L08024
L8-1
O-Ring Replacement
NOTE: It is not necessary to remove the individual
valve sections to accomplish repair, unless emergency
field repair is required to replace the O-rings between
sections to prevent leakage. Loosening and retightening of the main valve tie rod nut could cause distortion
resulting in binding or severely sticking plungers, poppet and spools.
To replace the O-rings between the valve sections:
1. Remove the four tie rod nuts and washers (7,
Figure 8-2) from one end of the valve. Slide the
tie rods from the valve and separate the sections.
Installation
1. Attach a suitable lifting device that can handle the
load safely to the hoist valve. Move the hoist
valve into position and secure in place with capscrews, nuts and lockwashers. Tighten capscrews to standard torque.
L8-2
L08024
8. O-Rings
9. Inlet Valve Body
10. O-Rings
INLET SECTION
Disassembly
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Disconnect the external tube (7, Figure 8-2) at
the cover end and remove. Remove capscrews
(14, Figure 8-5), remove cover (13). Remove
springs (12), check valves (11) and O-rings (10).
NOTE: Inlet section shown removed from main valve
body for clarity.
3. Remove capscrews (1) and cover (2). Remove
springs (3 & 5) and flow control/main relief valve
(4). Remove sleeve (6), low pressure relief (7)
and O-rings (8).
NOTE: If restrictor poppet removal in cover (2, Figure
8-5) is required, refer to step 4 and figure 8-6.
4. Remove sleeve (9), backup ring (8), O-ring (7),
backup ring (6). Remove backup ring (5), O-ring
(4), backup ring (3) and restrictor poppet (2).
5. Repeat steps 1 through 4 for the opposite inlet
section if disassembly is required.
FIGURE 8-6. RESTRICTOR POPPET REMOVAL
(Inlet Cover)
1. Inlet Cover
2. Restrictor Poppet
3. Backup Ring
4. O-Ring
5. Backup Ring
L08024
6. Backup Ring
7. O-ring
8. Backup Ring
9. Sleeve
L8-3
L8-4
3. O-Ring
1. Restrictor Poppet
4. O-Ring
2. O-ring *
5. O-Ring
3. Backup Ring *
* NOTE: Items 2 and 3 not used on all valves.
L08024
L08024
8. O-Ring
9. Restrictor Poppet
10. O-Ring
11. Spring
12. Restrictor Poppet (Red)
13. Spool Housing
14. Spool Assembly
L8-5
Assembly
POPPET COLOR
ORIFICE
DIAMETER
DRILL SIZE
Red
#28
Green
#42
White
#52
L8-6
L08024
3. Work Ports
Spool Section
Assembly
1. Lubricate spools (7, Figure 8-12) with clean hydraulic oil and re-install in their original bores.
Install springs (8).
2. Lubricate O-rings (5 & 6) with clean hydraulic oil.
Install O-rings in bottom of spool housing. Install
bottom cover (9) and secure in place with capscrews. Tighten capscrews to 60 ft. lbs. (81
N.m) torque.
3. Lubricate O-rings (5 & 6) and install in top of spool
housing. Install top cover (4) and secure in place
with capscrews. Tighten capscrews to 60 ft. lbs.
(81 N.m) torque..
4. If removed, install plugs (2) with new O-rings (3).
L08024
L8-7
1. Spool Housing
2. Plug
3. O-RIng
L8-8
4. Spool Cover
5. O-Ring
6. O-Ring
7. Spool
8. Spring
9. Spool Cover
L08024
Installation
L08024
5. Capscrew
6. Cotter Pin
7. Control Cable
8. Jam Nut
9. Sleeve
10. Pin
L8-9
Disassembly
1. Thoroughly clean the exterior of the valve. Match
mark components to assure proper reassembly.
L8-10
L08024
Assembly
5. Install tie rods. Install tie rod nuts. Tighten tie rod
nuts to the torques shown in Figure 8-16.
6. Install a new O-ring (27, Figure 8-14) and wiper
(26). Install seal retainer (25).
7. Install spacer (5), spring seats (19), and spring
(4). Thread detent pin (3) into spool (14). Slight
pressure will be required to compress the detent
spring. Tighten detent pin to 84-96 in. lbs. (9-11
N.m) torque. Install spring (20). Carefully install
spool into spool housing.
8. Apply grease to the cross holes of the detent pin
(3) to hold balls (21) and (2).
9. Slide detent sleeve (22) into cap (24) and place
over a punch. Using this punch, depress ball (21)
and insert balls (2) in detent pin cross holes.
10. While holding down on ball (21), slide detent
sleeve (22) and cap (24) as an assembly over the
detent pin (3). Continue to insert detent sleeve
(22) until it contacts spring seat (19).
L08024
4. O-ring
5. Outlet Housing
4. Tie Rod
5. Outlet Housing
L8-11
HOIST CYLINDERS
Removal
L8-12
L08024
Installation
7. Start engine, raise and lower body several times
to bleed air from cylinder. Check for proper operation and inspect for leaks.
8. Service hydraulic tank if necessary.
Install a retaining strap or chain to prevent the
cylinder from extending during handling. The hoist
cylinder weighs approximately 2500 lbs. (1135 kg).
Use a suitable lifting device that can handle the
load safely.
L08024
4. Retainer Ring
5. Bearing
6. Spacer
L8-13
L8-14
L08024
Disassembly
1. If removal of the hoist cylinder eye bearings is
necessary, remove retainer ring (4, Figure 8-19)
and press out bearing (5).
NOTE: As internal parts are exposed during disassembly, protect machined surfaces from scratches or
nicks.
L08024
10. Insert a .50 in. (13 mm) dia. x 53 in. (1350 mm)
threaded rod through the top and through the hole
in the disc. Thread a nut on the bottom end of the
threaded rod below the disc.
11. Screw a lifting eye on the top end of the rod. Attach
it to a lifting device and lift the second and first
stage cylinders out of the housing.
12. Remove lifting tools from the second and first
stage cylinder assembly.
13. Slide the second stage cylinder (2) down inside
the first stage cylinder (3). Remove snap ring (9)
from inside the first stage cylinder.
14. Remove second stage cylinder from first stage
cylinder by sliding it out the top.
15. Remove all old bearings, O-rings, and seals from
the hoist cylinder parts.
L8-15
L8-16
L08024
L08024
3. Plug
4. Check Ball
L8-17
L8-18
L08024
Assembly of Cylinder
1. Install seals (15, Figure 8-20) and bearing (14)
on second stage cylinder. Install bearings (19)
and buffer seal (18), rod seal (20) and rod wiper
(21) on first stage cylinder. Lubricate with clean
hydraulic oil (Type C-4).
12. Lubricate capscrews (1, Figure 8-24) with a lithium base grease. Install capscrews and plate (2)
and tighten to 575 ft. lbs. (780 N.m) torque.
3. Piston
10. Thread two guide bolts 4 in. (100 mm) long in the
end of the rod (1). Install seal (8) on the end of
the rod.
L08024
L8-19
DUMPING PROCEDURE
Raising the Body:
3. On the disabled truck, move the hoist control
lever to power up and then release it to place the
hoist pilot valve in the HOLD position (leave in
this position during entire procedure).
4. Start the engine on the good truck, place the hoist
control in the power down position and increase
engine RPM to high idle to dump the disabled
truck. If the body of the disabled truck fails to
raise, increase the good truck power down relief
pressure as follows:
a. Shut down engine and allow the hydraulic
system to bleed down.
L8-20
L08024
L09008
7. Backup Ring
8. Set Screw
9. Filter Element
10. Bowl
11. Bleed Plug
12. O-Ring
13. Bottom Plug
L9-1
Removal
Installation
2. Remove bleed plug (11, Figure 9-1). Remove bottom plug (13) and drain oil from the housing into
a suitable container.
INDICATOR SWITCH
Take care to avoid contact with hot oil if truck has
been operating. Avoid spillage and contamination!
L9-2
L09008
L09008
6. O-Ring
7. Filter Element
8. Bowl
9. O-Ring
10. Drain Plug
L9-3
Removal
INDICATOR SWITCH
Test Procedure
1. With the key switch Off allow at least 90 seconds
for the accumulators to bleed down.
Installation
1. Install new element (7). Install new O-ring (6) on
bowl.
2. Install bowl on filter head and tighten.
3. Install drain plug (10), and O-ring (9). Tighten bleed
plug (4).
INDICATOR SWITCH
The indicator switch (1, Figure 9-2) is factory preset to
actuate at 35 psid (240 kPa). The switch and warning
light should be routinely tested as a part of the regular
vehicle maintenance program. Refer to Indicator
Switch Test Procedure.
L9-4
L09008
L09008
L9-5
NOTES
L9-6
L09008
Steps indicated in this manner should be recorded on the data sheet for reference.
L10012
If the steering and brake pump has just been installed, it is essential that the steering pump case
is full of oil prior to starting the engine. Refer to
Steering Circuit Component Repair, Steering and
Brake Pump, Section L6 for instructions.
L10-1
Equipment Requirements
The following equipment will be necessary to properly
check-out the hydraulic steering circuit
Hydraulic schematic, refer to Section R.
Two 0-5000 psi (0-35,000 kPa) range calibrated pressure gauges and hoses.
A graduated container marked to measure liquid volume in cubic inches or milliliters.
Pump Pressure Control Adjustments
With the brake system functioning properly and the
parking brake on, proceed as follows:
1. Place selector switch in NEUTRAL, apply the
parking brake and place the Rest switch in the
ON position and the GF Cutout Switch in the
CUTOUT position. Shut down engine and turn
key switch off. Wait 90 seconds for the steering
accumulators to completely bleed down before
opening circuits to take leakage measurements,
to make repairs, or to install or remove a gauge.
1. Stroke Adjustment
3. Compensator Adjustment
2. Unloader Adjustment 4. GPA Port
L10-2
L10012
L10012
L10-3
L10-4
3. O-Ring
4. Relief Valve Adjustment
L10012
Equipment Requirements
The following equipment will be necessary to properly
test the steering circuit shock and suction valves:
Hydraulic schematic, refer to Section R.
Three 0-5000 psi (0-35,000 kPa) range calibrated pressure gauges and hoses.
11. Reset unloader valve to specified unload pressure; back out the unloader valve adjustment
screw completely counterclockwise.
L10012
L10-5
Pressure Checks
1. Install a 0-100 psi (0-1000 kPa) low pressure
gauge at the brake cooling circuit manifold block
(2, Figure 10-4) at the front of the hoist valve (1)
to monitor front brake cooling oil pressure.
2. Install a 0-3500 PSI (0-25,000 kPa) gauge in the
overcenter manifold (4) power down test port
marked TPD located on front face of manifold.
L10-6
Pressure at front and rear brake cooling circuits (3 & 4) should drop to 0 psi (0 kPa)
while body raises.
* Record on Data Sheet
L10012
Adjustment
If hoist relief pressure is incorrect on either gauge, the
corresponding relief valve should be readjusted. Adjust relief valve in rear hoist valve inlet section if the
rear pump section pressure was incorrect and/or adjust the relief valve in front hoist valve inlet section if
the front pump section pressure was incorrect.
1. Capscrew
2. Inlet Cover
3. Spring
4. Main Relief Valve
5. Spring
6. Sleeve
7. Secondary Low
Pressure Valve
8. O-Rings
9. Inlet Valve body
2. Check pressure again, repeating step 2. If necessary, repeat adjustment procedure until correct pressure is attained.
L10012
L10-7
2. Start engine and run at low idle. Allow the accumulators to fill and the steering pump to unload.
3. With the body resting on the frame and engine at
low idle, place hoist lever in the power down
position.
Pressure at the test port TPD on the overcenter manifold should be 1500 75 psi
(10,340 517 kPa).
* Record on Data Sheet
Adjustment
1. If power down relief pressure is not within specifications, adjust as follows:
a. Remove cap from power down relief valve (2,
Figure 10-6).
1.) To increase power down relief pressure, turn
adjusting screw in (clockwise).
L10-8
2. Relief Valve
L10012
1. Loosen locknut on adjustment stem of counterbalance valve (2, FIGURE 10-8) (Labeled CBV
on manifold). Turn adjustment stem fully clockwise to start adjustment procedure so counterbalance valve pressure is as low as possible.
Note: Turning adjustment stem in (clockwise) decreases the pressure. Turning the stem out (counterclockwise) increases the pressure. Complete valve
adjustment range is 3 turns.
L10012
L10-9
L10-10
L10012
The following procedures involve raising and lowering the dump body. Be certain adequate clearance is available before raising body to the full
up position.
10. Reduce engine speed to 1000 RPM and perform
the following:
In all of the following UP exercises, as the second stage starts out of the hoist cylinder in the
POWER UP mode, slowly decrease engine speed
to prevent sudden bottoming of the cylinders. Severe damage to the hoist cylinders may occur if
this precaution is not followed.
L10012
L10-11
NOTES
L10-12
L10012
UNIT NUMBER
SERIAL NUMBER
STEP 5____________ Bleeddown solenoid, steering relief, and piloted check valve leakage.
SHOCK AND SUCTION VALVES TEST
L10012
L10-13
UNIT NUMBER
SERIAL NUMBER
Operate hydraulic system to obtain proper operating temperature. Refer to Check-out Procedures.
BRAKE COOLING CIRCUIT TEST
STEP 1 ____________ Hoist pump outlet pressures, low idle, FLOAT position.
____________ Brake cooling circuit pressure, low idle, FLOAT position.
STEP 2 ____________ Brake cooling circuit pressure, low idle, POWER UP/DOWN position.
STEP 3 ____________ Brake cooling circuit pressure, 1500 RPM, HOLD/FLOAT position.
STEP 4 ____________ Brake cooling circuit pressure, 1500 RPM, POWER UP/DOWN position.
L10-14
L10012
SECTION M
OPTIONS AND SPECIAL TOOLS
INDEX
FIRE CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKFIRE ELECTRIC DETECTION & ACTUATION SYSTEM - SERIES 1
ANSULFIRE CONTROL SYSTEM, MANUAL . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . .
Recharging Procedures . . . . . . . . . . . . . . . . . . . . . . . . .
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M2.3-1
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M5-1
M5-1
M5-2
M5-3
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.
.
.
.
.
.
.
.
.
.
.
.
.
M9-1
M9-1
M9-2
M9-2
M9-4
M9-7
M9-18
M9-19
M13-1
M13-1
M13-1
M13-3
M13-3
M13-3
M01034 03/01
Index
M1-1
NOTES
M1-2
Index
M01034 03/01
M02003
M2.3-1
Actuator (Figure 2.3-3): Provides automatic and manual means of fire suppression system actuation. By
pulling the ring pin under the knob and then depressing
the red knob, the puncture pin will rupture the diaphragm in the actuator and apply the system. Automatically, the squib is fixed to rupture the cartridge disc
when the linear detection wire is exposed to temperatures in excess of its rated range.
M2.3-2
Squib (Figure 2.3-7): Is an electrically detonated component containing a small exact charge of powder.
When the actuation circuit is closed by the linear detection wire melting, an internal wiring bridge in the
squib heats up causing the power charge to detonate,
forcing the puncture pin to rupture the cartridge disc
to release the nitrogen gas charge.
M02003
NOTE: Remember to leave closed blank plug connection on the last length of detection wire.
When making connection, push plug into receptacle until a "click" is heard (Figure 2.3-8). Plugs
and receptacles are keyed to allow insertion only
in one direction. After "click" is noted, apply a
small amount of back pull to confirm connection
has been made.
M02003
M2.3-3
c. Proceed to the end of the last length of detection wire and remove the jumper assembly
(Figure 2.3-12). Finally, put original plugged
blank connector onto detection wire. The test
module light should immediately go out. If light
does not go out refer to "Troubleshooting".
d. Remove the test kit from the system by, first,
disconnecting the squib connector from the
test module (Figure 2.3-14). NOTE: Retain
these components for possible later use.
! CAUTION !
Remove jumper assembly. Otherwise, fire suppression system will discharge when squib is installed
in Electric Detection And Actuation System.
FIGURE 2.3-11. INSTALL JUMPER
2. The Linear Detection Wire
a. Using the furnished text kit, proceed to the end
of the last length of detection wire. Remove the
plugged blank connector (Figure 2.3.11) and
install the jumper assembly.
NOTE: Retain plugged connector to be reinstalled
after testing is completed.
b. With jumper in place, screw squib connector
into receptacle on test module (Figure 2.3-12).
Test module light should immediately illuminate. This test confirms that the wire is properly
installed and will function as designed. If test
module light does not illuminate on test module, refer to the "Troubleshooting" section.
M2.3-4
M02003
FIGURE 2.3-15.
FIGURE 2.3-16.
M02003
M2.3-5
4. Weigh the actuation cartridge on the Electric Detection and Actuation System. Replace cartridge
if the weight is 1/4 oz. (7 g) less than that stamped
on cartridge. Check the cartridge threads for
nicks, burrs, cross threading and rough on feathered edges. Examine gasket in bottom of Electric
Detection and Actuation System for elasticity. If
the temperature is below freezing, warm the gasket with body heat to insure a good seal. Clean
and coat lightly with a high heat resistant silicone
grease.
Daily
The machine operator should manually test system
power by pushing the button and noting illumination of
indicator light. This confirms battery power is available.
If light is not illuminated, refer to "Troubleshooting"
covered in this section.
Normal Maintenance Based On Actual Operating
Hours
Total system should be checked monthly or sooner,
depending on working conditions or truck maintenance to perform total system check.
NOTE: The squib should be replaced after being
in service for five years. The proper disposal of
the old squib should be done by actuating the
squib within the actuator body. To do this, remove
actuator LT-5-R cartridge (PB0674) from body.
Install test jumper assembly to end of linear detection wire assembly. This jumper will service as
a wiring short and cause the squib to discharge.
Remove jumper, clean actuator, install new squib
and reinstall cartridge.
System is now back in service.
5. Test system power by depressing button on control module. Note illumination of light while button
is depressed.
a. Check for wear due to abrasion (at wall penetrations, around corners, etc.).
b. Check for damage from direct impact or other
abuse.
c. Check mounting locations for tightness.
d. Insure mounting hardware has not come loose
or been broken, either of which would allow the
wire to sag.
M2.3-6
M02003
10. Remove the test kit from the system by disconnecting the squib connector from the test module
(Figure 2.3-21).
Failure to remove jumper assembly will cause system discharge when squib is installed into Electric
Detection and Actuation System.
11. Remove squib from actuator body and check that
it has not been fired. Reinstall squib and wrench
tighten firmly.
12. Reinstall squib connector to squib and firmly
tighten by hand.
13. Pull ring pin on Electric Detection and Actuation
System actuator and push pin several times to
insure smooth movement. Reinstall ring pin and
attach lead wire seal.
FIGURE 2.3-20. ATTACH INDICATOR LIGHT ASSY.
(Test Module)
If test module light does not illuminate, refer to
"Troubleshooting" covered in this section.
9. Proceed to the end of the last length of detection
wire and remove the jumper assembly. Put original plugged blank connector back on detection
wire. Test module light should immediately go out.
If light does not go out, refer to "Troubleshooting"
covered in this section.
IN CASE OF FIRE
Procedure to follow during and after a fire. In the event
of a fire, the following steps should be taken:
1. Turn the machine "Off".
2. Manually activate fire suppression system, if possible.
3. Move away from the machine taking a hand portable extinguisher along if you can.
4. Stand-by with a portable fire extinguisher to put out
any possible re- ignition of the fire after the fire
suppression system is expended.
Explanation of the above steps.
1. If you leave the machine running, it may add fuel
to the fire or restart the fire with sparks.
2. May help put fire down more quickly.
3. By leaving the immediate fire area, you protect
yourself from windblown flames, explosions or
other dangers created by the fire.
M02003
M2.3-7
What to Expect
When a fire suppression system discharges, there is
some noise, accompanied by clouds of dry chemical.
While breathing foreign particles is not pleasant, the
agent is non-toxic.
What to Do After the Fire is Out
The machinery should not be restarted until it has been
serviced and cleaned (water spray or steam may be
used to remove the dry chemical). If the Electric Detection and Actuation System cannot be recharged immediately, at least recharge the remainder of the fire
suppression system so that manually actuated protection is available.
Recharging the Electric Detection and Actuation
System
The recharge of the Electric Detection and Actuation
System is similar to the original procedure for installing
and placing the automatic detection system into service. Follow these procedures as outlined previously in
this manual, omitting the section which deals with
mounting the bracket and power wire.
Replace the entire length(s) of detection wire involved
in the fire area.
Before the system is put back into service, it is important that the inside chamber of the actuator be cleaned
thoroughly. Failure to do so may cause excessive
carbon build-up on the internal O-ring and piston
chamber. This build- up will also stop the puncture pin
from returning to its upmost position.
To clean actuator (See Figure 2.3-22):
1. Remove squib.
2. Remove actuator from bracket and loosen upper
portion of body.
3. Apply pressure to the bottom of the puncture pin.
This will force out the puncture pin and spring.
M2.3-8
M02003
Dead battery
Reconnect
Wire broken
Dead battery
M02003
M2.3-9
NOTES
M2.3-10
M02003
Operation
91461
M02004
5. Actuator Receiver
6. Cartridge
7. Bursting Disc Union
8. Dry Chemical Tank
91462
M2-1
Recharging Procedures
After actuating the fire control system, the system
should be recharged. Follow the procedure below for
each dry chemical tank and actuator installed:
1. Relieve the pressure from the lines by pulling the
ring on the safety relief valve.
2. Disconnect line from tank actuator and remove line
from the bursting disc union.
M2-2
7. Install the fill cap and tighten the cap hand tight.
M02004
M05002 10/96
M5-1
M5-2
6. Cover
7. Spring
8. Steel Ball
9. Valve Assembly
M05002 10/96
1. Hydraulic Tank
2. Filler Hose
7. Refueling Box
8. Capscrew
9. Tapped Bar
NOTE: This Illustration Represents a Typical Installation. Installation may vary depending on truck model.
M05002 10/96
3. Frame Rails
4. Fuel Tank
M5-3
NOTES
M5-4
M05002 10/96
SPECIAL TOOLS
PART NO.
DESCRIPTION
USE
EB1759
NItrogen Charging
Kit
Suspension &
Accumulator
Nitrogen Charging
PART NO.
DESCRIPTION
USE
EF4875
Roll-Out Assembly
Power Module
Removal &
Installation
PART NO.
DESCRIPTION
USE
TG1106
WA4826
Misc. lifting
requirements
M08012 9/99
Special Tools
M8-1
M8-2
PART NO.
DESCRIPTION
USE
PB8326
Miscellaneous &
Cab Mounting
PART NO.
DESCRIPTION
USE
TZ2734
3/4" Female
Adapter
Torque Wrench
Extension
PART NO.
DESCRIPTION
USE
TZ2733
Tubular Handle
Use with
PB8326 & TZ2734
PART NO.
DESCRIPTION
USE
BF4117
Seal Installation
Tool
ED3447
Seal Installation
Tool
Rear Axle/Hub
Adaptor Floating
Ring Seal
Installation
Special Tools
M08012 9/99
PART NO.
DESCRIPTION
USE
EH4638
Alignment Sleeve
Steering Linkage
& Tie Rod
Assembly.
Refer to Section
G.
PART
NO.
DESCRIPTION
USE
EF9302
Indicator Assembly
Measure Brake
Disc Wear
Refer to Section
J.
PART NO.
DESCRIPTION
USE
Electrical Harness
Payload Meter II
Download
Refer to
Section M,
Payload Meter.
EF9160
M08012 9/99
Special Tools
M8-3
PART NO.
ED8860*
DESCRIPTION
USE
Engine Turning
To Rotate
Tool
Engine Crankshaft
(MTU Engine Only)
NOTE:
To use this tool for the MTU/DDC 4000 Series Engine,
it must be used with the locally made Adapter Plate.
* This tool may also be acquired as MTU Part Number
F6 555 766.
PART NO.
DESCRIPTION
USE
Engine Turn-over
ED8860
Tool for MTU/DDC
To Rotate
w/Adapter
4000 Series
Engine Crankshaft
Plate
Engine
NOTE: To use the MTU engine turn-over tool for the
MTU/DDC 4000 Series Engine, it must be used with the
locally made Adapter Plate as shown here.
Remove screen/cover plate on the bottom of the engine
flywheel housing at the 5 or 7 oclock position.
Install assembly and use 1/2" drive wrench in driver
socket (4) to turn engine.
1. Adapter Plate
M8-4
Adapter Plate
USE
Use with ED8860
Engine Turning Tool
as shown above.
Special Tools
M08012 9/99
M08012 9/99
Special Tools
M8-5
DESCRIPTION
24**
72
5. Install the remaining capscrews, and progressively increase the torque in a circular pattern until
the tapered piston breaks loose, or the specified
1580 ft. lbs. torque on the 1.25" capscrew is
reached.
6. If the specified torque is reached and the tapered
piston is still not loose, apply heat at 2 places
(180 opposite) to the spindle.
Do not exceed 850F saturated temperature of
the spindle.
7. Tighten capscrews again to the maximum specified torque, and using a large hammer and heat
at the specified locations, carefully tap the spindle
on the top surface.
M8-6
Special Tools
M08012 9/99
M08012 9/99
Special Tools
M8-7
NOTES
M8-8
Special Tools
M08012 9/99
M09010 6/97
6. Temperature Sensor
7. Evaporator
8. Expansion Valve
9. Suction Line
M9-1
(HFC) refrigerant, commonly identified as HFC-134a, is being used in most current mobile air conditioning systems. Additionally, the practice of releasing either refrigerant to the atmosphere during the charging/recharging procedure is now prohibited.
These new restrictions require the use of new equipment and new procedures which are significantly different from
those traditionally used in air conditioning service techniques. The use of new equipment and techniques allows for
complete recovery of refrigerants, which will not only help to protect the environment, but through the re-cycling
of the refrigerant will preserve the physical supply, and help to reduce the cost of the refrigerant.
PRINCIPLES OF REFRIGERATION
Mining and construction vehicles have unique characteristics of vibration, shock-loading, operator changes,
and climate conditions that present different design
and installation problems for Air Conditioning systems.
Off-highway equipment, in general, is unique enough
that normal automotive or highway truck engineering
is not sufficient to provide the reliability to endure the
various work cycles encountered.
M9-2
Too frequently, the operator and the serviceman overlook the primary fact that no A/C system will function
properly unless it is operated within a completely controlled cab environment. The circulation of air must be
a directed flow. The cab must be sealed against seepage of ambient air. The cab interior must be maintained
for cleanliness, dust, and dirt which, if picked up in the
air system, will clog the intake side of the evaporator
coil.
AIR CONDITIONING
Air conditioning is a form of environmental control. As
applied to the cab, it refers to the control of temperature, humidity, cleanliness, and circulation of air. In the
broad sense, a heating unit is as much an air conditioner as is a cooling unit. The term Air Conditioner
is commonly used to identify an air cooling unit. To be
consistent with common usage, the term Air Conditioner will refer to the cooling unit utilizing the principles of refrigeration; sometimes referred to as the
evaporator unit.
M09010 6/97
In an air conditioning system, the refrigerant is circulated under pressure through the five major components in a closed circuit. At these points in the system,
the refrigerant undergoes predetermined pressure and
temperature changes.
The compressor (refrigerant pump) takes in low pressure heat laden refrigerant gas through the suction
valve (low side), and as its name indicates, pressurizes
the heat laden refrigerant and forces it through the
discharge valve (high side) on to the condenser.
Ambient air, passing through the condenser removes
the heat from the circulating refrigerant resulting in the
conversion of the refrigerant from gas to liquid.
The liquid refrigerant moves on to the filter-receiver
drier where impurities are filtered out, and moisture
removed. This component also serves as the temporary storage unit for the liquid refrigerant.
The liquid refrigerant, still under high pressure, then
flows to the expansion valve. This valve meters the
amount of refrigerant entering the evaporator. As the
refrigerant passes through the valve, it becomes a low
temperature, low pressure liquid and saturated vapor.
The remaining low pressure liquid immediately starts
to boil and vaporize as it approaches the evaporator.
This causes the refrigerant to become cold. The hot,
humid air of the cab is pulled through the evaporator
by the evaporator blower. Since the refrigerant is
colder than the air, it absorbs the heat from the air
producing cool air which is pushed back into the cab.
The moisture in the air condenses upon movement into
the evaporator and drops into the drain pan from which
it drains out of the cab.
The cycle is completed when the heated low pressure
gas is again drawn into the compressor through the
suction side.
This simplified explanation of the principles of refrigeration does not call attention to the fine points of refrigeration technology. Some of these will be covered in
the following discussions of the components, controls,
and techniques involved in preparing the unit for efficient operation.
M09010 6/97
M9-3
SERVICE VALVES
Quick-connect hose end fittings with integral service
valves attach to system service ports for servicing the
unit. A manifold gauge set is connected into the system
at the service valve ports and all procedures, such as
discharging, evacuating and charging the system, are
performed through the service valves.
CONDENSER
The condenser receives the high pressure, high-temperature refrigerant vapor from the compressor and
condenses it to high pressure, hot liquid.
RECEIVER-DRIER
The receiver-drier is an important part of the air conditioning system. The drier receives the liquid refrigerant
from the condenser and removes any moisture and
foreign matter present which may have entered the
system. The receiver section of the tank is designed to
store extra refrigerant until it is needed by the evaporator. The storage of this refrigerant is temporary and
is dependent on the demand of the expansion valve.
A desiccant is a solid substance capable of removing
moisture from gas, liquid or solid. It is held in place
within the receiver between two screens, which also
act as strainers. Sometimes it is simply placed in a
metal mesh or wool felt bag. Filtering is accomplished
by a separate strainer screen on the pickup tube.
Some sytems may utilize an accumulator instead of a
receiver-drier. If an accumulator is used, an expansion
(fixed-orifice) tube is used instead of the thermostatic
expansion valve described below. When used, the
expansion tube is located inside the inlet tube of the
evaporator and is used to restrict, but still allow a
continuous flow of refrigerant to the evaporator coil.
Ram air condensers depend upon the vehicle movement to force a large volume of air past the fins and
tubes of the condenser. The condenser is usually located in front of the radiator or on the roof of the truck.
M9-4
M09010 6/97
EVAPORATOR
The evaporator cools and dehumidifies the air before
it enters the cab. Cooling a large area requires that
large volumes of air be passed through the evaporator
coil for heat exchange. Therefore, a blower becomes
a vital part of the evaporator assembly. It not only draws
heat laden air into the evaporator, but also forces this
air over the evaporator fins and coils where the heat is
surrendered to the refrigerant. The blower forces the
cooled air out of the evaporator into the cab.
Heat exchange, as explained under condenser operation, depends upon a temperature differential of the air
and the refrigerant. The greater the temperature differential, the greater will be the amount of heat exchanged
between the air and the refrigerant. A high heat load
condition, as is generally encountered when the air
conditioning system is turned on, will allow rapid heat
transfer between the air and the cooler refrigerant.
The change of state of the refrigerant in and going
through the evaporator coil is as important as that of
the air flow over the coil.
M09010 6/97
M9-5
ELECTRICAL CIRCUIT
COMPRESSOR CLUTCH
THERMOSTAT
An electromagnetic clutch is used on the compressor
to provide a means of constant temperature control of
the cab. The clutch is controlled by a thermostat in the
evaporator which is set initially by the driver to a predetermined point. Coil temperature is then maintained
by the cycling action of the clutch.
The thermostat is simply a thermal device which controls an electrical switch. When warm, the switch is
closed; when cold, it is open. Most thermostats have a
positive OFF position as a means to turn the clutch OFF
regardless of temperature.
The bellows type thermostat has a capillary tube connected to it which is filled with refrigerant. The capillary
tube is attached to the bellows inside of the thermostat.
Expansion of the gases inside the capillary tube exerts
pressure on the bellows, which in turn closes the contacts at a predetermined temperature.
M9-6
M09010 6/97
SYSTEM SERVICING
Servicing an air conditioning system really means
closely monitoring refrigerant flow. For this reason,
the following procedures deal extensively with the
proper use, handling, care and safety factors involved
in the R-134a refrigerant quality and quantity in an air
conditioning system.
Because the refrigerant in an air conditioning system
must remain pressurized and sealed within the unit to
function properly, safety is a major consideration when
anything causes this pressurized, sealed condition to
change. The following warnings are provided here to
alert service personnel to their importance BEFORE
learning the correct procedures. Read, remember, and
observe each warning before beginning actual system
servicing.
NOTE: If the mine operates a fleet with some trucks
using R-12 and others using R-134a refrigerant, it is
essential that servicing tools that come into contact
with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one
type refrigerant only, to prevent cross contamination.
Although accidental release of refrigerant is a remote possibility when proper procedures are followed, the following warnings must be observed
when servicing AC systems:
Provide appropriate protection for your eyes (goggles or face shield) when working around refrigerant.
A drop of the liquid refrigerant on your skin will
produce frostbite. Wear gloves and exercise extreme care when handling refrigerant.
If even the slightest trace of refrigerant enters in
your eye, flood the eye immediately with cool water
and seek medical attention as soon as possible.
M09010 6/97
2. 60 Pound Cylinder
M9-7
M9-8
M09010 6/97
3. Service Hose
Connection
SERVICE VALVES
VACUUM PUMP
M09010 6/97
M9-9
M9-10
M09010 6/97
Shut off engine. DO NOT attempt to connect servicing equipment when the engine is running.
This gauge hook-up process will be the same, regardless of the gauge set being installed. Whether it is a
recovery station or individual gauges, the connections
are the same. The procedures performed next will vary
depending what type of equipment is being used. If a
recovery/recycling station is being used, complete
servicing can be accomplished. Using only a set of
gauges will limit the servicing to only adding refrigerant
or observing pressures.
M09010 6/97
M9-11
M9-12
M09010 6/97
Do not open high side hand valve. High side system pressure is greater than refrigerant container.
Serious personal injury may result if the container
explodes.
Use hand valve to regulate low side reading during
charging. DO NOT EXCEED 40 psi maximum.
Exceeding this pressure may cause compressor
failure.
M09010 6/97
M9-13
6. Start the recovery process by operating the equipment as per the manufacturers instructions.
7. Continue extraction until a vacuum exists in the AC
system.
8. If an abnormal amount of time elapses after the
system reaches 0 psi and does not drop steadily
into the vacuum range, close the manifold valves
and check the system pressure. If it rises to 0 psi
and stops, there is a major leak.
9. Check the system pressure after the recovery
equipment stops. After five minutes, system pressure should not rise above 0 gauge pressure. If
the pressure continues to rise, restart and begin
the recovery sequence again. This cycle should
continue until the system is void of refrigerant.
10. Check the sight glass oil level to determine the
amount of oil that needs to be replaced. (The
amount of oil that was lost during the recovery
cycle must be replaced back into the system).
11. Mark the cylinder with a RECOVERED (red) magnetic label to reduce the chance of charging a
system with contaminated refrigerant. Record the
amount of refrigerant recovered.
M9-14
M09010 6/97
M09010 6/97
In its natural state, refrigerant is a harmless, colorless gas, but when combined with an open flame,
it will generate toxic fumes (phosgene gas), which
can cause serious injuries or death.
NOTE: The refrigerant is heavier than air and will move
down when it leaks. Apply pickup hose or test probe
on the undersurface of all components to locate leak.
Electronic leak detector
(Refer to Figure 9-4). As the test probe is moved into
an area where traces of refrigerant are present, a visual
or audible announcement indicates a leak. Audible
units usually change tone or speed as intensity
changes.
M9-15
Tracer dyes
SYSTEM REPAIR
M9-16
M09010 6/97
Receiver-Drier
The receiver-drier can not be serviced or repaired. It
should be replaced whenever the system is opened for
any service. If the receiver-drier has a pressure switch
to control the clutch, it should be removed and installed
on the new unit.
Thermostat
A thermostat can be stuck open or closed due to
contact point wear or fusion. The thermostat temperature sensing element (capillary tube) may be broken or
kinked closed and therefore unable to sense evaporator temperature.
When thermostat contact points are stuck open or the
sensing element can not sense temperature in the
evaporator, the clutch will not engage (no AC system
operation). Causes are a loss of charge in the capillary
tube or a kink, burned thermostat contact or just no
contact. When troubleshooting, bypass the thermostat
by hot wiring the clutch coil with a fused lead. If the
clutch engages, replace the thermostat.
Thermostat contact points may be fused (burned)
closed and the clutch will not disengage. Causes are a
faulty switch that could be due to fatigue. The thermostat must be replaced. When the clutch will not disengage you may also note that condensate has frozen on
the evaporator fins and blocked air flow. There will also
be below normal pressure on the low side of the
system. Side effects can be compressor damage
caused by oil accumulation (refrigeration oil tends to
accumulate at the coolest spot inside the system) and
lower than normal suction pressure that can starve the
compressor of oil.
Clutch
Clutch problems include electrical failure in the clutch
coil or lead wire, clutch pulley bearing failure, worn or
warped clutch plate or loss of clutch plate spring temper. Defective clutch assembly parts may be replaced
or the whole assembly replaced. If the clutch shows
obvious signs of excessive heat damage, replace the
whole assembly.
The fast way to check electrical failure in the lead wire
or clutch coil is to hot wire the coil with a fused lead.
This procedure enables you to bypass clutch circuit
control devices.
Sometimes it may be necessary to use shims or enlarge the slots in the compressor mounting bracket to
achieve proper alignment.
Excessive clutch plate wear is caused by the plate
rubbing on the clutch pulley when the clutch is not
engaged or the clutch plate slipping when the clutch
coil is energized. A gap that is too small or too large
between the plate and clutch pulley or a loss of clutch
plate spring temper are possible causes. The ideal air
gap between the clutch pulley and the clutch plate is
0.022 to 0.057 in. If the gap is too wide, the magnetic
field created when the clutch coil is energized will not
be strong enough to pull and lock the clutch plate to
the clutch pulley.
Compressor
The compressor can fail due to shaft seal leaks (no
refrigerant in the system), defective valve plates, bearings, other internal parts or problems associated with
high or low pressure, heat or lack of lubrication. Be sure
the compressor is securely mounted and the clutch
pulley is properly aligned with the drive pulley.
Use a mechanics stethoscope to listen for noises
inside the compressor.
CHECKING COMPRESSOR OIL LEVEL
Every air conditioning system and compressor depends on refrigeration oil for lubrication and safe operation.
Refrigerant oil is a synthetic oil very susceptible to high
levels of water absorbtion. Always be sure the oil is an
approved type for use in the air conditioner compressor.
Refrigerant oil, under normal circumstances inside the
sealed system, cannot go anywhere, and there is no
need to check the oil at such times. Always keep a cap
on an oil container except when in use. Moisture is
quickly absorbed by the oil.
Whenever a system is opened for service, the compressor oil level should be checked and clean refrigeration oil added as required by the manufacturers
specifications (usually located on compressor).
M09010 6/97
M9-17
M9-18
3. Vacuum Pump
M09010 6/97
TROUBLESHOOTING
PRE-DIAGNOSIS CHECKS
If the system indicates Insufficient cooling, or no cooling, the following points should be checked before
proceeding with the system diagnosis procedures.
NOTE: If the truck being serviced is a Model 930E, be
certain the Rest Switch in the cab is ON. Place the GF
Cutout Switch in the CUTOUT position. (Refer to Fig.
3-1, Page E3-2, Propulsion System, for switch location.)
PREPARING FOR DIAGNOSIS
Successfully servicing an air conditioning system, beyond the basic procedures outlined in the previous
section, requires additional knowledge of system testing and diagnosis.
A good working knowledge of the manifold gauge set
is required to correctly test and diagnose an air conditioning system. An accurate testing sequence is usually
the quickest way to diagnose an internal problem.
When correctly done, diagnosis becomes an accurate
procedure rather than guesswork.
Compressor Belt - Must be tight, and aligned.
Compressor Clutch - The clutch must engage. If
it does not, check fuses, wiring, and switches.
Oil Leaks - Inspect all connection or components
for refrigeration oil leaks (especially in the area
of the compressor shaft). A leak indicates a
refrigerant leak.
Electrical Check - Check all wires and connections for possible open circuits or shorts. Check
all system fuses.
Note: Some systems use different safety devices in the
compressor circuit to protect the compressor. Check
the thermal fuse, the low pressure cutout switch, high
pressure cutout switch or trinary pressure switch if
equipped.
Cooling System - Check for correct cooling system operation. Inspect the radiator hoses, heater
hoses, clamps, belts, water pump, thermostat
and radiator for condition or proper operation.
Radiator Shutters - Inspect for correct operation
and controls, if equipped.
Fan and Shroud - Check for proper operation of
fan clutch. Check installation of fan and shroud.
M09010 6/97
M9-19
M9-20
M09010 6/97
1. Charge System
2. Performance Test System
Leaks Found:
1. If a leak is present at a connection, tighten the
connection, then add refrigerant as required.
2. If a system component needs to be replaced, recover all refrigerant from the system. Replace
the defective part, then check the compressor
oil level; refill compressor oil as necessary.
3. Evacuate system.
4. Charge system with new / recycled refrigerant.
5. Check A/C operation and do system
performance test.
TROUBLE: Little or No Cooling
Indications:
Low side pressure VERY LOW
High side pressure VERY LOW
Discharge Air Warm
No bubbles observed in sight glass,
may show oil streaks.
M09010 6/97
M9-21
Leaks Found:
M9-22
Repair Procedure:Test for leaks, especially around the compressor shaft seal area. When the leak is found,
recover refrigerant from the system and repair
the leak. Replace the receiver-drier or accumulator because the desiccant may be saturated
with moisture. Check the compressor and replace any refrigerant oil lost due to leakage.
Evacuate and recharge the system with refrigerant, then check AC operation and performance.
M09010 6/97
Repair Procedure: Test for leaks, recover refrigerant from the system and repair the leak. Depending on the type of system, replace the
receiver-drier or accumulator. Check and replace any compressor oil lost due to leakage.
Evacuate and recharge the system, then check
AC operation and performance.
M09010 6/97
M9-23
Cause- There could be a kink in a line, or other restriction in the high side of the system.
M9-24
M09010 6/97
Compressor Malfunction
Indications:
Gauge Reading- Low Side High
High Side Low
The compressor may be noisy when it
operates.
Cause- Defective reed valves or other compressor
components. If the compressor is not noisy, there
may be a worn or loose compressor clutch drive belt.
Repair Procedure: If the belt is worn or loose, replace or tighten it and recheck system performance and gauge readings. If inspection of the
compressor is required, all of the refrigerant
must be recovered and the compressor disassembled to the point that inspection can be performed. Replace defective components or
replace the compressor. If particles of desiccant are found in the compressor, flushing of
the system will be required. It will also be necessary to replace the receiver-drier. Always check
the oil level in the compressor, even if a new
unit has been installed. Rotary compressors
have a limited oil reservoir. Extra oil must be
added for all truck installations. Tighten all connections and evacuate the system. Recharge
the air conditioner with refrigerant and check
the system operation and performance.
M09010 6/97
M9-25
M9-26
M09010 6/97
COMPONENT
Maintenance Interval
(months)
3
12
Done
COMPONENT
1. COMPRESSOR
Maintenance Interval
(months)
3
Check mounting
bracket (tighten bolts)
Check alignment of
clutch w/crankshaft
pulley (within 0.06 in.)
Perform manifold
gauge check
Verify clutch is
engaging
2. CONDENSER
Inspect condensate
drain
6. OTHER Components
Check discharge lines
(hot to touch)
Inspect fittings/clamps
& hoses
Check thermostatic
switch for proper operation
3. RECEIVER - DRIER
Replace if system is
opened
M09010 6/97
Done
4. EXPANSION VALVE
12
M9-27
NOTES
M9-28
M09010 6/97
BATTERY
During operation, the storage batteries function as an
electrochemical device for converting chemical energy
into the electrical energy required for operating the
accessories when the engine is shut down.
M13002 2/99
M13-1
Idle batteries should not be allowed to stand unattended. If equipment is to stand unused for more than
two weeks, the batteries should be removed and
placed in a cool, dry place where they may be checked
periodically and charged when necessary. Remember, all lead-acid batteries discharge slowly when not
in use. This self discharge takes place even though the
battery is not connected in a circuit and is more pronounced in warm weather than in cold.
M13-2
Specific Gravity
Corrected to 80F (27C)
Freezing
Temperature
Degrees
1.280
-90F (-70C)
1.250
-60F (-54C)
1.200
-16F (-27C)
1.150
+5F (-15C)
1.100
+19F (-7C)
TABLE I
M13002 2/99
General Description
The Niehoff model N1227 or C609 (Figure 13-1) is a
heavy duty, 24 VDC unit rated at 220 amps. A solid
state voltage regulator (6) mounted externally on the
end housing assembly provides voltage control during
operation. A single output connection (5) is located on
the face of the control unit (4) for connection to the
truck battery positive circuit. The ground circuit cable
can be attached to either of two terminals (10) located
on the front housing. A fan guard (7) protects maintenance personnel from the rotating fan when the engine
is operating.
Most 24 volt charging system problems can be diagnosed with the alternator installed on the truck, operating under normal conditions. Many problems can be
attributed to loose or corroded cable connectors. It is
essential that all battery charging circuit cables are in
satisfactory condition and all connections are clean
and securely tightened.
Equipment Required:
Belt tension scale
Voltmeter, 0 - 40 volt range
Ammeter, 0 - 400 amp range
M13002 2/99
6. Voltage Regulator
7. Fan Guard
8. Cooling Fan Assembly
9. Mounting Lugs
10. Ground Terminals
M13-3
Test Procedure
Preliminary Checks
1. Check the drive belt tension as follows:
a. Apply 20.9 lbs. (9.5 kg) force at center of belt
span.
If voltmeter reading exceeds 30.5 volts, stop engine immediately and refer to Table II.
4. Inspect the wiring for defects. Check all connections for tightness and cleanliness. Remove and
clean battery cables.
5. If truck is equipped with a battery equalizer system, verify proper operation of equalizer and individual battery voltages. Refer to Battery
Equalizer, Section D.
Test Setup
2. As the batteries approach full charge, the amperage should fall as voltage rises.
3. When amps and volts readings stabilize, note
readings and refer to Table II to diagnosis system
condition.
AMPS
VOLTS
DIAGNOSIS
LOW
HIGH
NORMAL
HIGH
HIGH
LOW
LOW
LOW
NORMAL
LOW
HIGH
HIGH
M13-4
M13002 2/99
M13002 2/99
M13-5
M13-6
10. Screw
11. Control Unit
12. Screw
13. Rotor
14. Shaft & Core
15. B+ Bolt Assembly
16. Retainer Ring
17. Nut
18. Front Stator
19. Stud
20. Shell
21. Pan Head Screw
22. Field Coil
23. Rear Stator
24. Rotor
25. Rear Bearing
26. Screw
27. Voltage Regulator
M13002 2/99
NO VOLTAGE OUTPUT
No drive belt.
No link from R terminal to energize (E) terminal on alternator when engine operating.
Defective regulator.
Defective alternator.
NOTE: Until electrical system component temperatures stabilize, these conditions may be observed during cold start voltage tests.
Maintenance type:
Immediately after engine start, system volts are
lower than regulator setpoint with medium amps.
3-5 minutes into charge cycle, higher system volts
and reduced amps.
5-10 minutes into charge cycle, system volts are
at, or nearly at, regulator set point, and amps are
reduced to a minimum.
M13002 2/99
M13-7
High amps would be 50 to 75 amps for a Group8D, and 25 to 35 amps for a Group-31 size. High
amperage rates over a short period of time (2-3
hrs.) can severely damage any battery by overheating the battery and causing thermal runaway.
The battery, in effect, forgets its state of charge
and will accept all amps offered. The electrolyte
solution is boiled off as the battery moves into an
excessive gassing stage.
DEFINITIONS
NOTE: Charge voltage and amp rates vary from battery type to battery type, based on battery construction
technology and physical size of battery.
M13-8
M13002 2/99
GO TO ALTERNATOR
Test for battery B+ voltage (__________V)
at B+ terminal on alternator:
If there is no B+ voltage on B+ terminal,
repair VEHICLE wiring as necessary.
Continue test.
If B+ voltage is present on B+ terminal,
continue test.
Remove strap between R and E terminal.
Connect a 12 gauge jumper wire from the B+ terminal
on alternator to the E terminal on alternator.
M13002 2/99
M13-9
GO TO R TERMINAL ON ALTERNATOR
M13-10
M13002 2/99
TABLE OF CONTENTS
DIMENSIONS....................................................................................................................................................... M3-2
M13003 04/01
M13-1
ALTERNATOR DIMENSIONS
1. Mounting Bolt - 1/2 UNC; 45 ft.lbs. (61 N.m) torque
2. Mounting Bolt - 12/50 Dia; 65 ft.lbs. (88 N.m) torque
3. Ground Bolt, 3/8 - 16; 11 ft.lbs. (15 N.m) torque
Either Side; R.H. side shown
4. Locknut (5/16 - 18 UNF-2B) & Washer (to secure Pulley)
5. Voltage Regulator
6. Fan Nut; 50 ft.lbs. (68 N.m) torque
7. Slip Bushing
8. Allowable Mounting Bracket Dimensional Span
9. F+ Stud (NOTE: F+ Stud Not On All Models)
FASTENER DESCRIPTION
TORQUE SPECIFICATIONS
SAE
METRIC
Pulley Nut
162.7 Nm
Heat Sink, Cover Plate, Control Box Hold Down & Relay Terminal Screw
20 in. lbs.
2.3 Nm
20 in. lbs.
2.3 Nm
Ground Bolt
11 ft. lbs.
15 Nm
18 in. lbs.
2.0 Nm
18 ft. lbs.
24.4 Nm
45 ft. lbs.
61.0 Nm
11 ft. lbs.
15 Nm
Output Nut
20 22 ft. lbs.
27.1 29.8 Nm
60 70 in. lbs.
6.8 7.9 Nm
32 in. lbs.
45 in. lbs.
3.6 Nm
5 Nm
Fan Nut
50 ft. lbs.
67.8 Nm
8 10 in. lbs.
.9 1.1 Nm
M13-2
M13003 04/01
ALTERNATOR SPECIFICATIONS
VOLTS.............................................................24VDC
AMPS ................................................................... 240
GROUND ................................................. NEGATIVE
REGULATOR STEPS .............................................. 2
REGULATOR SETTINGS ......................... 27.6 / 28.6
WEIGHT ............................................ 65 lbs. / 29.3 kg
M13003 04/01
M13-3
SERVICE PARTS
REF.
NO.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
9.a
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
20.a
20.b
20.c
21.0
22.0
23.0
24.0
25.0
25.a
25.b
25.c
25.d
25.e
25.f
26.0
27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
PART
NO.
BF3715
BF1997
EF3527
BF1966
BF1989
BF1968
BF1988
BF1990
BF1970
BF3712
BF2002
BF1969
BF1972
BF1971
BF3716
BF1995
BF1996
BF3717
BF3718
BF3720
BF1973
BF1974
BF1975
BF3713
BF1992
BF1991
BF3719
BF3721
BF1976
BF1977
BF1980
BF1981
BF1978
BF1979
BF3722
BF3723
BF1982
BF1983
BF3724
BF1962
BF3714
BF1985
BF2003
BF2004
BF1961
BF3725
QTY.
1
1
1
1
1
1
1
15
1
1
18
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
12
9
1
1
9
1
1
1
1
18
9
1
1
2
1
1
1
1
1
1
3
DESCRIPTION
LOCKNUT (1)
FLAT WASHER (1)
PULLEY
BUSHING, PULLEY
RING, RETAINER (1)
BEARING, FRONT
RING, RETAINER (1)
SCREW, PAN HEAD - #8 - 32NC X 3/8" (1)
PLATE, COVER
HOUSING, FRONT
NUT - (SPECIAL)
COVER, CONTROL UNIT
TERMINAL, OUTPUT
CONTROL UNIT
BOLT (+) - 5/16" - 18NC X 3/4"
LOCKWASHER - 5/16" (1)
FLAT WASHER (1)
LOCKWASHER (1)
CAPSCREW - 1/2" - 13NC X 1" (1)
KEY WOODRUFF (1)
SHAFT/CORE/ROTOR ASSEMBLY
ROTOR ASSEMBLY
SHAFT/CORE ASSEMBLY
RING, RETAINING
LOCKWASHER (1)
CAPSCREW - 3/8" - 16NC X 5/8" (1)
CAPSCREW - #10 - 32NF X 1/2" (1)
NUT - #8 - 32NC (1)
SHELL/STATOR/FIELD ASSEMBLY
STATOR, FRONT
STUD
SHELL (2)
BUSHING, TENSION
COIL
STATOR, REAR
SCREW, PAN HEAD - #6 - 32NF X 3/8" (1)
NUT - #8 (1)
HOUSING, END
BEARING, REAR
SCREW, LOCK - #10 - 32NC X 5/8" (1)
REGULATOR
O-RING
FAN
FLAT WASHER (HARDENED) (1)
LOCKNUT - 1/4" - 20NF (1)
GUARD, FAN
SCREW, SOCKET HEAD - #10 - 32NF X 7/8" (1)
M13-4
M13003 04/01
ALTERNATOR PARTS
Refer to previous page for Parts List.
M13003 04/01
M13-5
ON-VEHICLE TEST
Equipment:
Belt Tension Gauge
Voltmeter, 0 - 40 Volt range
Ammeter, 0 - 400 Ampere range
Preliminary Checks:
1. Check Belt Tension.
Use Belt Tension Gauge to measure belt tension:
Poly V Belt Adjustment (20 lbs./strand):
240 lbs. maximum for 12 groove Poly V-belt.
2. Check Battery.
Batteries must be in good condition and fully
charged. If any battery condition is marginal, it
should be replaced with one known to be in good
condition.
For split battery pack, dual voltage systems, battery rest voltages should agree within 0.3 V.
When "12V" battery voltage is more than 0.3 V
lower than "24V" battery voltage, check the "12V"
battery circuit to verify adequate charge.
Polarity of battery and alternator must agree;
reverse polarity will damage the alternator.
The alternator is NEGATIVE ground.
3. Check electrical connections in charging circuit.
Make sure all connections are clean, tight, and
free of corrosion. Battery connections are especially important.
4. Check Energize circuit.
If alternator is not charging, check for voltage at
the alternator energize terminal. Refer to Figure
13-1 for energize terminal location on the outside
of the control box. Check for battery voltage at the
"E" terminal with engine running.
1. Alternator
2. Voltmeter
FIGURE 13-1.
3. Ammeter
4. Battery
Test Set-up
5. Discharge Battery as Follows:
a. Disable fuel system.
b. Turn all lights and accessories "ON". Crank the
engine for 10 15 seconds to discharge battery, then stop cranking engine.
c. Turn all lights and accessories off.
d. Enable fuel system.
6. Determine setpoints of regulator.
The setpoint of the alternator is 28V.
Normal range is within 0.2V of setpoint.
M13-6
M13003 04/01
VOLTS
DIAGNOSIS
LOW
HIGH
LOW
HIGH
LOW
HIGH
FACTORY
SETTING
NORMAL
RANGE
27.5
27.2 - 27.8
28.0
27.7 - 28.3
ON-VEHICLE TEST
Bypass Test:
Disconnect plug between alternator and regulator and
momentarily touch F- terminal from alternator plug
to ground.
M13003 04/01
FIGURE 13-3.
1. F+ Stud (some units have F+ Stud & Phase taps)
M13-7
BENCH TEST
VOLTS
DIAGNOSIS
Equipment:
Test Bench, with 15 20 Hp motor
set up to drive alternator to 7000 RPM.
Voltmeter, 0 40 Volt Range
Ammeter, 0 400 Amp Range
HIGH
LOW
HIGH
HIGH
LOW
LOW
HIGH
VOLTS
DIAGNOSIS
HIGH
LOW
LOW
HIGH
LOW
HIGH
Alternator connections and load same as test 2. Bypass regulator as shown in Figure 13-3. Note whether
amps rise to within +/- 10% of output rating when
connecting F- terminal to ground. Note whether amps
fall when disconnecting F- terminal. Then refer to
Table 13-5 below.
DIAGNOSIS
Amps Rise
Amps Fall
Alternator is OK.
See note, replace
regulator only if low
AMPS/low VOLTS
indicated in Test 1
and/or Test 2.
No Change
No Change
Alternator must be
repaired. Go to Static
Tests.
M13-8
M13003 04/01
STATIC TESTS
Static tests are performed on the partially disassembled alternator to confirm component failure
indicated by on-vehicle test or bench tests.
EQUIPMENT:
Ohmmeter, Simpson 260 or equivalent
Regulator Tester, or Ohmmeter
Diode Tester or Ohmmeter
Remove control box cover and drive pulley. Disconnect regulator from control unit. Remove cover plate.
Disconnect all phase leads attached to the front housing (P1 through P6 in Figure 13-6).
NOTE: Refer to disassembly procedures in Alternator
Disassembly section of this manual. Before repairing
the alternator, perform all static tests.
REGULATOR TESTS
Wire 4 to Ignition or B+
Refer to regulator tester manufacturers instructions
for test procedure.
If regulator tester is not available, it is difficult to test
regulator for open output transistor. However, most
regulator failures are caused by shorted output transistor, so the following procedure utilizing an ohmmeter, will often suffice when a regulator tester is not
available.
TEST 1 Check For Shorted Output Transistor
Set ohmmeter to x100 scale and make sure ohmmeter
is zeroed. Using the regulator connector plug, connect
one ohmmeter lead to terminal F-, connect to other
lead to terminal B-, and observe meter reading.
Reverse leads and observe meter reading. In one
direction the meter should read less than 600 ohms.
In the other direction the ohmmeter should read very
high. If ohmmeter reads zero in both directions, output
transistor is shorted and regulator must be replaced.
M13003 04/01
FIGURE 13-4.
1. Ignition (E)
5. F+ (Harness Lead #3)
(Harness Lead #4)
6. Ground Wire from Reg.
2. Relay (R)
(Harness Lead #2)
3. Terminal Block
7. B+ Buss Leads to
4. F- (Harness Lead #1)
Rectifier
M13-9
F-
GND* (B-)
VERY
HIGH
x1
F-
(F-) PIN
ZERO
x1
F+
(F+)
TERMINAL
ZERO
M13-10
FIGURE 13-6.
1. Positive Diode Studs 2. "S" Phase Terminal
NOTE: Heat sink diodes are de-rated for heavy duty
performance. If diode failure is detected, the entire
charging system should be examined for loose connections (especially battery). If diode failure is indicated, stator failure must also be suspected.
M13003 04/01
STATOR TESTS
NOTE: The front stator related Phase leads are P1,
P2, & P3; The rear ststor phase leads are P4,
P5, & P6
The Alternator has two separate assemblies that will
be checked individually. Make sure all phase leads are
disconnected from the heat sink (Refer to Figure 13-6).
Reverse ohmmeter leads, and again observe resistance between B+ terminal and each of the six heat
sink phase terminals S. All six readings should be
very high. If any reading is not alike, the diode rectifier
assembly is defective and the front housing assembly
must be replaced.
M13003 04/01
M13-11
ALTERNATOR DISASSEMBLY
Notes: Disassemble alternator only as far as necessary to replace defective part(s).
For stator removal, refer to BF4822 Stator Service Tool
Instructions.
In this publication, Front Housing refers to the Drive
End Housing, and Rear Housing refers to the opposite
end housing.
REGULATOR REMOVAL
1. Disconnect regulator from alternator harness.
2. Remove mounting hardware from regulator
mounting feet (Figure 13-9).
3. Remove regulator.
FAN REMOVAL
1. Remove fan guard.
2. Use a 3/4 socket wrench to loosen nut attaching
fan to alternator. Keep shaft from rotating by
holding the pulley in a vise, jaws padded with
brass or aluminum (Figure 13-7).
3. Remove nut and hardened washer.
4. Remove fan assembly from alternator.
FIGURE 13-9.
FIGURE 13-7.
PULLEY REMOVAL
1. Use a 15/16 socket wrench on the pulley nut.
Clamp the pulley in a vise, jaws padded with
brass or aluminum, and loosed pulley nut (Figure
13-8).
2. Remove pulley nut and hardened washer.
3. With a gear puller remove the pulley from the
shaft.
4. Remove woodruff key from shaft.
5. Remove pulley bushing from shaft.
FIGURE 13-8.
M13-12
M13003 04/01
FIGURE 13-12.
1. Machine Screws
Alternate Method
2b. Using an air hammer (air chisel) with a blunt
tipped tool, vibrate the area around the rotor
element to rotor core attaching studs. The vibrations should loosen any built up rust in that area.
Remove the rotor element.
If resistance is still felt, use the method described
in 2a., plus the air hammer.
FIGURE 13-10.
REAR ROTOR REMOVAL
1. Remove six flanged locknuts from core studs or
six self tapping screws (1, Figure 13-11). Scribe
location of stud or screw holes on rotor face plate.
FIGURE 13-11.
1. Self-Tapping Screws
2a. Use three 10-32 UNF x 2 long machine screws
as jacks in the three threaded holes of rotor end
plate (Figure 13-12). Pull rotor off of core gradually by working screws against core in sequence.
If rotor resists movement, see alternate method
below.
M13003 04/01
M13-13
FIGURE 13-13.
1. Cover
3. Front Cover Screw
2. Field Leads (white wires)
M13-14
M13003 04/01
FIGURE 13-15.
1. Cover Screws (TOP) 2. Control Unit Screw
M13003 04/01
M13-15
FIGURE 13-17.
1. Jack Screws
FIGURE 13-16.
1. Flanged Locknuts or Screws
2a. Use three 10-32 UNF x 2 long machine screws
as Jacks in the three threaded holes of rotor end
plate (Figure 13-17). Pull rotor off core gradually
by working screws against core in sequence.
Alternate Method
2b. Using an air hammer (air chisel) with a blunt
tipped tool, vibrate the area around the rotor
element to rotor core attaching studs. The vibrations should loosen the built up rust in that area.
Remove the rotor element. If resistance is still felt,
use the method described in 2a. above, plus the
air hammer.
FIELD COIL REMOVAL
M13-16
FIGURE 13-18.
1. Bobbin Removal Tool 2. Stator & Shell Assembly
(BF4820)
M13003 04/01
ALTERNATOR ASSEMBLY
FIELD COIL ASSEMBLY
1. Lay stator and shell assembly on its side, phase
leads to the left (Figure 13-20).
2. Insert field coil from right hand side of stator and
shell assembly, field leads (white wires with
spade terminals) facing toward phase leads.
1. Field Leads
FIGURE 13-19.
FIGURE 13-20.
2. Remove or Insert
Field Coil from this end.
3. As field coil is inserted into stator and shell assembly thread the field leads through the proper openings between the front stator windings.
M13003 04/01
M13-17
FIGURE 13-21.
1. Field Coil Bobbin Ear
FIGURE 13-23.
1. Retaining Ring (Tapered)
2. Front Housing
3. Retaining Ring (Flat, both sides)
4. Bearing - Outer Race
FIGURE 13-22.
M13-18
M13003 04/01
4. Using tool BF4818 and a press, press front bearing into front housing until bearing seats against
retaining ring (Figure 13-24). Outer ring will be
installed after housing is placed on shaft.
FIGURE 13-24.
1. Tool BF4818
FRONT ROTOR ASSEMBLY
1. Position rotor assembly on front end of shaft and
core assembly.
Note: Front end of shaft and core assembly has
woodruff key slot in shaft (Figure 13-25).
1. Shaft
FIGURE 13-25.
3. Slot
1. Arbor Press
FIGURE 13-26.
2. Tool BF4810
M13003 04/01
M13-19
1. Field Leads
FIGURE 13-28.
2. Phase Leads
M13-20
FIGURE 13-27.
3. Field Leads
4. Drain Holes
M13003 04/01
1. Field Leads
FIGURE 13-29.
2. Phase Leads
M13003 04/01
FIGURE 13-31.
1. Cover Screws (TOP) 2. Control Unit Screw
Tighten nine screws to 20 in.lbs. (2.3 N.m) torque.
7. Position the insulating sleeving over wire terminals prior to attaching ring terminals to E & R
(or phase terminals) studs.
NOTE: Assembly sequence for E & R terminal (or
phase terminals) is: insulator-flat washer-terminal-nut.
M13-21
FIGURE 13-33.
1. Ring Seal Groove
5. Ring Seal
2. Ring Seal
6. Ring Seal Groove
3. Bearing
7. Fan Mounting Hardware
4. O-Ring
8. Fan Guard Screws
FIGURE 13-32.
1. Studs or Screws
M13-22
M13003 04/01
To use new service parts on product manufactured before the modification date, follow these
instructions:
Fan Replacement (Fan with Ring Seal)
Remove the fan and rear bearing seal. Remove
the old fan assembly from the alternator.
FIGURE 13-35.
1. Ring Seal Groove
4. Fan Mounting Hardware
2. Bearing
5. Fan Guard Screws
3. Bearing Seal
Shaft/Core Replacement
Remove old shaft/core assembly. Remove the
shaft/core assembly from alternator (as directed
in this publication). Remove the front seal from
the old end housing.
FIGURE 13-36.
1. BF4821 Insertion Tool placed here.
M13003 04/01
M13-23
REGULATOR ASSEMBLY
FIGURE 13-38.
1. Ball Bearing
2. Shaft
3. Support
4. Bushing
FIGURE 13-37.
5. Front Housing
6. End Housing
7. BF4821 Insertion Tool
M13-24
M13003 04/01
FAN ASSEMBLY
PULLEY ASSEMBLY
FIGURE 13-39.
1b. When repairing units manufactured before June
1994, the ring seal and contact seal must be
removed before installing the fan (Refer to Figure
13-34).
2. Use hardened washer and locknut to fasten fan
to alternator. Place alternator and pulley into vise.
With a 3/4 socket, tighten fan nut (Figure 13-39).
Torque fan nut to 50 in. lbs. (68 N.m).
Note: Brass or aluminum jaw protectors must be inserted into vise jaws to prevent damage to pullley.
M13003 04/01
FIGURE 13-40.
M13-25
M13-26
8. Lift the top thrust plate up and off the guide pin.
Turn the top thrust plate so that the guide pin does
not re-enter the slot.Lower the top thrust plate and
allow it to rest on top of the guide pin.
9. Lubricate approximately 1 of the jack screw
where it enters the pressure plate with white lube
or a wheel bearing type of grease. Also place a
dab of this grease on both sides of the thrust
washer that is placed under the hex head of the
jack screw.
10. Position the stator leads so that they will not snag
on the pressure plate when the pressure plate is
being inserted into, then through, the stator. Bend
the stator leads over the top of the support ring
(this will help to eliminate interference).
11. Wrap a clean shop towel around the jack screw
and lift the pressure plate/jack screw/top thrust
plate assembly. Insert the pressure plate into and
through the top stator assembly. Position the
pressure plate in the space between the two
stators, where the field coil had been. Turn the
pressure plate to align the poles of the pressure
plate with the poles of the stator. This is easily
done by grasping both the jack screw and guide
pin and twisting. The pressure plate will then
rotate. Before releasing the assembly, make sure
the top thrust plate will once again rest on the end
of the guide pin, not the support ring.
12. Position the stator leads inside the support ring.
Firmly grab the top thrust plate at the outer edge,
twist slightly until the guide pin enters the curved
slot. Lower the top thrust plate onto the support
ring. The top of the support ring should enter the
mating groove in the top thrust plate.
13. Thread the jack screw in, until the head of the jack
screw contacts the top thrust plate.
14. Look through the large diameter holes (torque arm
holes) in the thrust plate to confirm the proper
seating of the pressure plate steps against the
stator. Adjust the pressure plate as necessary.
NOTE: The pressure plate is properly seated when the
outer edge of the pressure plate presses against the
field coil mounting tabs on the stator. Make sure that
ALL field coil mounting tabs are in contact with the
pressure plate.
15. Continue threading the jack screw in, until significant resistance is felt. Check position of the pressure plate again.
M13003 04/01
16. If the tool assembly attempts to rotate after significant resistance is felt, insert torque arm into
the large diameter holes in top thrust plate and
use torque arm to prevent tool assembly from
rotating. Continue threading jack screw in until
stator is removed from shell, observe caution
below.
CAUTION:The movement of the stator should be
checked often during stator removal process. Use
the exposed portion of the guide pin as an indicator of stator movement. Tension on the removal
tool will abruptly cease when the stator is free of
the shell. The service technician may be startled
by this abrupt looseness, exposing the technician
to potential injury. Keep the stator service tool vertical. Do not use the tool laying on its side.
FIGURE 13-41.
1. Bottom Thrust Plate
5. Locating Rod (long)
2. Stator Indexing Pins
6. . Locating Pin
3. Guide Pin
7. Locating Rod (short)
4. Jack Screw
8. Pressure Plate
M13003 04/01
M13-27
FIGURE 13-42.
1. Top Thrust Plate
5. bottom Thrust Plate
2. Support Ring
6. Torque Arm
3. Stator & Shell Assy.
7. Front Stator
4. Support Ring
8. Rear Stator
M13-28
M13003 04/01
PAYLOAD METER II
M20-6
M20-6
M20-6
M20-7
M20-7
M20-7
M20-8
M20-8
M20-12
M20-12
M20-12
M20-12
M20-12
M20-12
M20-13
M20-13
M20-13
M20-14
M20-14
M20-14
M20-14
M20-14
M20-15
M20007 10/00
Payload Meter II
M20-17
M20-17
M20-17
M20-17
M20-18
M20-18
M20-1
M20-28
M20-28
M20-28
M20-29
M20-30
M20-2
Payload Meter II
M20007 10/00
PAYLOAD METER II
ON BOARD WEIGHING SYSTEM (OBWS)
GENERAL INFORMATION
The Payload Meter II On Board Weighing System
displays and records the payload weight along with
other operating information. The system consists of a
payload meter, pressure sensors, deck mounted lights
and an inclinometer.
The payload meter (Figure 20-1) uses the four suspension pressures and an inclinometer to determine the
load in the truck. The payload weight can be displayed
in short tons or metric tons.
There are three external deck-mounted lights on each
side of the truck. The lights indicate payload weight
divided into three separate stages. A forecast feature
will flash a deck mounted light predicting the payload
weight if the next bucket of material is dropped into the
body.
M20007 10/00
Payload Meter II
M20-3
7. Total/Shift Switch
Payload
Date & Time
Cycles
8. Light/Increment Switch
Travel Distance
9. Memory Card
Used to receive data from the payload meter
memory to this card which can then be used to
transfer the data into a personal computer. This
enables the memory to be downloaded and saved
when a personal computer is not available.
10. Cover
Protective cover for the Memory Card. Do not
open or place foreign objects in slot.
5. Mode Switch
This switch is used to select the mode or system
that will allow a function to be performed.
This may include:
Various settings or corrections to the display
Memory card downloading
Clearing data
Display of Abnormalities or Warnings
Setting the speed limit
Setting the date and time
6. Calibration/Clear Switch
Used to calibrate the machine when the conditions regulate this action.
Also used with the TOTAL/SFT switch to clear
total payload and overall number of cycles.
M20-4
Payload Meter II
M20007 10/00
Any other method will not allow the payload system to register properly.
* Do not activate the Lamp Test switch during
loading. Inaccurate and inconsistent data may be
stored.
* At the loading area do not release the Brake Lock
(or Park Brake switch) until the loading is complete and the load shock from the last load
dumped has settled.
* The loading area surface must be maintained as
flat and level as possible. The On Board Weighing
System can compensate for slight variations in
grade and unevenness, but ruts, berms, rocks,
etc. will cause the system to record inaccurate
and inconsistent data.
* Regularly remove carryback from the dump body.
* Calibrate periodically.
Green
Amber Green
Off
Off
PAYLOAD WEIGHT
M20007 10/00
Payload Meter II
M20-5
THEORY OF OPERATION
Linkage Factor
Basic Description
The payload meter uses the four suspension pressures and the inclinometer to determine the load in the
truck. These inputs are critical to the calculation of the
load. The other inputs to the payload meter (Body Up,
Speed, Brake Lock, Alternator R Terminal, and Engine
Oil Pressure) are used to indicate where the truck is in
the haul cycle. These inputs enable the payload meter
to make time and distance measurements for the haul
cycle.
The suspension pressures are the key ingredients in
determining the sprung weight of the truck. These
pressures are converted into forces using the formulas
shown below. These forces are combined with the
geometry of the truck to produce the load calculation.
It is critical that the suspension pressure sensors are
functioning properly.
Sprung Weight =
2
Suspension Diameter (Psi Left + Psi Right)
4
Figure 20-3.
M20-6
Payload Meter II
M20007 10/00
Brake Lock
Number Data
Description
10
11
12
13
14
15
16
3.9
M20007 10/00
Payload Meter II
M20-7
These calculations used a 13" front suspension diameter and 10" rear suspension diameter.
2
Suspension Diameter (Psi Left + Psi Right)
4
Front Weight
Front Weight
100.70
Rear Weight
113.70
Total Weight
214.40
1.00
214.40
- Calibration (13)
-70.60
Current Load(15)
143.80
2. Month:Day of Calibration
XX:XX
Psi
Psi
Psi
Psi
Tons
Tons
Nose Up Positive
1. Year of Calibration
Sprung Weight =
Units
75.10
Tons
1.53
113.70
4. Press MODE once and "CHEC" will
flash on the display.
5. Press MODE once and the meter will return to
normal operation.
Figure 20-5.
M20-8
Payload Meter II
M20007 10/00
ITEM
UNIT
RANGE
REMARKS
1 - 65535
Number
Month
Month
1 - 12
Day
Day
1 - 31
Time Hour
Hour
24 Hour Clock
Time Minute
Minute
Payload
Metric tons
Short tons
0 - 6553.5
Minute
0 - 6553.5
Miles/Km
0 - 25.5
Mph/Kmh
0 - 99
Mph/Kmh
Minute
0 - 6553.5
Minute
0 - 6553.5
Minute
0 - 6553.5
1 - 59
0 - 99
Miles/Km
0 - 25.5
Mph/Kmh
0 - 99
Mph/Kmh
0 - 99
Minute
0 - 6553.5
Dumping Time
Minute
0 - 6553.5
Speed Limit
Mph/Kmh
M20007 10/00
Payload Meter II
0 - 99
M20-9
UNIT
RANGE
REMARKS
1 - 65535
Number
Year
0 - 99
Month
Month
1 - 12
Day
Day
1 - 31
Time Hour
Hour
24 Hour Clock
Time Minute
Minute
0 - 59
Year
0 - 99
Month
Month
1 - 12
Day
Day
1 - 31
Time Hour
Hour
24 Hour Clock
Time Minute
Minute
Total Payload
Metric tons
Short tons
Number
0 - 59
0 - 999900.0
0 - 9999
The engine operation numbers are included in the fault and warning data.
ITEM
Error Code
UNIT
RANGE
Number
1 - 65535
Number
1 - 255
Year
0 - 99
Month
1 - 12
Day
1 -31
Hour
24 Hour Clock
Minute
0 - 59
M20-10
REMARKS
Payload Meter II
M20007 10/00
Engine Operation
ITEM
UNIT
RANGE
REMARKS
Number
1 - 65535
Year
0 - 99
Month
1 - 12
Month
Day
Day
1 - 31
Time Hour
Hour
24 Hour Clock
Minute
0 - 59
Time Minute
NOTE: If the engine operation number is a 0, this indicates that the problem occurred or was canceled (depends on
the operation that was performed) when the key switch was in the ON position and the engine was not running.
UNIT
RANGE
REMARKS
0 - 999900.0
0 - 9999
Total Payload
Metric Tons
Short Tons
Digital Number
Year
0 - 99
Month
Month
1 - 12
Day
Day
1 - 31
Time Hour
Hour
24 Hour Clock
Time Minute
Minute
0 - 59
Other Data
CONTENT
ITEM
Calibration Data
M20007 10/00
UNIT
RANGE
Km/MPH
REMARKS
0 - 99
Digital Number
0 - 13
Year
Year
0 - 99
Month
Month
1 - 12
Day
Day
1 - 31
Hour
Hour
24 Hour Clock
Minute
Minute
Payload Meter II
Communication Mode
0 - 59
M20-11
OPERATOR FUNCTIONS
This memory location is separate from the main payload data storage. This memory is not cleared when
the Data All Clear Operation is performed. Clearing
this memory does not affect the main payload data
storage.
Clearing this memory does not affect the main payload data storage.
M20-12
Payload Meter II
M20007 10/00
Position
4*
4 - 685E
5 - 630E
B - 730E
C - 930E
D - 530M
E - 330M
Switch Settings
F - 830E
5
DOWN
DOWN
UP
Figure 20-6.
M20007 10/00
Payload Meter II
M20-13
Setting "PL:00"
1. Press and hold the LIGHT/INC and MODE
switches. The display will show.
2. Press and hold the LIGHT/INC and TOTAL/SFT
switches.
The display will show.
3. Press the CAL/CLR switch once.
The display will show.
4. Press the CAL/CLR switch once.
The display will show.
Setting "UP:00"
Refer to "Calculation Method" for instructions to display truck pitch angle. With truck on level ground,
properly charged suspensions, and empty the display
should indicate 0.0 1.0. Remember this is not a live
display. After adjustment, Service Check Mode must
be entered again to obtain a new reading.
M20-14
Payload Meter II
M20007 10/00
Calibrating a Truck
The payload meter should be calibrated whenever one
of the following occurs:
1. When a new payload meter is installed.
2. When a suspension sensor has been changed.
3. Whenever the suspensions have been serviced
or the Nitrogen levels have changed.
4. Once a month thereafter.
To calibrate the payload meter:
1. With the engine running and the truck stopped,
press and hold the CAL/CLR switch until "CAL" is
flashing on the display.
2. Drive the truck until the speed is approximately
6-10 MPH (10-15 Km/H)
3. Press the CAL/CLR switch once.
4. Drive until the display switches back to the time
of day. This will take up to 30 seconds.
5. The payload meter is now calibrated and ready
for normal operation.
M20007 10/00
Payload Meter II
M20-15
DISPLAYS AT START-UP
POWER ON:
ALL external display lamps (Figure 20-2) will come on
and stay on for approximately 27 seconds during the
Power-up Process.
Refer to Operator Check Mode, Setting the Option Code and to Method of Operation for more
information on this function.
NORMAL OPERATION
M20-16
Payload Meter II
M20007 10/00
Speed Limit
Option
Code
Stand Alone
10
12
M20007 10/00
NOTES:
COMMUNICATION MODE
Payload Meter II
M20-17
DOWNLOAD OF INFORMATION
M20-18
Payload Meter II
M20007 10/00
C7: Low.
Condition of the Spare Digital Input 2 signal.
The panel will display C8:XX for 3 seconds,
then:
C8:oo High.
C8: Low.
Mechanical trucks
M20007 10/00
Payload Meter II
M20-19
M20-20
Payload Meter II
M20007 10/00
M20007 10/00
Payload Meter II
M20-21
Mechanical Trucks
Hours:Minutes
Psi
Psi
Psi
Psi
6. Front Weight
Tons
7. Rear Weight
Tons
No s e
Positive
C1
Electric Trucks
C2
Body Up
C3
8. Degree of Incline
C4
Alternator R Terminal
C5
C6
C7
C8
C9
Speed
C10
C11
Units
Up
Vehicle Speed
Tons
Tons
Volts
S1:xx - Minutes*10
S4:xx - Minutes*10
S5:xx - Minutes*10
S6:xx - Minutes*10
M20-22
Payload Meter II
M20007 10/00
Memory Storage
PL:10
The PL mode setting can have a significant impact on
the perceived accuracy of the payload meter.
PL:00 is the only recommended setting.
Use of settings other than PL:00
is NOT recommended.
M20007 10/00
Payload Meter II
M20-23
Gear Ratio
Remarks
00
31.875
Original
01
36.400
High Traction
02
28.125
Standard
03
26.625
High Speed
M20-24
Payload Meter II
M20007 10/00
M20007 10/00
Payload Meter II
M20-25
M20-26
Payload Meter II
M20007 10/00
Installation
Installation
1. Install inclinometer (3, Figure 20-13) with capscrews, nuts and lockwashers (4).
2. Install new O-ring on adapter (3) and install complete adapter/sensor assembly into valve (2).
Hold valve body and tighten adapter/sensor assembly to 103 ft.lbs. (176 N.m) torque.
3. Connect sensor wiring to truck wiring harness.
The sensors have three wires. Be sure that wires
are connected correctly. (Figure 20-12)
Wire Color
Wire Function
Black
Ground (GND)
Red
+ Power
White
Signal
INCLINOMETER
As the truck is tilted fore or aft, the weight distribution
between the front and rear axles changes. To compensate for this, the inclinometer measures the ground
angle at which the truck rests. This data is then sent
to the payload meter so it can calculate the correct
payload weight. The inclinometer is located below the
operators center console (passenger seat structure).
Wire Color
Wire Function
Black
Ground (GND)
White
Signal
Red
+ Power
Removal
1. Disconnect inclinometer wire lead from harness.
2. Remove the three capscrews, nuts and lockwashers (4, Figure 20-13) and inclinometer (3).
Adjustment
1. Park the truck on a 0% grade.
2. Loosen the three Inclinometer mounting capscrews (4, Figure 20-13) and rotate the Inclinometer until a voltage range of 2.6 0.1 Volts
can be measured (using aVolt/Ohm Meter) at pins
1 and 2 of the inclinometer electrical harness
connector.
3. Tighten all capscrews (4, Figure 20-13) to standard torque, after adjustment.
M20007 10/00
Payload Meter II
M20-27
SCOREBOARD
Description
The Scoreboard from Komatsu Mining Systems uses
information from the Payload Meter to display the
current load. It uses ultra-high-brightness LED technology to form 3 digits. The sign is fully sunlight readable and housed in a rugged steel enclosure.
The Scoreboard displays each swing pass as the truck
is being loaded. As the truck drives away, the sign will
display the last swing pass until the final load calculation is made. It will then switch to display the final load
calculation and hold it until the truck dumps. The sign
will then clear for the empty ride back to the shovel.
Making Connections
The Scoreboard connects to the RS232 port on the
Payload Meter. It must share this connection with other
dispatch systems like Modular Mining as well as the
PC download connection. This sharing of the single
port creates special circumstances when using a Personal Computer or dispatch system.
The Scoreboard is in constant communications with
the Payload Meter and must acknowledge every message from the meter. In addition, the Scoreboard must
also signal the Payload Meter that it is ready to receive
messages by supplying a 5vdc signal over the CTS
line. Installations that include Modular Mining or other
dispatch systems must take over the responsibility for
acknowledging messages from the Payload Meter. To
do this, the return communications line and the CTS
line from the Scoreboard must be cut and taped back.
When this is done, the Scoreboard simply monitors
communications between the Payload Meter and
Modular Mining. The Modular Mining system acknowledges each message from the meter.
Sharing this RS232 port with the Personal Computer
for downloading can also create problems with communications. The Payload Meter can confuse messages from the PersonalComputer and Scoreboard.
To eliminate this problem, the Scoreboard must be
turned off during downloading of the Payload Meter. Using the circuit breaker to turn off the main power
to the Scoreboard is the best way to accomplish this.
The power to the Scoreboard must be turned off before
communications between a Personal Computer and
the Payload Meter can start. Once the download process is finished, the power needs to be restored to the
Scoreboard to keep from receiving F99 or F93 error
codes.
M20-28
Payload Meter II
M20007 10/00
M20007 10/00
Payload Meter II
M20-29
M20-30
Payload Meter II
M20007 10/00
CONNECTIONS
CN1 - AMP MIC-MKII 13 Pins White Connector
No.
Description
Lamp Relay 1
Lamp Relay 2
Comments
Description
RTS
SG
Lamp Relay 3
RD
Lamp Relay 4
TX
Lamp Relay 5
CTS
DTR
DSR
10
Running - 28VDC
Off - 0VDC
11
12
13
No.
Comments
Running Open
Off - Closed
+18V
Sensor GND
1-5VDC Normal
1-5VDC Normal
1-5VDC Normal
Inclinometer
10
Description
Analog Input 1
Analog Input 2
Digital Input 1
Digital Input 2
6
7
11
12
M20007 10/00
Payload Meter II
M20-31
Circuit Description
+18 volt sensor power supply
39FA
39FB
39FC
39FD
39FE
Inclinometer signal
39FG
Sensor ground
39A
39B
39C
39D
39E
39G
39AA
39BA
39CA
73FSL
73MSL
714A
Speed signal
714AT
Speed signal
63L
39H
35L1
35L2
35L3
35L4
35L5
35L6
35L7/35L4
M20-32
Scoreboard 1 to scoreboard 2
35L8
35L9
21C
21D
Payload Meter II
M20007 10/00
21D
Alternator "R"
Terminal
Engine Running
Open
24VDC
Engine Stopped
Ground
Open
Condition
M20007 10/00
Payload Meter II
M20-33
NOTES
M20-34
Payload Meter II
M20007 10/00
SECTION N
OPERATORS CAB
INDEX
TRUCK CAB . . . . . . . . . . . . .
Description . . . . . . . . .
PREPARATION FOR REMOVAL
Removal . . . . . . . . . . .
Installation . . . . . . . . .
CAB DOOR . . . . . . . . . . .
Removal . . . . . . . . . . .
Installation . . . . . . . . .
Door Adjustment . . . . . .
Replace Door Glass . . . .
GLASS REPLACEMENT . . . .
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. N2
N2-1
N2-2
N2-2
N2-4
N2-4
N2-4
N2-4
N2-5
N2-7
N2-13
CAB COMPONENTS . . . . . .
WINDSHIELD WIPER . . . .
WINDSHIELD WASHER . .
HEATER/AIR CONDITIONER
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. N3
N3-1
N3-2
N3-3
OPERATOR COMFORT . . . . . . . .
OPERATOR SEAT . . . . . . . . .
Adjustment . . . . . . . . . .
Removal . . . . . . . . . . . .
Installation . . . . . . . . . .
HEATER/AIR CONDITIONER . . .
Operation . . . . . . . . . . .
HEATER COMPONENTS . . . . .
Circuit Breakers . . . . . . . .
Heater Control Components .
Heater Coil . . . . . . . . . .
Fan Motor and Speed Control
Actuators . . . . . . . . . . .
Filter . . . . . . . . . . . . . .
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. N4
N4-1
N4-1
N4-1
N4-1
N4-2
N4-2
N4-3
N4-3
N4-3
N4-3
N4-4
N4-4
N4-4
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. N5
N5-1
N5-1
N5-1
N5-3
N5-3
N5-7
N5-11
N5-13
N5-20
N01020 03/01
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Index
N1-1
NOTES
N1-2
Index
N01020 03/01
TRUCK CAB
Description
The truck cab is a fully insulated design incorporating
an integral ROPS structure for maximum operator
comfort and safety. All gauges, switches, and controls
have been designed to simplify operation and are
placed within easy reach of the operator. Servicing of
cab and associated electrical systems is simplified by
use of heavy-duty connectors on the various wiring
harnesses. Hydraulic components are located outside
of the interior and are accessed through covers (2,
Figure 2-1) on the front of the cab.
N02015 4/00
Truck Cab
N2-1
PREPARATION
1. Reduce the engine speed to idle. Place the selector switch in NEUTRAL and apply the parking
brake. Be certain the parking brake applied indicator lamp in the overhead panel is illuminated.
2. Place the drive system in the REST mode by
turning the Rest switch on the instrument panel
ON. Be certain the REST warning lamp is illuminated.
Read and observe the following instructions before attempting any repairs!
Removal
After the truck is parked in position for the repairs, the
truck must be shut down properly to ensure the safety
of those working in the areas of the deck, electrical
cabinet and retarding grids. The following procedures
will ensure the electrical system is properly discharged
before repairs are started.
N2-2
Truck Cab
N02015 4/00
Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere. An
approved Recovery/Recycle Station must be used
to remove the refrigerant from the air conditioning
system.
N02015 4/00
Truck Cab
N2-3
CAB DOOR
The cab door assemblies are similar except for the
hinge side. Each is hinged on the rear edge with a
heavy duty hinge. For repairs on the door latches or
window controls it is usually better, but not necessary,
to remove the door from the cab and lower it to the floor
for service.
Removal
1. If overhead space is available, raise body to allow
access to door with overhead hoist. Secure body
in raised position with safety cables.
Installation
2. After cab is positioned, insert the remaining capscrews and hardened washers. (32 total). Tighten
the capscrews to 700 ft. lbs. (950 N.m) torque.
Installation
7. Refer to Heater/Air Conditioning System in Section M for detailed instructions regarding evacuation and recharging with refrigerant.
N2-4
Truck Cab
N02015 4/00
Door Adjustment
If adjustment is necessary to insure tight closure of
door, loosen striker bolt in the door jam, adjust, and
retighten.
A rubber sealer strip is mounted with adhesive around
the perimeter of the door assembly to exclude dirt and
drafts. This sealer strip should be kept in good condition and replaced if it becomes torn or otherwise
damaged.
4. The door seal should firmly grip the paper all along
the top, front, and bottom edge of the door. If the
paper is loose all around, REPEAT STEP 2. If the
paper is firmly gripped, but can be removed without tearing it, open door and tighten the jam bolt
completely without affecting the adjustment.
3. Frame
4. Seal
N02015 4/00
Truck Cab
N2-5
a. Remove hair pin clip (1, Figure 2-6) and bolt (2)
from the door check strap closest to the door.
4. Door
5. Lower Latch
N2-6
Truck Cab
N02015 4/00
FIGURE 2-6.
4. Wiring Harness
5. Panel Screws
6. Window Regulator
Mounting Screw
N02015 4/00
Truck Cab
N2-7
FIGURE 2-8.
FIGURE 2-7.
1. Support Block
N2-8
Truck Cab
FIGURE 2-9.
2. Screws
N02015 4/00
1. Screws
FIGURE 2-10.
2. Rubber Felt Insert
FIGURE 2-12.
1. Window Frame
2. Window Bracket
10. Move window glass and frame to an area where
the glass can be removed. Slide the glass down
and out of the window channels.
11. Before installing new window glass, first inspect
the window frame. In each corner there is an "L"
shaped bracket with 2 screws in it to hold the
corners of the frame together. Check the screws
(1, Figure 2-13) to be sure they are tight. Also be
sure the rubber felt insert in the window channels
is in good condition. Replace, if necessary.
12. Slide the new window glass into the window frame
glass channels. Move the glass to the top of the
frame.
FIGURE 2-11.
1. Screws
Lift door glass up in the frame (1, Figure 2-12) so that
it is near the top. Holding the glass in place, tilt frame
out at the top. Lift frame and glass straight up and out
of door.
N02015 4/00
Truck Cab
N2-9
FIGURE 2-13.
1. "L" Shaped Brackets
FIGURE 2-14.
1. Capscrew & Nut
3. Mounting Screw 2. Mounting Screws Outside Door Handle
Latch
4. Latch Assembly
5. Window Frame
N2-10
Truck Cab
N02015 4/00
FIGURE 2-15.
21. Lift door panel, regulator and glass up to align
screw holes in the panel with holes in door frame.
Install screws that retain panel to door frame.
22. Hook-up electrical connector for the window regulator. Install the two cap screws that hold the door
strap bracket to the door frame.
23. Align door check strap opening with holes in the
bracket and install bolt. Install the hair pin clip. See
Figure 2-6.
N02015 4/00
Truck Cab
N2-11
N2-12
FIGURE 2-17.
1. Door Opening Seal
2. DoorHinge Seal
Truck Cab
N02015 4/00
GLASS REPLACEMENT
ADHESIVE-BONDED WINDOWS
Recommended Tools/Supplies
Pneumatic knife,
or a piano wire type cutting device
Replacement Procedure
The first concern with all glass replacement is
SAFETY! Wear heavy protective gloves and safety
eyeglass goggles when working with glass.
1. Using a permanent marker, mark all the edges of
the glass to be replaced on the cab skin
(all windows, except the front windshield piece,
rear cab window, and door windows).
All edges must be marked in order to apply the
adhesive properly.
N02015 4/00
Truck Cab
N2-13
Installation
Removal
1. Lift windshield wiper arms out of the way if windshield is to be replaced.
2. Starting at the lower center of the glass, pull the
glass weatherstrip locking lip out (2, Figure 2-18).
Use a non-oily rubber lubricant and a screwdriver
to to release the locking lip.
3. Remove glass from weatherstrip by pushing out
from inside the cab.
4. Clean weatherstrip grooves of dirt, sealant etc. Be
certain perimeter of cab glass opening is clean
and free of burrs etc.
1. Glass
2. Locking Lip
N2-14
4. If windshield was being replaced, lower windshield wiper arms/blades back to the glass.
FIGURE 2-18.
3. Sheet Metal
4. Weatherstrip Material
Truck Cab
N02015 4/00
CAB COMPONENTS
WINDSHIELD WIPER
The windshield wipers are operated by a 24 volt electric motor. The wiper can be adjusted for a variable
intermittent delay or a constant low or high speed by
the switch mounted on the instrument panel.
Motor Removal
Motor Installation
1. Align motor mounting holes with cab bracket.
2. Install mounting screws and washers. Tighten
mounting screws to 16 ft. lbs (22 N.m) torque.
N03011 7/98
3. Windshield
4. Retainer
1. Wiper Arm
2. Nut
3. Spring Washer
4. Cap
Cab Components
5. Pivot shaft
6. Nut
7. Washer
8. Retainer
N3-1
Installation
1. Insert wiper arm pivot shaft (5, Figure 3-2) through
hole in windshield frame and install nut (6) and
washer (7).
2. Install cap (4). Attach linkage to pivot arm by
pressing over retainer (8) and turning retainer
clockwise until locked.
3. Install wiper arm (1) in location noted during
removal and install spring washer (3) and retaining nut (2). Tighten nut to 13 ft. lbs. (17 N.m)
torque.
4. Connect windshield washer hose.
5. Install access panel machine screws.
6. Verify proper operation and arc of wiper arm.
Reposition arm on pivot splines if blade contacts
windshield weatherstrip.
WINDSHIELD WASHER
Operation
The windshield washer, mounted on the right side of
the hydraulic components cabinet behind the cab, has
a 3.8 liter (1 gal) plastic reservoir (1, Figure 3-3) with
a 24 volt electric pump (2).
The washer is controlled by the windshield wiper
switch mounted on the instrument panel and is activated by pressing the knob. When the switch is activated, washing solution is pumped through the outlet
hose (3) and fed to a jet located in each of the windshield wiper arms.
Service
If windshield washer maintenance is required, check
the strainer opening for obstructions and inspect the
hoses for damage. Check the voltage to the pump from
the control switch. If the pump is inoperable, replace it
with a new pump assembly.
Note: The pump is only available as an assembly and
cannot be repaired.
N3-2
Cab Components
3. Outlet Hose
4. Filler Cap
N03011 7/98
HEATER/AIR CONDITIONER
HEATER COMPONENTS
The heater assembly incorporates all the controls necessary for regulating the cab interior temperature;
heated air during cold weather operation, outside air
during mild temperatures and cooled, de-humidified air
during warm weather operation if the optional air conditioning system is installed.
CIRCUIT BREAKERS
Before attempting to troubleshoot the electrical circuit
in the heater enclosure, turn key switch ON and verify
circuit breaker CB31 (located on Power Distribution
Module behind operators seat) and the internal heater
circuit breaker have not opened by verifying +24VDC
is present on the junction block (24, Figure 3-5).
An engine driven freon compressor passes air conditioning system refrigerant through an evaporator coil
mounted in the same enclosure. The same blowers
used for heating move air across the evaporator to
provide cooled air through the outlet vents.
All heater and air conditioner controls are mounted on
a pod on the face of the enclosure.
FIGURE 3-4. CAB HEATER/AIR
CONDITIONER COMPONENTS
1. Enclosure
2. Heater Control Module
3. Water Control Valve
4. A/C Freon Hoses
5. Water Outlet (To Engine)
6. Water Inlet (From Engine Water Pump)
7. Evaporator Coil
8. Heater Coil
N03011 7/98
Cab Components
N3-3
HEATER COIL
Test
Test
If the motor (39) does not operate at any of the speed
selections, verify battery voltage is available at the
circuit breakers (refer to electrical schematic, Section
R). If voltage is present, the motor is probably defective and should be removed and replaced.
If the motor operates at high speed, but does not
operate at reduced speed, inspect the resistors for
physical damage or an open circuit. Replace resistors
as required.
FILTER
Service
Inlet filters (6) in the heater cover and the cab access
panel need periodic cleaning to prevent restrictions in
air circulation. The recommended interval for cleaning
and inspection is 250 hours, but in extremely dusty
conditions, the filters may need daily service and inspection, especially the outer panel filter on the cab
shell. The filter elements should be cleaned with water
and dried in a dust free environment before reinstallation. Replace the filter element every 2000 hours or
sooner if inspection indicates a clogged or damaged
filter.
ACTUATORS
Three (3) linear actuators (22, Figure 3-5) are installed
inside the heater housing and are used to actuate the
flappers for the following:
Defroster outlet
Bi-level or floor outlets
Inside or outside air selection
A failure to switch one of the above modes of operation
may be caused by a faulty actuator.
N3-4
Cab Components
N03011 7/98
N03011 7/98
Cab Components
N3-5
NOTES
N3-6
Cab Components
N03011 7/98
OPERATOR COMFORT
Installation
OPERATOR SEAT
The operators seat provides a fully adjustable cushioned ride for the drivers comfort and ease of operation.
1. Mount seat assembly to seat riser. Install capscrews (11, Figure4-1), lockwashers (12), flatwashers (13) and nuts (14). Tighten capscrews to
standard torque.
Adjustment
Removal
1. Remove capscrews (11, Figure 4-1) and hardware
that secures the seat base to the riser. Remove
capscrews (15) that secures tether (10) to floor.
2. Remove seat assembly from cab to clean work
area for disassembly.
N04020
Operator Comfort
N4-1
HEATER/AIR CONDITIONER
The heater assembly incorporates all the controls necessary for regulating the cab interior temperature;
heated air during cold weather operation, outside air
during mild temperatures and cooled, de-humidified air
during warm weather operation.
The following information primarily describes the
heater system. Refer to Section M, Air Conditioning
System for detailed information concerning the complete air conditioning system operation, repair, and
system recharging instructions.
OPERATION
Heat for the cab is provided by passing coolant from
the engine cooling system through a heater coil. Blowers move air across the heating coil which warms the
air for heating or defrosting.
An engine driven freon compressor passes refrigerant
through an evaporator coil mounted in the same enclosure. The same blowers used for heating move air
across the evaporator to provide cooled air through the
outlet vents.
All heater and air conditioner controls are mounted on
a pod on the face of the enclosure. Refer to Figure 4-2
for the following:
Defroster Switch (1): This is a 2-position toggle
switch; down is "OFF". Up provides air flow
through the defroster vents.
Outside/Inside Air Control Switch (2): This is a
2-position toggle switch; down recirculates cab
air. Up allows outside air to flow through heater
or air conditioner coils.
Heat Vent Control Switch (3): This is a 2-position
toggle switch; down is "OFF". Up provides
heated air flow to the cab floor.
Temperature Control Knob (4): This is a variable
rotary control. Rotating the knob counterclockwise (blue arrow) will select increasingly cooler
temperatures. Rotating the knob clockwise (red
arrow) selects increasingly warmer temperatures.
Fan Control (5); This is a 3-position rotary switch;
rotate knob to select low, medium, or high fan
speed.
5. Fan Control
6. Heater/Air
Conditioner Selector
7. Outlet Vents
N4-2
Operator Comfort
N04020
HEATER COMPONENTS
Test
CIRCUIT BREAKERS
Before attempting to troubleshoot the electrical circuit
in the heater enclosure, turn key switch ON and verify
circuit breaker CB31 (located on Power Distribution
Module behind operators seat) and the internal heater
circuit breaker have not opened by verifying + 24VDC
is present on the junction block (24, Figure 4-4).
N04020
Operator Comfort
N4-3
FILTER
Service
Inlet filters in the heater cover and the cab access panel
need periodic cleaning to prevent restrictions in air
circulation. The recommended interval for cleaning
and inspection is 250 hours, but in extremely dusty
conditions, the filters may need daily service and inspection, especially the outer panel filter on the cab
shell. The filter elements should be cleaned with water
and dried in a dust free environment before reinstallation. Replace the filter element every 2000 hours or
sooner if inspection indicates a clogged or damaged
filter.
ACTUATORS
Three (3) linear actuators (22, Figure 4-4) are installed
inside the heater housing and are used to actuate the
flappers for the following:
Defroster outlet
Bi-level or floor outlets
Inside or outside air selection
A failure to switch one of the above modes of operation
may be due to a faulty actuator.
Test
Visually inspect the flapper and linkage for the function
being diagnosed. Make certain the flapper is not binding or obstructed, preventing movement from one
mode to the other.
Verify voltage is present at the actuator when the toggle
switch is closed or absent when the toggle switch is
opened.
If voltage is proper, disconnect actuator from flapper
and verify actuator force is comparable to a known
(new) actuator. If not, replace with a new actuator.
N4-4
Operator Comfort
N04020
N04020
Operator Comfort
N4-5
NOTES
N4-6
Operator Comfort
N04020
STEERING COLUMN
The steering column and steering wheel used in the
Komatsu truck will adjust through a tilt angle to provide
the most comfortable wheel position for all operators.
Tilt angle is adjusted by pulling the tilt lever (3, Figure
5-1) toward the steering wheel and moving the wheel
to the desired position. Releasing the lever will lock the
wheel in one of five positions.
The steering column also contains a directional signal
flasher control lever (2) combined with a headlight high
and low beam selector switch. A right turn is signaled
by raising the lever, and a left turn by lowering the
lever. Indicator lights located above the speedometer
and tachometer will flash to indicate the turn direction
selected. To select the headlight low beams, pull the
lever (2) toward the steering wheel. To select high
beams, pull the lever again. An indicator light mounted
between the turn indicators will illuminate when high
beams are selected. The horn is controlled by pressing
the button in the center of the steering wheel.
N05044
N5-1
N5-2
7. Instrument Panel
8. Grade/Speed Chart
9. Radio Speakers
10. Warning Alarm Buzzer
11. Radio, AM/FM Stereo, Cassette
12. Warning Lights Dimmer Control
N05044
DYNAMIC RETARDING
Dynamic retarding is available in FORWARD/REVERSE at all truck speeds above 0 mph/kph; however, as the truck speed slows below 3 mph (4.8 kph),
the available retarding force may not be effective. Use
the service brakes to bring the truck to a complete stop.
Dynamic retarding will not hold a stationary truck on
an incline; use the parking brake or wheel brake lock
for this purpose.
Dynamic retarding is available in NEUTRAL only
when truck speed is above 3 mph (4.8 kph).
When Dynamic Retarding is in operation, the engine
RPM will automatically go to an advance RPM retard
speed setting. This RPM will vary depending on the
temperature of several components in the electrical
system.
N05044
N5-3
N5-4
N05044
INSTRUMENT PANEL
The Instrument Panel (7, Figure 5-2) includes a wide
variety of switches, gauges, and indicators. Refer to
INSTRUMENT PANEL AND INDICATOR LIGHTS, for
a detailed description of function and location of these
components.
GRADE/SPEED CHART
The Grade/Speed chart (8, Figure 5-2 & shown here)
provides the recommended MAXIMUM truck speeds
for descending various grades with a fully loaded truck.
The operator should reference this chart before descending any grade with a loaded truck. Proper use of
Dynamic Retarding will maintain a safe speed.
Two lists are provided, one a continuous rating and the
second a short-term (3-minute) rating. Both lists are
matched to a truck at maximum Gross Vehicle Weight.
The continuous numbers on the chart indicate the
combination of speeds and grades which the vehicle
can safely negotiate for unlimited time or distance.
The short-term (3-minute) numbers listed on the chart
indicate the combination of speeds and grades which
the vehicle can safely negotiate for three minutes.
These speeds are faster than the continuous values,
reflecting the thermal capacity of various system components. System components can accept heating at a
higher-than-continuous rate for a short period of time
beyond which the system would become over-temperature.
If the vehicle is operated at short-term grade and
speed limits for a period of time greater than three
minutes, the retarding effort may begin to reduce,
resulting in vehicle acceleration. The service brakes
are available to slow the truck within the continuous
level. This reduction in retarding effort will be gradual
as the vehicle moves from the short-term limits to the
continuous limits.
N05044
N5-5
RADIO SPEAKERS
WINDSHIELD WIPERS
PAYLOAD METER
The Payload Meter (15, Figure 5-2) and Download
Connector (14) is used to provide management with
operational data such as tonnage hauled and cycle
times. Refer to Section M, Optional Equipment, for a
more complete description of the payload meter and
its functions.
N5-6
N05044
CENTER CONSOLE
N05044
N5-7
ASH TRAY
LIGHTER
The LIGHTER (5, Figure 5-4) may be used for lighting
cigars/cigarettes.
Always use CAUTION with smoking materials!.
This socket may also be used for a 12 VDC power
supply.
Use this switch to shutdown engine if engine does not shutdown by turning off keyswitch, or to
shutdown engine without turning off 24 VDC electric
circuits.
Move hoist lever forward to down position and release. Releasing the lever places hoist control valve in
the float position allowing the body to return to frame.
N5-8
N05044
T h i s p u s h - b u t t on
switch (9, Figure 5-4)
is spring-loaded to the
OFF position.
When pushed in and
held, this switch may be used for several functions.
1. This switch permits the operator to override the
body-up limit switch and move the truck forward
when the Selector Switch is in Forward, the dump
body is raised, and the brakes are released.
Use of the override switch for this purpose is
intended for emergency situations only!
2. The push button deactivates the retard pedal
function when speed of truck is below 3 mph (4.8
kph).
3. The override switch is also used to reset an
electric system fault when indicated by a red
warning light (Refer to Instrument Panel And
Indicator Lights, Overhead Warning / Status
panel).
The RSC Adjust Dial (12, Figure 5-4) allows the operator to vary the downhill truck speed that the Retard
Speed Control system will maintain when descending
a grade. This function can be overridden by either the
accelerator, retard lever, or retard pedal.
"OFF"
"ON"
N05044
N5-9
PASSENGER SEAT
N5-10
N05044
N05044
N5-11
N5-12
11. 71/79M/SPR55/79H/72F/SPR54
12. 712BL/52B/39H/710/SPR59
13. 71/52C/21PB/21
14. 41TS/74X/74Z/710
15. 45R/710
16. 41H/710
17. 45L/710
18. 41TS/77/77A/710
19. 712D/710/49
20. 712D/31PS/710/49
21. 712D/31TS/710/49
22. 712D/38G/710/49
23. 15V/72MT/49/710
24. 11L/36
25. 15V/34BT/710/49
26. 710/72RQ
27. 11D/41L/41TS
28. High 66S/Low 66L/710/66P Park/
712W / Washer 66
29. 49/41TS
N05044
Starting
When the switch is rotated one position clockwise, it is
in the Run position and all electrical circuits (except
Start) are activated.
1. With Selector Switch in Neutral, rotate
keyswitch fully clockwise to Start position, and
hold this position until engine starts.
Start position is spring-loaded to return to Run
when key is released.
2. After engine has started, place REST switch in
Off position (de-activate the REST mode of
operation). Refer to discussion of REST SWITCH
(26, Figure 5-5).
Cold Weather Starting
Do not crank an electric starter for more than
30 seconds at a time.
Allow two minutes for cooling before attempting
to start engine again.
Severe damage to starter motor can result from
overheating.
N05044
N5-13
Operation
1. Stop truck. Reduce engine RPM to low idle. Place
Selector Switch in Neutral (see OPERATOR
CONTROLS) and apply Parking Brake switch.
Place REST switch in On position (put drive
system in REST mode of operation). Refer to
discussion of REST SWITCH (26, Figure 5-5).
a. Press top of switch to the On (center position), then press firmly to the Momentary
(upper position) and hold briefly to activate the
5 Minute Idle Timer (switch is spring-loaded to
return to On position when released). At the
same time, while holding the Momentary
switch position, turn the keyswitch counterclockwise to the OFF position.
N5-14
N05044
Do not use this switch to stop truck, unless footoperated treadle valve is inoperative. Use of this
switch applies rear service brakes at full, unmodulated pressure!
Do not use brake lock for parking. With engine
stopped, hydraulic pressure will bleed down, allowing brakes to release!
PARKING BRAKE CONTROL
N05044
N5-15
TACHOMETER
VOLTMETER
The voltmeter (19, Figure 5-5) indicates the voltage of the 24V battery
system. Normal indicated voltage at
high RPM is 27 to 28 volts with batteries in fully charged condition.
When keyswitch (10) is On and
engine is NOT running, voltmeter indicates battery charge condition.
This light (15, Figure 5-5) illuminates to indicate the right turn signals are operating when the turn
signal lever on the steering column
is moved upward. Moving the lever
to its center position will turn indicator Off.
FUEL GAUGE
The fuel gauge (22, Figure 5-5) indicates how much diesel fuel is in the
fuel tank.
The fuel tank capacity is
1200 gallons (4542 liters).
SPEEDOMETER
The speedometer (18, Figure 5-5) indicates the truck
speed in miles per hour (MPH), or with OPTIONAL
speedometer, it may indicate truck speed in kilometers
per hour (KPH).
N5-16
N05044
REST SWITCH
The REST switch (26,
Figure 5-5) is a rocker
type switch with a locking
device for the OFF (left
side) position. When in
this position, a small black
tab must be pushed to the
left to unlock the switch before it can be depressed to
switch to the ON (right side) position. When in the ON
position, an internal amber lamp will illuminate. It
should be activated to de-energize the AC Drive
System whenever the engine is to be shutdown, or the
truck parked for a length of time with the engine
running.
The Selector Switch must be in neutral and the vehicle
not moving to enable this function. This will allow the
engine to continue running while the AC Drive System
is de-energized.
The hourmeter (24, Figure 5-5) registers the total number of hours the
engine has been in operation.
Refer to Safety Procedures, and check all LINKON, or LINK ENERGIZED, indicator lights to
verify the AC DRIVE system is DE-ENERGIZED
before before performing any maintenance on the
Drive System.
HYDRAULIC OIL
TEMPERATURE GAUGE
N05044
N5-17
LIGHT SWITCH
The instrument panel lights, clearance lights, and the headlights are
controlled by this three position
rocker type switch (27, Figure 5-5).
Off is selected by pressing the
bottom of the switch. Press the top
of the switch until it reaches the first
detent to select the panel, clearance, and tail lights
only.
Press the top of the switch again, until it reaches the
second detent to select headlights, as well as panel,
clearance, and tail lights.
N5-18
N05044
Indicator
Description
Row /
Column
Indicator
Description
A1*
Not Used
Red - 12FD/34TL
B1
Red - 12F/33A
C1
Red - 12F/33K
D1
Not Used
Red - 12F/79V
E1
Red - 12F/33L
A2*
Red - 12MD/34LL
B2*
Not Used
Red - 12FD/SPR1
C2*
Amber - 12MD/31CB
A6
No Propel
Red - 12M/75NPI
B6*
Amber - 12MD/72PR
C6*
Propel System
Not Ready
Amber -12MD/72NR
D6*
Reduced
Propulsion System
Amber -12MD/72LP
E6*
Retard @
Continuous Level
Amber - 12MD/76LR
D2*
Amber - 12MD/39
E2*
Low Fuel
Amber - 12MD/38
A3*
Amber - 12MD/52A
B3*
Amber - 12MD/44L
C3*
Body Up
Amber - 12MD/63L
D3*
Dynamic Retarding
Amber - 12MD/44DL
E3
STOP ENGINE
Red - 12M/509MA
A4*
Not Used
Amber - 12MD/SPR2
B4*
Amber - 12MD/47L
C4*
Amber - 12MD/23L1
D4*
Amber - 12MD/31R
E4*
CHECK ENGINE
Amber - 12MD/419
N05044
A5
No Power
Red - 12M/75-6PI
B5
Propulsion System
Warning
Amber - 12F/79WI
C5
Propulsion System
Temperature
Amber - 12F/34TW
D5
Hydraulic Oil
Temperature High
Red - 12F/34TGI
E5*
STOP ENGINE
Red - 12FD/528AL
SWITCHES
7
11L/45L/45R
33H/710
N5-19
A1
Not Used
B1
RED
C1
Low Accumulator
Precharge Pressure
RED
D1
Not Used
E1
RED
N5-20
The low accumulator precharge warning light, if illuminated, indicates low nitrogen precharge for the steering accumulator(s). To check for proper accumulator
nitrogen precharge, engine must be stopped and hydraulic system completely bled down; then turn
keyswitch to Run position. Warning light will NOT
illuminate if system is properly charged. The warning
light will flash if the nitrogen precharge within the
accumulator(s) is below 1100 45 psi (7585 310
kPa).
If low accumulator
precharge warning
light flashes, notify
maintenance personnel. Do not attempt further operation until the
accumulators have been recharged with nitrogen
to 1400 psi (9653 kPa). Sufficient energy for emergency steering may not be available, if system is
not properly charged.
D1. NOT USED
Not currently used. Reserved for future use or options.
E1. Low Brake Pressure
This red indicator light indicates a malfunction within
the hydraulic brake circuit. If this light comes on and
buzzer sounds, shut down truck operation and
notify maintenance personnel.
NOTE: Adequate hydraulic fluid is stored to allow the
operator to safely stop the truck.
N05044
A3
Parking Brake
AMBER
B3
Service Brake
AMBER
AMBER
C3
Body Up
AMBER
D3
Dynamic Retarding
AMBER
E3
Stop Engine
RED
A2
B2
Not Used
C2
D2
E2
Low Fuel
RED
AMBER
This amber dynamic retarding indicator light illuminates whenever the retarder pedal (or retarder lever)
is operated, RSC (Retard Speed Control) is activated,
or the automatic overspeed retarding circuit is energized, indicating the dynamic retarding function of the
truck is operating.
N05044
N5-21
A4
Not Used
B4
AMBER
C4
AMBER
D4
AMBER
E4
Check Engine
AMBER
N5-22
N05044
No Power
RED
B5
Propulsion System
Warning
AMBER
C5
Propulsion System
Temperature
AMBER
D5
RED
E5
Stop Engine
RED
A5. NO POWER
This red No Propel/No Retard indicator light indicates a fault has occurred which has eliminated the
retarding and propulsion capability. A warning buzzer
will also sound.
If this condition occurs, the operator should safely
stop the truck, move Selector Switch to Neutral,
apply the Park Brake, shutdown engine, and notify
maintenance personnel immediately.
N05044
N5-23
No Propel
RED
B6
AMBER
C6
Propel System
Not Ready
AMBER
The amber Reduced Propulsion light is used to indicate that the full AC Drive System performance in
propulsion is not available. At this time, the only event
that should activate this light is the use of Limp Home
Mode. This mode of operation requires a technician
to enable.
Reduced Propulsion
AMBER
E6
Retard At Continuous
Level
AMBER
A6. NO PROPEL
The red No Propel light indicates a fault has occurred
which has eliminated the propulsion capability.
If this condition occurs, the operator should safely
stop the truck, move Selector Switch to Neutral,
apply the Park Brake, shutdown engine, and notify
maintenance personnel immediately.
N5-24
N05044
N05044
N5-25
NOTES
N5-26
N05044
SECTION P
LUBRICATION AND SERVICE
INDEX
LUBRICATION AND SERVICE . . . . . . . . . . . .
Service Capacities . . . . . . . . . . . . . .
Hydraulic Tank Service (Filling Instructions)
Coolant Level Check . . . . . . . . . . . . .
Radiator Filling Procedure . . . . . . . . . .
Cooling System Recommendations . . . . .
LUBRICATION CHART . . . . . . . . . . . .
10 Hours . . . . . . . . . . . . . . . . . . .
50 Hours . . . . . . . . . . . . . . . . . . .
100 Hours . . . . . . . . . . . . . . . . . . .
250 Hours . . . . . . . . . . . . . . . . . . .
500 Hours . . . . . . . . . . . . . . . . . . .
1000 Hours . . . . . . . . . . . . . . . . . .
2500 Hours . . . . . . . . . . . . . . . . . .
5000 Hours . . . . . . . . . . . . . . . . . .
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. P3-1
. P3-1
. P3-3
. P3-4
. P3-4
. P3-4
. P3-4
. P3-5
. P3-6
. P3-8
. P3-8
. P3-10
. P3-11
. P3-14
P01015 03/01
Index
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P2-1
P2-1
P2-1
P2-2
P2-2
P2-2
P2-3
P2-4
P2-6
P2-7
P2-8
P2-10
P2-11
P2-12
P2-12
P1-1
NOTES
P1-2
Index
P01015 03/01
Liters
U.S.
Gallons
280
74
Cooling System:
Cummins QSK-60C Engine
594
157
1325
350
76
20
4542
1200
Hydraulic System:
Refer to Hydraulic Tank Service.
Wheel Motor Gear Box
(each side)
Fuel Tank (Diesel Fuel Only)
P02034
P2-1
Cooling System is pressurized due to thermal expansion of coolant. DO NOT remove radiator cap
while engine and coolant are hot. Severe burns
may result.
COOLING SYSTEM
ANTI - FREEZE RECOMMENDATIONS
(Ethlyene Glycol Permanent Type Anti-Freeze)
Percentage of
Protection
Anti-Freeze
To
10
+23F
5C
20
+16F
9C
25
+11F
11C
30
+ 4F
16C
35
3F
19C
40
12F
24C
45
23F
30C
50
34F
36C
55
48F
44C
60
62F
52C
Use only anti-freeze that is compatible with engine as
specified by engine manufacturer.
P2-2
P02034
P02034
P2-3
COMMENTS
INITIALS
P2-4
P02034
INITIALS
P02034
P2-5
INITIALS
P2-6
P02034
COMMENTS
INITIALS
*1. HYDRAULIC SYSTEM FILTERS Replace filter elements only, after the initial 100
and 250 hours of operation; then at each 500
hours of operation thereafter.
P02034
P2-7
INITIALS
1. ENGINE - Refer to Cummins Operation & Maintenance manual for complete specifications regarding engine lube oil specifications.
NOTE: If engine is equipped with the CENTINEL* oil
system, engine oil and filter change intervals are extended beyond 250 hours. Refer to Cummins Operation & Maintenance manual for specific oil & filter
change intervals.
a. Change engine oil. Lube Key A.
b. Replace lube oil filters.
NOTE: When installing spin-on filter elements,
follow the instructions as specified by the filter
manufacturer. The tightening instructions are
normally printed on the outside of the filter. Do
not use a wrench or strap to tighten filter
elements.
c. Check the fan belt tension.
Refer to Cummins Operation & Maintenance
manual for specific fan belt adjustment instructions.
2. FUEL FILTERS - Change the Fuel Filters (Fuel
Separators).
Refer to Cummins Operation & Maintenance manual for specific fuel filter replacement instructions.
P2-8
P02034
COMMENTS
INITIALS
4. COOLING SYSTEM a. Check cooling system for proper coolant mixture. Add coolant mixture as required.
b. COOLANT FILTERS - Change coolant filters.
Refer to engine manufacturers maintenance
manual for coolant filter replacement instructions and proper coolant mixture instructions.
5. REAR WHEEL MOUNTING - Using a mirror on a
long rod and a flashlight, inspect where possible,
all inner and outer wheel mounting nuts/studs for
any evidence of looseness, damage, or missing
hardware.
If wheel mounting nuts/studs must be secured or
replaced, the outer wheel must be removed for
access. Refer to Section G, for these procedures.
6. REAR AXLE HOUSING - Check the rear axle
housing for fluid leaks by removing the two drain
plugs on the bottom of the axle housing. If fluid is
present, the cause must be found and corrected
before releasing truck to operation.
7. STEERING LINKAGE - Check torque on pin retaining nuts (steering linkage), 525 ft.lbs. (712
N.m). Check torque on tie rod retaining capscrews, 310 ft.lbs. (420 N.m).
8. MAGNETIC PLUG - Remove magnetic plug from
front wheel covers and inspect for debris. Clean
the plug and perform any necessary repairs.
* These checks are required only after the first 250
hours of operation (such as: the commissioning
of a new truck, or after a new or rebuilt component
installation), check:
*9. HYDRAULIC SYSTEM FILTERS Replace filter elements only after the initial 250
hours of operation; then at each 500 hours of
operation thereafter.
Check oil level. Add oil as necessary.
Lube Key B.
*10. MOTORIZED WHEEL GEAR CASE - Refer to the
G.E. planned maintenance manual and specific
motorized wheel shop manual.
P02034
P2-9
INITIALS
P2-10
P02034
INITIALS
P02034
P2-11
COMMENTS
INITIALS
COMMENTS
INITIALS
P2-12
P02034
P03012 03/01
P3-1
P03012 03/01
System Operation:
1. During truck operation, with the pump and timer
systems in a rest state, a preset time interval
occurs.
2. The solid state system timer sends out a 24 VDC
signal to energize SV1, causing it to open.
3. As SVI opens, the resulting hydraulic fluid pressure
flows through the pressure reducing valve closing
the vent valve and also flows on to SV2.
4. The pressure reducing valve lowers hydraulic fluid
pressure to the operating range of the hydraulic
pump [maximum pressure 300 p.s.i. (2069 kPa)].
5. After the system pressure has been reduced, it
passes on to SV2. Each operation of SV2 moves
the hydraulic cylinder which operates the grease
pump. As SV2 turns On and Off (refer to cycle
timer/flasher below), it changes the direction of
the hydraulic cylinder movement back and forth,
thus causing a pumping action.
6. The cycle timer/flasher sends a pulsing signal, 1
second On and 1 second Off (adjustable), to
SV2. Solenoid valve SV2 directs the hydraulic fluid
to the pump at 30 cycles/minute.
7. With the vent valve closed, the pump continues to
cycle until lubricant pressure rises to 2,000 psi (13
790 kPa) and the injectors have metered grease
to the points of lubrication.
8. If system pressure rises above 2000 psi (13 790
kPa), the N/C pressure switch will open until the
timed cycle is complete and the solid state system
timer terminates the 24VDC signals to SV1 and
SV2. (See NOTE: below step 11.)
9. As SV2 is de-energized the pump stops cycling.
10. As SV1 is de-energized, the hydraulic fluid stops
flowing to the pressure reducing valve and the vent
valve allowing it to open.
11. As the vent valve opens, the grease pressure drops
to zero (0), so the injectors can recharge for their
next output cycle.
NOTE: When the N/C pressure switch opens, SV2 is
de-energized causing the pump to stop; however, until
the timed cycle is complete, SV1 remains energized,
keeping the vent valve closed and holding pressure in
the grease line. If the grease line pressure now drops
to where the switch closes again, the pump will restart
to hold grease line pressure, but the injectors will not
recharge.
12. The system is now at rest, ready for another lube
cycle and the sequence repeats itself.
P03012 03/01
P3-3
GENERAL INSTRUCTIONS
Lubricant Required for System
Refer to Lubrication Chart, for correct lubricant specifications.
1. Above 90F (32C) - Use NLGI No.2 multipurpose
grease (MPG).
2. -25 to 90F (-32 to 32C) - Use NGLI No. 1 MPG.
3. Below -25F (-32C) - Refer to local supplier for
extreme cold weather lubricant requirements.
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 reprime the system to eject all
entrapped air.
NOTE: To run the grease pump when priming the lube
system, connect a jumper wire between the ignition
and solenoid posts on the solid state timer.
This equipment generates very high grease pressure. Extreme caution should be used when operating this equipment as material leaks from loose
or ruptured components can inject fluid through
the skin and into the body causing serious bodily
injury including possible need for amputation. Adequate protection is recommended to prevent
splashing of material onto the skin or into the eyes.
4. Repeat step 3 until all lines are full and all plugs
replaced.
NOTE: Fill each feed line with grease before connecting lines to the injector outlets and bearings. This will
prevent having to cycle the individual injectors once
for each 1.0 in. (25 mm) length of feed line between
the injector and bearing fitting.
System Checkout
To check system operation (not including timer), proceed as follows:
1. Lift the passenger seat and connect a jumper wire
between SOL terminal and LUBE SW terminal
on the 24 VDC solid state lube timer.
Turn keyswitch "ON". Pump should operate.
NOTE: If terminal post identification on the solid state
timer is not legible, refer to Figure 3-7 for terminal
positions.
If any fluid appears to penetrate the skin, get emergency medical care immediately! Do not treat as a
simple cut. Tell attending physician exactly what
fluid was injected.
If overpressurizing of the equipment is believed to have
occurred, contact a factory authorized warranty and
service center for inspection of the pump. Specialized
equipment and knowledge is required for repair of the
pump or adjustments other than the maintenance
specified in this manual.
Annual inspection by the factory authorized warranty
and service center is recommended.
P03012 03/01
P03012 03/01
P3-5
Injector Adjustment
The injectors may be adjusted to supply from 0.008 in3
to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per injection
cycle. The injector piston travel distance determines
the amount of lubricant supplied. This travel is in turn
controlled by an adjusting screw in the top of the
injector housing.
Turn the adjusting screw (1, Figure 3-4) counterclockwise to increase lubricant amount delivered and clockwise to decrease the lubricant amount.
When the injector is not pressurized, maximum injector
delivery volume is attained by turning the adjusting
screw (1) fully counterclockwise until the indicating pin
(8) just touches the adjusting screw. At the maximum
delivery point, about 0.38 inch (9.7 mm) adjusting
screw threads should be showing. Decrease the delivered lubricant amount by turning the adjusting screw
clockwise to limit injector piston travel. If only half the
lubricant is needed, turn the adjusting screw to the
point where about 0.19 inch (4.8 mm) threads are
showing. The injector will be set at minimum delivery
point with about 0.009 inch (0.22 mm) thread showing.
NOTE: The above information concerns adjustment of
injector delivery volume. The timer adjustment should
also be changed, if overall lubricant delivery is too little
or too much. Injector output should NOT be adjusted
to less than one-fourth capacity.
P3-6
P03012 03/01
INJECTOR OPERATION
STAGE 1.
The injector piston (2) is in its normal or
"rest" position. The discharge chamber (3)
is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant (6), the slide valve (5) is about to open
the passage (4) leading to the measuring
chamber (1) above the injector piston (2).
STAGE 2.
When the slide valve (5) uncovers the passage (4), lubricant (6) is admitted to the
measuring chamber (1) above the injector
piston (2) which forces lubricant from the
discharge chamber (3) through the outlet
port (7) to the bearing.
STAGE 3.
As the injector piston (2) completes its
stroke, it pushes the slide valve (5) past the
passage (4), cutting off further admission of
lubricant (6) to the passage (4) and measuring chamber (1). The injector piston (2)
and slide valve (5) remain in this position
until lubricant pressure in the supply line (6)
is vented (relieved at the pump).
STAGE 4.
After venting, the injector spring expands,
causing the slide valve (5) to move, so that
the passage (4) and discharge chamber (3)
are connected by a valve port (8). Further
expansion of the spring causes the piston
to move upward, forcing the lubricant in the
measuring chamber (1) through the passage (4) and valve port (8) to refill the discharge chamber (3).
P03012 03/01
P3-7
P3-8
P03012 03/01
8. Solenoid (SV1)
12. Hydraulic Supply
9. Gauge (Cyl. Press.)
13. Hyd. Tank (Return)
10. Pressure Switch, N/C 14. Injectors
2,000 PSI (13 790 kPa)
11. Orifice Assembly
8. Battery (24 V)
9. Cycle Timer
10. Pressure Switch, N/C
2,000 PSI (13 790 kPa)
P3-9
P3-10
P03012 03/01
TROUBLESHOOTING CHART
If the following procedures do not correct the problem, contact a factory authorized service center. When submitting
equipment to be repaired, be sure to state the nature of the problem and indicate if a repair cost estimate is required.
POSSIBLE CAUSES
Timer malfunction.
Pump malfunction.
NOTE: On intial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing
cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as specified.
P03012 03/01
P3-11
POSSIBLE CAUSES
Check Timer.
Fuse blown (circuit breaker tripped) on power connection to timer, or wire is otherwise damaged.
Replace Timer.
Replace Timer.
P3-12
P03012 03/01
POSSIBLE CAUSES
TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) Times More Often Than Set Time Interval:
Electrical noise is being introduced into the power
supply to the timer overcoming suppressor capacitor
causing uncontrolled turn-on of its output relay.
P03012 03/01
P3-13
5. System Checkout
a. Remove all SL-1 injector cover caps to allow
visual inspection of the injector cycle indicator
pins during system operation.
b. Start truck engine.
c. Lift the passenger seat and connect a jumper
wire between SOL (Wire 68A) and LUBE SW
on the 24VDC solid state timer (Figure 3-7).
The hydraulic grease pump should operate.
d. Keep the jumper wire connected until the pump
stalls out at 2000 PSI. (Refer to NOTE: following
step 7, page 3-3, regarding pressure switch.)
e. With the pump in the stalled-out mode, check
each SL-1 injector assembly.
The cycle indicator pin should be retracted
inside the injector body.
f. Once all of the SL-1 injectors have been inspected under pressure remove the jumper
wire between the SOL terminal and LUBE
SW terminal on the timer assembly. The pump
should shut off and the pressure in the system
should drop to zero venting back to the grease
reservoir.
g. With the system vented, check all of the SL-1
injector indicator pins.
All of the pins should be visable.
NOTE: Refer to the system troubleshooting
chart, if the injectors are not working properly.
Replace or repair injectors, if defective.
h. Reinstall all injector cover caps.
i. Check timer operation.
With engine running, lube system should activate within 5 minutes. The system should build
2000PSI within 25-40 seconds.
P3-14
P03012 03/01
SECTION Q
ALPHABETICAL INDEX
A
Abbreviations, Propulsion System . .
Accelerator Pedal . . . . . . . . . . .
Accumulator, Steering . . . . . . . .
Accumulator, Brake . . . . . . . . . .
AC Drive System Electrical Checkout
AID System . . . . . . . . . . . . . .
Air Cleaners . . . . . . . . . . . . . .
Air Conditioning System . . . . . . .
Component Service . . . . . . . . .
Alarm Indicating Device (AID) . . . .
Alternator, 24VDC (240 Amp) . . . .
Alternator, Propulsion . . . . . . . . .
Antifreeze Recommendations . . . .
Anti-sway Bar . . . . . . . . . . . . .
Automatic Lubrication System . . . .
Axle, Rear . . . . . . . . . . . . . . .
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E2-41
E2-51
. L6-2
J3-22
. E3-1
. D3-3
. C5-1
. M9-1
. M9-1
. D3-3
M13-1
. C4-1
. P2-2
. G4-4
. P3-1
. G4-1
B
Batteries . . . . . . . . . . .
Maintenance and Service .
Battery Charging System . .
General Description . . . .
Troubleshooting . . . . . .
Battery Control Box . . . . .
Battery Disconnect Switches
Battery Equalizer . . . . . .
Bearing, Wheel
Front, Installation . . . . .
Front, Adjustment . . . . .
Bleeddown Manifold Valve .
Body, Dump . . . . . . . . .
Body Guide . . . . . . . . .
Body Pad . . . . . . . . . .
Body-Up Retention Cable .
Body-Up Switch . . . . . . .
Brake Accumulators . . . .
Q01028 04/01
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. D2-1
. D2-1
M13-3
M13-3
M13-3
. D2-3
. D2-4
. D2-5
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. G3-7
. G3-7
. L6-1
. B3-1
. B3-4
. B3-3
. B3-4
D3-13
J3-22
Brake Circuit . . . . . . . . . . . . . .
Bleeding Procedures
Service Brakes . . . . . . . . . . .
Parking Brake . . . . . . . . . . .
Checkout Procedure . . . . . . . . .
Failure Modes Checkout Procedure
Troubleshooting . . . . . . . . . . .
Brake Disc Wear Indicator . . . . . .
Brake, Parking . . . . . . . . . . . . .
Brake Seal Assembly, Rear . . . . . .
Brake Seal Gap Adjustment (Rear) .
Brakes, Wet Disc . . . . . . . . . . .
Brake Valve . . . . . . . . . . . . . .
Test and Adjustment . . . . . . . . .
. . . . J2-1
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J5-14
. J7-6
. J4-5
. J4-6
. J4-9
. J5-2
. J7-1
J5-11
J5-10
. J5-1
. J3-1
J3-10
C
Cab . . . . . . . . . . . . . . . . . . . . .
Capacities, Service . . . . . . . . . . . .
Charging Procedure
Brake Accumulators (Hydraulic Cabinet)
Brake Accumulators (Frame Mounted) .
Steering Accumulators . . . . . . . . .
Suspensions . . . . . . . . . . . . . . .
Checkout Procedures
Brake Apply Circuit . . . . . . . . . . .
Brake Cooling Circuit . . . . . . . . . .
Data Sheet (Hydraulic System) . . . . .
Electrical Propulsion System . . . . . .
Hoist Circuit . . . . . . . . . . . . . . .
Steering Circuit . . . . . . . . . . . . . .
Circuit Breaker Chart . . . . . . . . . . .
Center Console . . . . . . . . . . . . . .
Control Cabinet, Electrical . . . . . . . .
Cooling System, Engine . . . . . . . . . .
Cooling System, Disc Brakes . . . . . . .
Cylinders
Hoist . . . . . . . . . . . . . . . . . . .
Steering
Removal . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . .
Alphabetical Index
. N2-1
. P2-1
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J3-25
J3-29
. L6-5
H4-1
. . J4-1
. L10-6
L10-13
. E2-1
. L10-6
. L10-1
. D3-15
. N5-7
. E2-47
. C3-1
. . L2-6
. L8-12
. G3-10
. L6-10
Q1-1
D
Decks . . . . . . . . . . . . . . . . . .
Diagnostic Information Display (DID)
Fault Codes . . . . . . . . . . . . .
Diode Board . . . . . . . . . . . . . .
Differential Pressure Switch . . . . .
Dual Relay Valve . . . . . . . . . . .
Dump Body . . . . . . . . . . . . . . .
Dump Procedure, Disabled Truck . .
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B2-3
E2-5
E2-5
D3-8
J3-18
J3-15
B3-1
L8-20
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D3-6
E2-1
R1-1
C4-6
C4-3
A2-3
E
Electrical Interface Cabinet . . . .
Electrical Propulsion Components
Electrical System Schematic . . .
Engine . . . . . . . . . . . . . . .
Engine/Alternator Mating . . . . .
Engine Specifications . . . . . . .
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F
Fan, Heater . . . . . . . . . . .
Filters, Hydraulic . . . . . . . . .
5 Minute Idle Timer . . . . . . .
Flow Amplifier . . . . . . . . . .
Flushing, Hydraulic System . . .
Front Suspension, HYDRAIR II
Front Tires and Rims . . . . . .
Front Wheel Hub and Spindle .
Fuel Tank . . . . . . . . . . . . .
Vent . . . . . . . . . . . . . . .
Gauge Sender . . . . . . . . .
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. N4-4
. . L9-1
. D3-1
. . L6-6
L10-10
. H2-1
. G2-2
. G3-1
. B4-1
. B4-3
. B4-3
HYDRAIR II Suspensions
Front . . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . .
Oil and Nitrogen Specifications
Hydraulic System
Disc Brake Cooling System . .
Filters . . . . . . . . . . . . . .
Hoist Pump . . . . . . . . . . .
Strainers . . . . . . . . . . . . .
Schematic . . . . . . . . . . . .
Steering/Brake Pump . . . . . .
System Flushing . . . . . . . .
Tank . . . . . . . . . . . . . . .
Troubleshooting
Hoist Pump . . . . . . . . . .
Steering System . . . . . . .
. . . . . . H2-1
. . . . . . H3-1
. . . . . . H4-6
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. L2-6
. L9-1
. L3-1
L3-15
. R1-1
L6-12
L10-10
L3-14
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L3-13
L6-23
I
Indicator Lights . . . . . . . . . . . . . . . N5-11
Instrument Panel . . . . . . . . . . . . . . N5-11
L
Ladders . . . . . . . . . . . . .
Load Testing . . . . . . . . . .
Lubrication and Service . . . .
Lubrication Chart . . . . . . . .
Lubrication System, Automatic
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. B2-2
E3-26
. P2-1
. P2-3
. P3-1
M
Metric Capscrews, Torque Chart . . . . . . A5-2
Metric Conversion Chart . . . . . . . . . . . A5-6
G
Grille, Hood & Ladders . . . . . . . . . . .
B2-2
N
Nitrogen Specifications
. . . . . . . . . . . H4-6
H
Heater/Air Conditioner . . . . .
Actuators . . . . . . . . . . . .
Coil . . . . . . . . . . . . . . .
Fan Motor and Speed Control .
Hoist Circuit Operation . . . . .
Hoist Limit Switch . . . . . . . .
Hoist Pilot Valve . . . . . . . . .
Hoist Cylinders . . . . . . . . . .
Hoist Relief Valve (Adjustment)
Hoist Valve . . . . . . . . . . . .
Hood . . . . . . . . . . . . . . .
Hub, Wheel . . . . . . . . . . . .
Q1-2
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N4-2
N4-4
N4-3
N4-4
. L7-1
D3-14
. L8-9
L8-12
L10-7
. L8-1
B2-2
G3-1
O
Oiling and Charging Procedure,
Operator Cab Controls . . . . .
Optional Equipment
Air Conditioning System . . .
Alternator, 24VDC, 240 AMP
Fire Control System . . . . .
Fuel, Quick Fill . . . . . . . .
Payload Meter II . . . . . . .
Overhead Display Panel . . . .
Alphabetical Index
Susp.. . . . H4-1
. . . . . . . N5-1
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. M9-1
M13-1
. M2-1
. M5-1
M20-1
N5-19
Q01028 04/01
P
Parking Brake . . . . . . . . . . . . .
Pedal
Accelerator . . . . . . . . . . . . .
Retarder . . . . . . . . . . . . . . .
Service Brake . . . . . . . . . . . .
Plates, Warning and Caution . . . . .
Portable Test Unit (PTU) . . . . . . .
Power Module . . . . . . . . . . . . .
Power Train . . . . . . . . . . . . . .
Engine/Alternator Mating . . . . . .
Engine . . . . . . . . . . . . . . . .
Pressure Control Adjustment, Pump
Propulsion System Controller (PSC)
Checkout Procedure . . . . . . . .
Pump, Hoist System . . . . . . . . .
Pump, Steering/Brake System . . . .
. . . . J7-1
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E2-51
E2-51
. J3-3
. A4-1
. E3-4
. C2-1
. C4-1
. C4-3
. C4-6
L10-2
. E2-3
E3-18
. L3-1
L6-12
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. C3-1
. G4-1
. H3-1
. G2-3
. D3-9
E2-51
. G2-6
. B3-5
R
Radiator . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . .
Rear HYDRAIR II Suspension
Rear Tire and Rim . . . . . . .
Relay Boards . . . . . . . . . .
Retarder Pedal, Electronic . . .
Rims . . . . . . . . . . . . . . .
Rock Ejectors . . . . . . . . . .
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S
Safety Rules . . . . . . . . . . . . . . . .
Software Functions, PSC . . . . . . . . .
Starter, 24VDC (Refer to Engine Service
Seal Assemblies, Gap Adjustment
Front Wheel . . . . . . . . . . . . . . .
Rear Wheel . . . . . . . . . . . . . . .
Seat, Operator . . . . . . . . . . . . . .
Service Capacities . . . . . . . . . . . .
Solenoid
Bleeddown . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . .
Specifications
HYDRAIR II Oil . . . . . . . . . . . .
HYDRAIR II Nitrogen . . . . . . . . .
Hydraulic Oil . . . . . . . . . . . . . . .
Lubrication Chart . . . . . . . . . . . .
Truck Specifications . . . . . . . . . . .
Q01028 04/01
. . A3-1
. E2-30
Manual)
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. G3-9
J5-10
. N4-1
. P2-1
. . L4-3
. . M8-1
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H4-6
H4-6
P2-1
P2-3
A2-3
. G3-1
. D2-3
. N5-20
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. L6-5
N5-1
L10-1
. L5-1
L6-10
L6-23
L3-15
. H2-1
. H3-1
. . L4-5
. J3-18
. . L4-3
T
Tank
Fuel . . . . . . . . . . . . .
Hydraulic . . . . . . . . . .
Tie Rod . . . . . . . . . . . .
Tires and Rims
Front . . . . . . . . . . . .
Rear . . . . . . . . . . . . .
Toe-In Adjustment . . . . . .
Tools, Special . . . . . . . .
Torque Tables
Metric Capscrews . . . . .
Standard . . . . . . . . . .
12-Point Capscrews (Grade
Troubleshooting
Air Cleaner . . . . . . . . .
Brake System . . . . . . .
Hoist Pump . . . . . . . . .
Steering Circuit . . . . . . .
Truck Control Interface (TCI)
Checkout Procedure . . . .
. . . . . . . . B4-1
. . . . . . . . L3-14
. . . . . . . . G3-9
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G2-2
G2-3
G3-12
M8-1
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9) . . . . . .
A5-2
A5-1
A5-2
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C5-5
. J4-8
L3-13
L6-23
E2-4
E3-12
U
Unloader Valve, Adjustment
Alphabetical Index
. . . . . . . . L10-2
Q1-3
V
Valves
Bleeddown Solenoid . . . . . . . . .
Brake . . . . . . . . . . . . . . . . .
Dual Relay . . . . . . . . . . . . . .
Flow Amplifier . . . . . . . . . . . .
Hoist . . . . . . . . . . . . . . . . .
Hoist Pilot . . . . . . . . . . . . . .
Hoist Relief, Adjustment . . . . . . .
Pressure Compensator, Adjustment
Steering Control . . . . . . . . . . .
Unloader, Adjustment . . . . . . . .
Q1-4
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.
.
.
.
. L4-3
. J3-1
J3-15
. L4-6
. L8-1
. L8-9
L10-7
L10-2
. L5-1
L10-2
Weights (Truck) . . . . . . . . . . . . . .
Wheel Bearing Adjustment
Front Wheel . . . . . . . . . . . . . . .
Front Wheel Bearing Seal Adjustment
Wheel Hub and Spindle . . . . . . . . .
Wheel Motors . . . . . . . . . . . . . . .
Wheels and Tires
Front . . . . . . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . . . . . .
Window Service, Cab . . . . . . . . . .
Windshield Washer . . . . . . . . . . . .
Windshield Wiper . . . . . . . . . . . . .
Alphabetical Index
. . A2-4
.
.
.
.
.
.
.
.
G3-7
G3-9
G3-1
G5-4
.
.
.
.
.
.
.
.
.
.
G2-2
G2-3
N2-7
N3-2
N3-1
Q01028 04/01
SECTION R
SYSTEM SCHEMATICS
INDEX
R01046
930E Schematics
with Cummins QSK60 Series Engine
R1-1
NOTES
R1-2
930E Schematics
with MTU/DDC 4000 Series Engine
R01046