Manual 830E AC-Ingles
Manual 830E AC-Ingles
Manual 830E AC-Ingles
Shop
Manual
DUMP TRUCK
®
NOTES:
Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-
sonnel must read and understand this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis-
closed except in accordance with written authorization from KAC.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The
Company reserves the right to make changes or add improvements at any time without incurring any obli-
gation to install such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication.
Customers should contact their local Komatsu distributor for information on the latest revision.
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.
NON-OEM PARTS IN CRITICAL SYSTEMS
For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.
Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the
Komatsu product on the supplier and user. Komatsu will not in any case accept
responsibility for the failure or performance of non-OEM parts in its products,
including any damages or personal injury resulting from such use.
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 per-
sonnel 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 accom-
plishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other gen-
eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major
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 metric (SI) and U.S. standard units throughout and all references to “Right”,
“Left”, “Front”, or “Rear” are made with respect to the operator's 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 135 N·m (100 ft lbs) torque. All torque specifications have ±10%
tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig-
nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
(Gross Vehicle Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers
represent the basic truck model. The letter “E” designates an Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the original man-
ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo-
nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
(GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the
GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable
payload. 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.
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
HYDRAIR® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L
OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
STORAGE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
STEERING
Turning Circle - Front Wheel Track . . 28.4 m (93 ft.)
Twin hydraulic cylinders with accumulator assist to
provide constant rate steering. Emergency power
steering automatically provided by accumulators.
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
• Ensure all guards and covers are in their proper • Before making any modification, consult your
position. Repair any damaged guards and authorized regional Komatsu America Corp.
covers. (See Walk-Around Inspection, later in distributor. Komatsu will not be responsible for
this section.) any injury or damage caused by any
unauthorized modification.
• Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. Always Leaving The Operator’s Seat
use these safety features, properly.
While leaving the operator's seat, DO NOT touch any
• Never remove any safety features. Always keep controls. To prevent accidental operations from
safety features in good operating condition. occurring, always perform the following:
• Improper use of safety features may result in
• Move the shift control lever/switch to NEUTRAL
serious bodily injury or death.
and apply the parking brake.
• Lower the dump body, and move the hoist control
lever to the FLOAT position.
• Stop the engine. When exiting the machine,
always lock compartments, and take the keys
with you to prevent entry from unauthorized
persons.
• Use the handrails and steps marked by arrows in • To prevent hot engine oil spray:
the diagram below when getting on or off the 1. Stop the engine.
machine.
2. Wait for the oil temperature to cool down.
3. Turn the cap slowly to allow pressure to dissi-
pate.
• Keep serviceable fire fighting equipment on • When operating in hazardous areas and areas
hand. Report used extinguishers for replacement with poor visibility, designate a person to direct
or refilling. work site traffic.
• Always apply the parking brake when the truck is • DO NOT allow any one to enter the line of travel
parked and unattended. DO NOT leave the truck of the machine. This rule must be strictly obeyed
unattended while the engine is running. even with machines equipped with a back-up
alarm or rear view mirror.
• Park the truck a safe distance away from other
vehicles as determined by the supervisor.
• 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.
Warning Tag
• Never start the
engine or operate
the controls while a
person is performing
maintenance.
Serious injury or
death may result.
• Always attach a warning tag to the control lever
in the operator's cab to alert others that you are
working on the machine. Attach additional 1. To hold the dump body in the up position, raise
warning tags around the machine, if necessary.
the body to it's maximum height.
• These tags are available from your Komatsu 2. Remove cable (3) from its stored position on the
distributor. body, and install between rear body ear (1) and
• Part No. 09963-03000 axle housing ear (4).
3. Secure the cable clevis pins with cotter pins.
4. Return the cable to stored position (2) after
Proper Tools maintenance is complete.
• Use only tools suited to
the task. Using
damaged, low quality,
faulty, or makeshift tools
can cause personal
injury.
• Extra precaution should be used when grinding,
welding, and using a sledge-hammer.
12. Before leaving this position, look under the 18. Move around the right dual tires. Inspect
lower edge of the chassis to ensure the flexible between the tires for rocks, and check the con-
duct that carries the air from the blower to the dition of the rock ejector. Inspect the tires for
final drive housing is in good condition with no cuts or damage, and for correct inflation.
holes or breakage. Also, look up at the main 19. Perform the same inspection for wheel lugs/
hydraulic pumps to see that there is no leakage wedges, wheel cover latches, and wheel leaks
or any other unusual condition with the pumps that was done on the left hand dual wheels.
or the pump drive shafts.
20. Move in front of the right dual tires and inspect
13. Move around the dual tires, and check to see the hoist cylinder in the same manner as the left
that all lugs/wedges are in place and tight. side. Check integrity and condition of the body-
Inspect latches on the wheel cover to be sure up limit switch. Remove any mud/dirt accumula-
they are properly latched. Inspect the wheel for tion from the switch.
any oil that would indicate brake leakage or
21. Move around the fuel tank. Inspect the fuel sight
wheel motor leakage.
gauge, (this should agree with what will show
Check the dual tires for cuts, damage or bub- on the gauge in the cab). Inspect the attaching
bles. Verify that inflation appears to be correct. hardware for the fuel tank at the upper saddles,
If the truck has operating on a flat tire, the tire and then at the lower back of the tank for the
must be cool before moving the truck inside a security and condition of the mounts. Check the
building. Check for any rocks that might be hoist filters for leaks.
lodged between the dual tires. Inspect the rock
22. Move behind the right front wheel, and inspect
ejector condition and straightness so that it can
the steering cylinder. Check for proper greasing
not damage a tire.
and inspect the mounting hardware. Check the
14. Inspect the left rear suspension for damage and suspension mounting hardware and suspension
for correct rod extension. Check for leaks. extension. Ensure the suspension protective
Ensure that the covers over the chrome piston boot is in good condition. Inspect the hub and
rod are in good condition. Inspect for proper brakes for any unusual conditions. Check the
greasing. entire area for leaks.
Operation
The truck is equipped with an emergency steering
system in the event of a failure in the oil supply to the
main steering system. The emergency steering sys-
tem was designed to meet or exceed SAE J1511 and Ensure no one is near the front tires during this
ISO 5010 standards. test. All personnel are warned that the clearances
change when the truck is steered and this could
If the low steering system pressure indicator light and
cause serious injury.
alarm are activated, a failure in the hydraulic oil sup-
ply to the steering and brake system exists. When
the alarm is activated, there is enough hydraulic This test can only be performed with an empty truck.
pressure stored in the brake and steering accumula- 1. Ensure no one is near the front tires during this
tors to allow the operation of the steering and brake test. Use a spotter to keep the area around the
functions. However, this oil supply is limited. There- front tires clear of personnel during this test.
for, it is important to stop the truck as quickly and
safely as possible after the alarm is first activated. 2. Start the engine and allow the hydraulic system
to reach full pressure and the accumulators to
If the oil supply pressure drops to a pre-determined fill with oil.
level, the low brake pressure warning light will also 3. Shut the engine off by using the engine stop
illuminate. If the oil pressure continues to decrease, button located on the center console. DO NOT
the brake auto-apply feature will activate and the ser- turn the key switch OFF.
vice brakes will apply automatically to stop the truck.
4. Turn the steering wheel.
1. Stop the truck as quickly as possible by using
the foot pedal to apply the service brakes. If q If the front tires respond to the steering
possible, steer the truck to the side of the road wheel input, the emergency steering
system is functioning properly. Turn the key
while braking.
switch to the OFF position.
2. When stopped, shift the directional control lever
to PARK. This will apply the parking brake. q If the front tires do not steer, turn the key
switch to the OFF position and notify
3. Turn the key switch OFF and notify mainte- maintenance personnel immediately. Do
nance personnel. not drive the truck until the problem has
4. If safe to do so, place wheel chocks in front or been repaired and the truck can pass this
behind the wheels so that truck can not roll. test.
5. If traffic is excessive near the disabled machine, If the truck passes this test, the emergency steering
mark the truck with warning flags during day- system is functioning properly.
light hours or use flares at night. Adhere to local
regulations.
SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B ft lbs CODE (O.D.) UNF-2B ft lbs
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
ft lbs 0 1 2 3 4 5 6 7 8 9
0 (N·m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage
ft lbs 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page A5-5 regarding Table usage
psi 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page A5-5 regarding Table usage
psi 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
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). 3. Multiply by 10:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to psi row 0, column 5; read 34.475
2. Go to psi row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
sq. ft. – ft2 sq. centimeters (cm2) 929 sq. centimeters (cm2) sq. ft. – ft2 0.001
cu. in. – in.3 cu. centimeters (cm3) 16.39 cu. centimeters (cm3) cu in – in.3 0.061
cu. in. – in.3 liters (l) 0.016 liters (l) cu in – in.3 61.02
cu. ft. – ft3 cu. meters (m3) 0.028 cu. meters (m3) cu ft – ft3 35.314
cu. ft. – ft3 liters (l) 28.3 liters (l) cu ft – ft3 0.0353
ton (short) metric ton 0.0907 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
quart – qt liters (l) 0.946 kilogram (kg) ton 0.0011
gallon – gal liters (l) 3.785 metric ton ton 1.1023
HP (horsepower) Watts 745.7 liters (l) quart – qt 1.0567
HP (horsepower) kilowatts (kw) 0.745 liters (l) gallon – gal 0.2642
Watts Horsepower HP 0.00134
kilowatts (kw) Horsepower HP 1.3410
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
g. Check and tighten the engine mounts. a. Replace hydraulic filter elements and clean
suction strainer elements. While suction
6. Inspect and service the transmission according strainers are removed, inspect and clean the
to the Transmission service manual. interior of the tank thoroughly to remove all
NOTE: If a hydraulic pump or the engine is sediment and foreign material.
inoperative, the dump body should be raised with a b. Inspect all hydraulic lines for deterioration or
crane so body holding devices can be installed. damage. Replace suspect lines - don't risk
hose ruptures or blow outs.
6 Months to 24 Months
This procedure describes the proper method for the
long term storage of an engine.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
LADDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7
Read and observe the following instructions • All hoses and mating fittings should be capped as
before attempting any repairs! 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,
• Do not attempt to work in deck area until body Truck Cab, in this manual.
safety cables have been installed.
• Do not step on or use any power cable as a
handhold when the engine is running. Preparation
• Do not open any electrical cabinet covers or 1. Reduce the engine speed to idle. Place the
touch the retarding grid elements until all selector switch in PARK. Be certain the parking
shutdown procedures have been followed. brake applied indicator lamp in the overhead
• All removal, repairs and installation of panel is illuminated.
propulsion system electrical components, 2. Place the drive system in the rest mode by turn-
cables etc. must be performed by an ing the rest switch on the instrument panel ON.
electrical maintenance technician properly Ensure the rest warning lamp is illuminated.
trained to service the system.
3. Shut down the engine using the key switch. If,
• In the event of a propulsion system for some reason the engine does not shut
malfunction, a qualified technician should down, use the shutdown switch on the center
inspect the truck and verify the propulsion
console.
system does not have dangerous voltage
levels present before repairs are started. 4. Verify the link voltage lights are off. If they
remain on longer than 5 minutes after shut-
down, notify the electrical department.
After the truck is parked in position for the repairs, 5. Verify the steering accumulators have bled
the truck must be shut down properly to ensure the down by attempting to steer.
safety of those working in the areas of the deck, elec-
6. Bleed down the brake accumulators using the
trical cabinet and retarding grids. The following pro-
manual bleed valves on the brake manifold.
cedures will ensure the electrical system is properly
discharged before repairs are started. 7. Open the battery disconnect switches.
Installation
Repeat above steps in reverse order for installation
of components. Tighten all attaching hardware to
standard torque values listed in Section “A”.
Reinstall all wiring and hoses removed and be cer-
tain all clamps are installed and secure.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
1. Dump Body 3. Body Guide Wear FIGURE 3-6. BODY-UP CABLE INSTALLATION
2. Body Guide Plates 1. Rear Body Ear 3. Cable
Structure 4. Axle Housing Ear
2. Cable Storage Structure
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 ejec-
tors 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 6.35 mm (0.25
in.).
2. With the truck parked on a level surface, the
arm structure (Refer to Figure 3-7) should be
approximately 88 mm (3.50 in.) from the wheel
spacer ring (3) when hanging vertical. FIGURE 3-7. ROCK EJECTOR
NOTE: With rock ejector arm (1, Figure 3-8) hanging 1. Rock Ejector Arm 3. Rear Wheel Spacer
vertical as shown, there must be NO GAP at stop 2. Wear Plate Ring
block (3). Adjust stop block as necessary to obtain
NO GAP.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Removal
1. Drain the fuel below the level of the fuel gauge
sender.
If a tank is to be weld repaired, special precau-
tions are necessary to prevent fire or explosion. 2. Disconnect the wires from terminals (18).
Consult local authorities for safety regulations 3. Remove sender mounting hardware (19). Care-
before proceeding. fully remove the sender and gasket.
Installation
1. Clean the mating surfaces. Install a new gasket.
Cleaning
2. Install the fuel gauge sender in the tank. Ensure
The fuel tank is provided with a drain and a cleaning the float is oriented properly and moves freely.
port in the side that allows steam or solvent to be uti- 3. Install sender mounting hardware (19) and
lized in cleaning tanks that have accumulated foreign tighten the cap screws to the standard torque.
material.
4. Connect the wires to terminals (18).
It is not necessary to remove the tank from the truck 5. Fill the fuel tank and check for leaks.
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 con-
tact 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 tempo-
rary 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 ser-
vice. All openings should be sealed for rust preven-
tion.
Disassembly
1. Remove clamp (3, Figure 4-2), cover (2) and
screen (1).
2. Remove ball cage (10), solid ball (11) and float
balls (12).
3. Unscrew end fitting (7) from body (4).
4. Remove stem (8) and valve spring (5).
Assembly
1. Clean and inspect all parts. If any parts are
damaged, replace the entire assembly.
2. Place valve spring (5) into position in body (4).
3. Insert stem (8) into end fitting (7).
4. Screw end fitting (7) into body (4). Ensure the
components are properly aligned and seated.
5. Place screen (1) and cover (2) into position on
the breather. Install clamp (3).
6. Insert the balls into ball cage (10) with solid ball
(11) on top.
7. Insert the ball cage onto the stem. A minimum
of two cage coils must be seated in the groove
on the stem. Ensure the solid ball is able to seat FIGURE 4-2. BREATHER VALVE
properly on the stem. If not, adjust the cage
accordingly. 1. Screen 7. End Fitting
2. Cover 8. Stem
3. Clamp 9. O-Ring
4. Body 10. Ball Cage
5. Valve Spring 11. Solid Ball
FUEL RECEIVERS (WIGGINS QUICK FILL) 6. O-Ring 12. Float Ball
Fuel receiver assembly (2, Figure 4-1) is mounted on
the side of the fuel tank.
Keep the cap on the fuel receiver to prevent dirt build
up in valve area and nozzle grooves. LOW FUEL SWITCH
If fuel spills from the fuel tank breather valve (7), or if Low fuel switch (13, Figure 4-1) controls the low fuel
the tank does not completely fill, check the breather level indicator on the overhead warning indicator light
valve to see whether the float balls are in place and panel in the operator cab. The switch is calibrated to
the outlet screen is clean. If the breather valve is turn on the low fuel indicator when the usable fuel
operating properly, the problem will most likely be in remaining in the tank is approximately 25 gallons (95
the fuel supply system. liters).
ENGINE
INDEX
POWER MODULE
INDEX
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-8
Installation
1. Inspect the main frame guide rails. Remove any
debris which would interfere with power module
installation.
2. Clean the main frame rear support brackets.
FIGURE 2-5. SUBFRAME ROLLERS Apply a light film of soap solution to each rubber
bushing (5, Figure 2-4) located at the rear of the
1. Roller Assembly 3. cap screws subframe.
2. Subframe
3. Check the subframe rollers making sure they
roll freely and are in the “roll-out” position. (Fig-
ure 2-5).
23. Attach lifting device to hoist and attach to 4. Attach a lifting device to engine/alternator cra-
engine/alternator cradle structure and front sub- dle structure and front subframe lifting points.
frame lifting points as shown in Figure 2-6. (Figure 2-6)
Remove safety chain.
14. Lower the rear portion of the subframe until the 25. Install transition structure (3) to alternator.
subframe rubber bushings are seated in the 26. Lift main alternator blower intake duct (2) into
rear mounting brackets located on the main position and install all mounting hardware at
frame of the truck. mounts.
15. After subframe is seated in frame mounts, the 27. Install control cabinet air hose (5), electrical
safety chain may be removed from the front cables and any other hoses and wiring removed
subframe member. during power module removal.
16. Install cap screws (9, Figure 2-4) and lockwash- 28. Connect all remaining electric, oil, and fuel
ers in the front mount and tighten cap screws to lines.
298 ±30 N·m (220 ±22 ft lbs) torque. Install
29. Attach hoist to the front center deck and lift into
ground strap between frame and subframe.
position. Align the rear center deck mounting
Reinstall air dam. Install cover (10) if grille is
holes with the support structure in front of the
installed.
electrical cabinet. Install cap screws and flat
washers. Do not tighten at this time.
30. Align the front center deck, front mounting holes
with both left and right fender supports. Install
cap screws and flat washers. Tighten all deck
mounting cap screws to standard torque values.
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10
External Cleaning
Many radiator shops use a hot alkaline soap, caustic
soda or chemical additives in their boil-out tanks,
which can attack solders. These tanks are generally
not recommended. Before such tanks are used for
cleaning, ensure that the cleaning solutions are
not harmful to solder. Otherwise, damage to the FIGURE 3-5. BREAKER TOOL (XA2307)
radiator will result. Completely rinse the cleaned
tube or core in clean water after removing it from the
boil-out tank. 1. Start at the top row of tubes. Use the breaker
As an alternative to boil-out tanks, radiators can be tool (XA2307) to loosen the tube to be removed.
cleaned externally with a high pressure washer and When using the breaker tool, position it at the
soap. In most cases, it may be best to blow out any top or bottom of the tube. Never position it in the
dry dirt with a high pressure air gun prior to washing middle of the tube or damage may result. Use
the core with the high pressure washer. the breaker tool to lightly twist the tube back
and forth within the seals to loosen the grip.
Refer to Figure 3-5.
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-9
4. Reach through the access opening and remove FIGURE 4-4. ALTERNATOR TO ENGINE
12 cap screws (6, Figure 4-4) joining the engine MOUNTING
drive ring (7) to the alternator rotor (8). (Rotate
crankshaft with barring tool to align each cap 1. Alternator 5. Cap Screw
screw with access hole.) 2. Flywheel Housing 6. Cap Screw (12 each)
Adapter 7. Engine Drive Ring
3. Cap Screw (16 each) 8. Alternator Rotor
4. Flywheel Housing
NOTE: The clearance between the head of the cap 8. Note shim location and quantity. Retain shims
screw (3) and the flywheel housing (4) will not permit for possible use during reinstallation.
complete removal of the cap screws at all locations. 9. For further disassembly instructions for the
Be sure all the cap screw threads are completely alternator refer to the General Electric Service
disengaged from the alternator housing (1). Manual.
Description T.I.R.
Max. Flywheel Housing Bore 0.66 mm
Eccentricity (0.026 in.)
Max. Face Runout, Flywheel 0.25 mm
Housing (0.010 in.) FIGURE 4-5. SHIM LOCATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-6
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-20
1. Orifice Fitting 16. External Snap Ring (Spacer) 32. Internal Snap Ring
2. Dowel Pin (Rear) 17. Seal Ring (Hook-Type) 33. Main Bearing (Front)
3. Pitot Tube 18. Bolt 34. O-Ring Seal
4. Wear Sleeve 19. Washer 35. Bearing Retainer (Front)
5. Retainer/Seal Assembly 20. Pulley 36. Oil Seal
6. Shaft Assembly 21. Pulley Adapter 37. Washer
7. Name Plate Kit 22. Seal Ring (Large) 38. Bolt
8. Washer 23. Piston 39. Wear Sleeve
9. Bolt 24. Seal Ring (Small) 40. Retainer/Seal Assembly
10. Oil Seal 25. Spring Washer 41. Sleeve Bearing (Rear, Short)
11. Bearing Retainer (Rear) 26. Shim 42. Fan Mounting Hub
12. Bearing Spacer 27. External Snap Ring 43. Dowel Pin (Front)
(External Snap Ring) 28. External Snap Ring 44. Sleeve Bearing (Front, Long)
13. O-Ring Seal 29. Clutch Hub 45. End Cap
14. Main Bearing (Rear) 30. Facing Plate
15. Internal Snap Ring 31. Steel Clutch Plate
1. Support the fan clutch on a bench with fan 3. Remove O-ring seal (34).
mounting hub (42) facing upward. Support the
assembly beneath the pulley. Remove bolts
(38) and washers (37).
FIGURE 7-6.
7. Remove front oil seal (36).
FIGURE 7-9.
FIGURE 7-7.
8. Remove internal snap ring (32).
6. Position the sub-assembly beneath the ram of a
press. Support the assembly beneath the
bearing retainer as close as possible to fan
mounting hub (42). Press the fan mounting hub
out of the front bearing using tooling (B).
FIGURE 7-13.
12. Inspect sleeve bearing (44) and sleeve bearing FIGURE 7-16.
(41). Compare the color of each bearing to the
chart above. The lighter the appearance of the 14. Remove the stack of facing plates (30) and
bearing, the more worn it is. If either bearing steel clutch plates (31) from inside the pulley.
needs replacing, proceed to the next step. If the
bearings are in good condition, skip the next
step.
FIGURE 7-17.
FIGURE 7-15. 15. Remove external snap ring (27), shim (26), and
spring washer (25).
13. Position tooling (C) against sleeve bearing (41).
Press the front sleeve bearing downward to
press it out of the fan mounting hub. Rear
sleeve bearing (44) will be pressed out
simultaneously.
FIGURE 7-18.
18. Support beneath the pulley to prevent it from
dropping to the bench. Remove bolts (9) and
16. Attach wire lifting hooks to piston (23). Use the lockwashers (8).
lifting hooks to pull the piston from pulley
adapter (21).
FIGURE 7-19.
FIGURE 7-21.
17. Remove seal rings (22) and (24) from the
piston. 19. Install lifting eyebolts to the shaft and bearing
retainer assembly. Use a suitable lifting device
to lift the assembly from the pulley. Remove O-
ring seal (13).
NOTE: It may be necessary to use a soft rubber
mallet to separate the shaft and bearing retainer from
the pulley.
FIGURE 7-25.
FIGURE 7-23.
21. Remove both seal rings (17). 23. Remove internal snap ring (15).
FIGURE 7-26. 26. Use tooling (E) to press rear bearing (14) out of
rear bearing retainer (11).
FIGURE 7-29.
1. Check the shaft assembly for wear or damage. Refer to Figure 7-31 for dimensions.
NOTE: Some shafts were manufactured as two-piece assemblies. Do not attempt to separate the shaft assembly.
2. Inspect and clean the pitot tube holes in the shaft. Use a standard reamer (straight flute, 0.3770 in. diameter).
Remove pipe plugs in the shaft for cleaning and reinstall using Loctite® Primer N and #242.
FIGURE 7-34.
FIGURE 7-33.
FIGURE 7-39.
FIGURE 7-38.
FIGURE 7-42.
FIGURE 7-41.
FIGURE 7-43.
FIGURE 7-47.
FIGURE 7-49.
8. Apply Loctite Primer N and #609 to the mating 10. Turn the retainer over on the press bed. Coat
surfaces of front bearing (33) and front bearing the outside diameter of front oil seal (36) and
retainer (35). Place the bearing into position on the mating surface on the bearing retainer with
the retainer with the notch for the bearing pin Loctite Primer N and #242 (or equivalent).
facing downward.
Use tooling (E) to press the oil seal into the front
Press the front bearing into the bearing retainer bearing retainer until it is flush with the front
using tooling (E) or equivalent. Press ONLY on face. Ensure that the lip of the seal is dry.
the outer race of the bearing until it seats at the Wipe any excess Loctite from the seal area and
bottom of the bore. remove any rubber strings from the seal.
FIGURE 7-52.
FIGURE 7-55.
FIGURE 7-56. 17. Coat the outside diameter of rear bearing (14)
and the mating surface of bearing retainer (11)
with Loctite Primer N and #609 or equivalent.
The end of the bearing with the notch is
installed first. Using tooling (F) or equivalent,
press the bearing into the bearing retainer.
Press ONLY on the outer race of the bearing
until the bearing bottoms out in the bore.
• Rear (notched) wear sleeve (4) is NOT
interchangeable with front wear sleeve (39).
The inside diameter of the rear wear sleeve is
color coded blue.
• Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from
occurring.
• Use extreme care when handling the wear
sleeve. The slightest nicks or scratches may
cause leakage.
19. Some fan clutches were assembled with an external snap ring that is used as a spacer between the bearing
and the oil seal. Newer models were assembled using a notched spacer. If an external snap ring was used,
place snap ring (12) on top of the bearing (oil seal side). If a notched spacer was used, the spacer will be
installed in a later step. Proceed to the next step.
FIGURE 7-60.
FIGURE 7-61.
20. Coat the outside diameter of rear oil seal (10) 21. If a bearing spacer is used instead of a snap
with Loctite Primer N and #242 (or equivalent). ring (as explained in Step 19), place the spacer
Use tooling (E) or an equivalent to install the oil into position in the groove on shaft assembly
seal in the rear bearing retainer until it is flush (6). Note the location of the spacer in Figure 7-
with the rear face. 61.
Do not lubricate the seal. The seal is made of
teflon and must be installed dry.
FIGURE 7-66.
FIGURE 7-65.
FIGURE 7-69.
FIGURE 7-68.
FIGURE 7-71.
FIGURE 7-73.
FIGURE 7-72.
FIGURE 7-74.
36. Install bolts (9) with lockwashers (8). Tighten
each bolt to 49 - 58 N•m (36 - 43 ft lbs).
34. Lubricate O-ring seal (13) with petroleum jelly or
an oil-soluble grease and install it in the pulley
groove.
FIGURE 7-77.
FIGURE 7-75.
35. Lubricate hook-type seal rings (17) on the shaft 37. If removed, install orifice fitting (1) in the “oil in”
assembly. Carefully lower the shaft sub- port of the bracket.
assembly into the pulley bore and onto the
pulley until the retainer rests on the pulley.
Use caution when lowering. Damage to the
sleeve bearings may result if the shaft is cocked
during installation.
38. Turn the assembly over on the bench. Install remaining bolts (38) and lockwashers (37). Tighten each bolt to
49 - 58 N•m (36 - 43 ft lbs).
1. The fan clutch should be fully locked up with 275 kPa (40 psi) oil pressure supplied at the control pressure
port.
2. Operate the fan clutch with 82° C (180° F) oil supplied to the “oil in” port for 2 hours. Manually engage and
disengage the clutch during the test to operate seals in both modes. Restrict the fan mounting hub rotation
while the clutch is disengaged, but ensure that the fan mounting hub is allowed to rotate freely while the clutch
is engaged.
The fan clutch rotation causes the pitot tubes to pump lubricating oil from inside the fan clutch,
maintaining low internal oil pressure. If lubricating oil is supplied to the fan clutch before it is rotating in
the proper direction, internal pressures will become excessive, causing the oil seals to leak.
INDEX
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 FOL-
LOWED. Before attempting repairs or working near propulsion system components, the following
precautions and truck shutdown procedure must be followed:
•DO NOT step on or use any power cable as a handhold.
•Never open any electrical cabinet covers or touch the retarding grid elements. Additional pro-
cedures 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.
•Prior to welding on the truck, maintenance personnel should attempt to notify the Komatsu
Factory Representative. The welding ground electrode should be attached as close as possi-
ble to the area to be welded. Never weld on the rear of the electrical control cabinet or the
retard grid exhaust air louvers.
After the truck is parked in position for the repairs, the truck must be shut down properly to ensure the
safety of anyone working in the areas of the deck, electrical cabinet, traction motors, and retarding grids.
The following procedure will ensure that the electrical system is properly discharged before repairs are
begun.
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19
Troubleshooting
Lead-acid storage batteries contain sulfuric acid Two most common problems that occur in the charg-
which, if handled improperly, may cause serious ing system are undercharging and overcharging of
burns on skin or other serious injuries to person- the truck's batteries.
nel. Wear protective gloves, aprons and eye pro-
tection when handling and servicing lead-acid An undercharged battery is incapable of providing
storage batteries. See the precautions in Section sufficient power to the truck's electrical system.
A of this manual to ensure proper handling of Some possible causes for an undercharged battery
batteries and accidents involving sulfuric acid. are:
During operation, the storage batteries function as an • Sulfated battery plates
electrochemical device that converts chemical
• Loose or corroded battery connections
energy into the electrical energy that is required for
operating the accessories when the engine is off. • Defective wire in electrical system
• Loose alternator drive belt
• Defective alternator
BATTERIES
Overcharging, which causes overheating, is first indi-
Maintenance and Service cated by excessive use of water. If allowed to con-
tinue, the cell covers will push up at the positive ends
The electrolyte level of each cell should be checked
and, in extreme cases, the battery container will
at the interval specified in Section P, Lubrication and
become distorted and cracked.
Service. Add water if necessary. The proper level to
maintain is 10 to 13 mm (3/8 to 1/2 in.) above the Leakage can be detected by continual wetness of the
plates. To ensure maximum battery life, use only dis- battery or excessive corrosion of the terminals, bat-
tilled water or other types of water recommended by tery carrier and surrounding area. (A slight amount of
the battery manufacturer. After adding water in freez- corrosion is normal in lead-acid batteries). Inspect
ing weather, operate the engine for at least 30 min- the case, covers and sealing compound for holes,
utes to thoroughly mix the electrolyte. cracks and other signs of leakage. Check the battery
hold down connections to ensure that the tension is
not great enough to crack the battery or loose
enough to allow vibration to open the seams. A leak-
ing battery must be replaced.
Isolator Diode
A Schottky type isolation diode (9) is used to provide
isolation between the electrical system battery cir-
cuits and the dual cranking motor start command cir-
cuits. This device controls the direction of current
flow in high current applications.
Check Valve
Timer Solenoid Verify no internal leakage exists in the check valve
when the engine is running. Check valve leakage
The timer solenoid (3, Figure 2-3) controls the prelu-
back to the prelube pump will cause extensive dam-
brication cycle. Current is supplied to the timer
age to the pump.
through the key switch. The ground path is com-
pleted by the normally closed pressure switch (2). If check valve replacement is required, ensure the
valve is installed with the arrow pointed toward the
When the switch opens, current is redirected to the
engine, and NOT toward the pump.
engine cranking motor solenoids (8) for engine
cranking.
Timer Solenoid
Inspect timer solenoid for physical damage and to
verify wiring is in good condition.
• Cranking motor has no prelubrication, no delay If the cranking motor is totally inoperative and no pre-
and no crank. lubrication, no delay and crank, this indicates a possi-
ble failure of the prelubrication timer solenoid.
Remove the wire from the pressure switch (ground
wire) and activate the key switch for several seconds.
a. If the cranking motor delays - then cranks, the
Prelube Timer Solenoid is bad. Replace the
timer solenoid assembly.
b. If the cranking motor is still inoperative, check
the truck cranking motor switch circuit. Make
sure proper voltage is available to the Prelube
Timer Solenoid when the key is activated.
• Cranking motor prelubricates, delays, then does Indication is either a timer failure, or a cranking motor
not crank. problem.
a. Place a jumper wire to the cranking motor
solenoid “S” post. If the engine starts to crank,
replace the Prelube Timer Solenoid.
b. If the engine fails to crank when the "S" post
is energized with voltage, check out cranking
motor bendix solenoid and cranking motor
pinion drive.
Removal
Installation
1. Disconnect battery power:
1. Align cranking motor (2, Figure 2-6) housing
a. Open the battery disconnect switch to with the flywheel housing adaptor mounting
remove power from the system. holes and slide into position.
b. Disconnect the negative (-) battery cables 2. Insert cranking motor cap screws (1).
first. 3. Connect marked wires and cables to cranking
c. Disconnect the battery positive (+) battery motor and solenoid terminals.
cables last. 4. Install in the following sequence:
2. Mark wires and cables and remove from crank- a. Connect the battery positive (+) cables first.
ing motor (2, Figure 2-4) and solenoid (3) termi-
nals. b. Connect the battery negative (-) cables.
3. Remove cranking motor mounting cap screws 5. Close the battery disconnect switch.
(1).
4. Remove cranking motor assembly from fly-
wheel housing.
SOLENOID CHECKS
A basic solenoid circuit is shown in Figure 2-7. Sole-
noids can be checked electrically using the following
procedure.
Test
1. With all leads disconnected from the solenoid,
make test connections as shown to the sole- FIGURE 2-8. SOLENOID HOLD-IN WINDING TEST
noid, switch terminal and to the second switch
terminal “G”, to check the hold-in winding (Fig-
ure 2-8).
2. Use the carbon pile to decrease the battery volt-
age to 20 volts. Close the switch and read cur-
rent.
The ammeter should read 6.8 amps
maximum.
3. To check the pull-in winding, connect from the
solenoid switch terminal “S” to the solenoid
motor “M” or “MTR” terminal (Figure 2-9).
Bearing Replacement:
1. If any of the bronze bearings are to be replaced,
dip each bearing in SAE No. 20 oil before
pressing into place.
2. Install wick, soaked in oil, prior to installing
bearings.
3. Do not attempt to drill or ream sintered bear-
ings. These bearings are supplied to size. If
drilled or reamed, the I.D. will be too large and
the bearing pores will seal over.
4. Do not cross-drill bearings. Because the bear-
ing is so highly porous, oil from the wick touch-
ing the outside bearing surface will bleed
through and provide adequate lubrication.
5. The middle bearing is a support bearing used to
prevent armature deflection during cranking.
The clearance between this bearing and the
armature shaft is large compared to the end
frame bearings.
Motor Assembly:
1. Install the end frame (with brushes) onto the
field frame as follows:
FIGURE 2-10. PINION CLEARANCE CHECK
a. Insert the armature (45, Figure 2-6) into the CIRCUIT
field frame (35). Pull the armature out of the
field frame just far enough to permit the
brushes to be placed over the commutator.
b. Place the end frame (1) on the armature
shaft. Slide end frame and armature into 5. Using a new gasket (72), install drive housing
place against the field frame. (69) and secure with screws (70).
c. Insert screws (34) and washers (33) and 6. Assemble field coil connector (42) to solenoid.
tighten securely. 7. Adjust pinion clearance per instructions on the
2. Assemble lever (63) into lever housing (78) If following page.
removed. 8. After pinion clearance has been adjusted, install
3. Place washer (79) on armature shaft and install gasket (74) and plug (73).
new O-ring (80). Position drive assembly (71) in
lever (63) in lever housing. Apply a light coat of
lubricant (Delco Remy Part No. 1960954) on
washer (75) and install over armature shaft.
Align lever housing with field frame and slide
assembly over armature shaft. Secure with
screws (76) and washers (77).
4. Assemble and install solenoid assembly
through lever housing and attach to field frame.
Install nut (64) but do not tighten at this time.
Install brush inspection plugs (52).
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16
NOTE: For more information about relay boards RB1 through RB9, refer to Relay Boards later in this section.
When the temperature is low and the resistance is NOTE: Some electronic engine controls monitor
high, Q1 is off and no high temperature indication coolant level. If the engine controls monitor the
occurs. When the coolant temperature is excessive, circuit, a 2KΩ resistor is installed to replace the
resistance decreases to a point where Q1 will turn on probe and disable the AID system circuit.
and ground the flasher through D8, the alarm horn
through D12, and the high temperature light through
terminal D8. R14 can adjust the temperature (resis-
tance) at which the circuit is activated.
NOTE: Some electronic engine controls monitor
coolant temperature. If the engine controls monitor
the circuit, a 2K ohm resistor is installed to replace
the temperature sensor and disable the AID system
circuit.
The latch circuit monitors the accumulator precharge
pressure switches. When one of the pressure
switches closes, Q5, which supplies power to the
gate of SCR Q7, will be turned off. With Q7 turned
on, Q9 will supply the ground path to turn on the low
accumulator precharge indicator light and sound the
alarm horn. The indicator light is connected to 12F
and will flash off and on. The SCR will remain on until
power is removed from the card by turning the key
switch OFF.
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 con-
tacts close, an electrical signal is sent to the hoist-up
limit solenoid valve, located in the hydraulic brake
cabinet, to prevent further oil flow to the hoist cylin-
ders.
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch assem-
bly.
Adjustment
1. Raise the body so that the hoist cylinders are
within 152 mm (6 in.) of maximum travel.
2. Adjust the hoist limit switch to achieve an air
gap (dimension “A”) of 12.70 to 14.30 mm (0.50
to 0.56 in.) between the sensing area and actu-
ator arm (3). Tighten the cap screws.
Service
Keep the sensing area clean and free of metallic dust
and other debris that may damage or inhibit opera-
tion of the switch. If the switch is damaged or not
functioning, the switch must be replaced.
FIGURE 3-9. HOIST LIMIT SWITCH ADJUSTMENT
FUSE BLOCK #1
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 15 A/C, Heater Blower Motor 12H
2 15 Windshield Washer / Wiper 63
3 5 Instrument Panel Gauges 712G
4 10 Key Switch Power 712P
5 10 Hoist Limit Solenoid 712H
6 15 Turn Signal / Clearance Lights 712T
7 10 Engine Options 712E
8 10 AID and Indicator Lights 12M
9 5 Engine Start Failure 712SF
10 10 Engine Shutters 712R
11 10 Dome Light Switch 712A
13 10 Radio Memory 65
17 15 Key Switch Supplemental Power 11KS
18 15 Payload Meter Lights 39J
19 5 Payload Meter System 39G
FUSE BLOCK #2
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 15 Service Lights 11SL
2 15 Cab Dome, Fog, Ladder Lights 11L
3 15 Hazard Lights 46
4 10 Interface Module 11INT
5 10 VHMS & Orbcomm Controllers 85
6 20 Modular Mining System 11M
7 15 VHMS & Orbcomm Battery 11DISP
8 15 Headlights 11HDL
9 15 Oil Reserve System Pump 11ORS
10 15 Oil Reserve System Control 11RCNT
11 20 Hydraulic Bleed Down 11BD
12 10 Engine Load 11EM
13 10 Key Switch Power 11KS
FUSE BLOCK #4
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 10 Brake Circuits 71BC
2 5 PLMIII 712K, 712PL
3 5 Interface Module 87
4 10 VHMS Supply 71VHM
5 5 Modular Mining System 712MM
6 5 Display Module 86
7 10 Hydraulic Bleeddown Signal 71BD
8 10 OP Switch LED Power 71LS
9 10 Selector Switch Power 71SS
17 5 Temperature Gauge 15V
18 15 Pedal Voltage 15PV
19 5 Engine Interface 15VL
CIRCUIT BREAKERS
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
RB3 - CB11 12.5 Back Up Horn and Lights 79A
RB1 - CB13 12.5 Turn Signals / Clearance Lights 11CL
RB1 - CB14 12.5 Turn Signal Flasher 11Z
RB1 - CB15 12.5 Tail Lights 41T
RB3 - CB16 12.5 Retard Lights 44D
RB3 - CB17 12.5 Manual Backup Lights 47B
RB3 - CB18 12.5 Stop Lights 44A
RB3 - CB19 12.5 Backup Lights and Horn 79A
RB4 - CB20 12.5 Engine Control Power 23D
RB4 - CB21 12.5 Service Lights, Horn, Solenoid 11A
RB4 - CB22 12.5 Engine Run Relay 439E
RB5 - CB23 12.5 Headlights, Left Low Beam 11DL
RB5 - CB24 12.5 Headlights, Right Low Beam 11DR
RB5 - CB25 12.5 Headlights, Left High Beam 11HL
RB5 - CB26 12.5 Headlights, Right High Beam 11HR
RB5 - CB27 12.5 Headlights and Dash Lights 11D
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Undercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Overcharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-7
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22
Field Coil Test 1: Check for Open or Shorted Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-78
Freezing
An undercharged battery is extremely susceptible to
freezing when stored in cold weather.
The electrolyte of a battery in various stages of
charge will start to freeze at temperatures indicated
in Table 10-1.
The temperatures in Table 10-1 indicate the points at
which the first ice crystals appear. Lower tempera-
tures must be reached for a solid freeze. Solid freez-
ing of the electrolyte may crack the battery case and
damage the positive plates. A battery with at least a
75% charge is in no danger of freezing, especially
during winter weather.
General Description Drive end housing (9) and anti-drive end housing (6)
each contain a bearing to support drive and rotor
The Niehoff model C653A 28-Volt (260 Amp) alterna- shaft (1). They are attached to each end of the shell
tor is self-rectifying. All windings and current-trans- assembly by long threaded studs.
mitting components are non-moving, so there are no
brushes or slip rings to wear out. Drive end housing assembly (9) has an area called
control housing (2), containing all the required inter-
When controlled by voltage regulator (5), these alter- nal electrical connections for the alternator. It also
nators become self-energizing through an internal contains a thermal switch used to protect the B+ ter-
dual diode trio. A residual magnetic field induces a minal.
small voltage in the stator and energizes the field
coil. The field coil continues receiving incremental Battery positive terminal (4) is located on the face of
voltage until full voltage is achieved. Alternating cur- control housing (2) for connection to the truck’s bat-
rent (AC) is rectified into a direct current (DC) output tery positive circuit. The ground circuit cable can be
through the diodes. The regulator controls voltage attached to either of two ground terminals (10)
output and has a D+ terminal to provide a DC output located on the front housing. Fan guard (7) protects
signal to the truck’s electrical system, confirming maintenance personnel from the rotating fan when
alternator operation. An R terminal provides optional the engine is operating.
AC output. Identification plate (3) contains general alternator infor-
mation, including model number and serial number.
.
Alternator Specifications
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28VDC
Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Negative
Regulator Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 10-2. TERMINAL LOCATIONS
Regulator Settings . . . . . . . . . . . . . . . . . . . . . . . 27.5
B+. Battery Positive D+. DC Output ...................................... 28.5
B-. Battery Negative R. AC Output ...................................... 28.0
...................................... 29.0
Battery Positive (B+)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 29 kg (65 lbs)
Main positive power terminal on the alternator.
Located on the control housing. Performance Curve
Battery Negative (B-) Measurements listed on the curves are for a stabi-
lized machine at maximum output at temperatures
Main negative power terminal (ground) on the alter- indicated for each curve.
nator. Located on the drive end housing.
DC Output (D+)
Positive DC voltage output from the alternator. May
be used for specific control circuit. Located on the
regulator. Limited to one or two amp output.
AC Output (R)
Relay terminal. AC current output terminal for the
tachometer or for relay use. Located on the regulator.
TORQUE SPECIFICATIONS
Item Description Metric SAE
1 Ground Bolt (B-), M10 X 1.5 15 N·m 11 ft lbs
2 Pulley Nut, M20 X 1.5 163 N·m 120 ft lbs
3 Output Bolt (B+), M12 X 1.75 32 N·m 24 ft lbs
4 Fan Nut, M16 X 1.5 67 N·m 50 ft lbs
5 Regulator Hold Down Screw, M5 X 0.8 8.5 N·m 75 in. lbs
6 Regulator Terminal (R), M6 X 1 4.5 N·m 40 in. lbs
7 Regulator Terminal (D+), M5 X 0.8 4.5 N·m 40 in. lbs
DIMENSIONS
A Housing Diameter 203.2 mm 8.0 in.
B Overall Length Minus Drive Shaft 292.0 mm 11.5 in.
C Shaft Diameter 22.22 mm 0.875 in.
D Height (Centerline to Top) 142.0 mm 5.59 in.
E Height (Centerline to Bottom) 135.6 mm 5.34 in.
F Width (Centerline to Regulator) 139.2 mm 5.48 in.
Equipment
• Digital Multimeter (DMM)
• Ammeter (digital, inductive)
• Regulator tester
FIGURE 10-11. PIN CONNECTION
Identification Record IDENTIFICATION
Alternator model number ______________ 2. Connect one meter lead to pin A (F-, Figure 10-
Regulator model number ______________ 11) connector socket in the regulator, and con-
nect the other lead to pin C (B-) connector
Set point(s) listed on regulator __________
socket in the regulator. Observe the meter read-
Regulator Tester ing.
3. Reverse the leads and observe the meter reading.
A regulator tester can test all regulator functions. If a
regulator tester is used, follow the regulator tester 4. In one direction, the DMM must register a tone.
manufacturer’s instructions. In the other direction, the DMM must show OL
(out of limits).
If a regulator tester is not available, the regulator can
5. If the DMM shows zero in both directions, the
only be tested for a shorted power transistor.
power transistor is shorted and the regulator
must be replaced.
FIGURE 10-16.
3. How can voltage regulators be tested? Voltage regulators can be tested using several methods.
Refer to the Regulator Bypass test (No Output) 1. The first method is to remove the suspect regulator and
section for additional testing information. substitute a known good regulator and then conduct the
alternator output test. If the alternator performs properly,
the suspect regulator is confirmed defective and must
be replaced.
2. The second method, incorporating the process of elimi-
nation, is to follow a diagnostic sequence and test the
individual alternator component functions to determine if
the components are good or bad. After systematically
eliminating the alternator components as the cause of
the problem, most likely, the regulator is defective.
Replace the regulator.
3. The third method involves utilizing a direct regulator
tester which is commercially available. When using a
tester to test a regulator, follow the instructions supplied
by the tester manufacturer and service manual for
proper terminal connections. If the regulator is not prop-
erly connected, the tester or the regulator may be dam-
aged. Refer to the regulator tester manufacturer's
instructions to determine if the regulator is defective.
7. An alternator is being tested on a test bench and it does The maximum alternator output is dependent on the
not reach its full-rated output. What could be wrong? alternator shaft speed. If the test bench motor is not
properly rated, the alternator shaft will turn too slowly.
The alternator will not reach its rated output. When
testing an alternator on a test bench, ensure the test
bench motor is powerful enough to drive the alterna-
tor shaft at full load. To properly test the alternator
rated at 28-Volts and more than 200 amps, a bench
motor rated at 30 hp is required. Testing an alternator
using an underrated bench motor can lead to misdi-
agnosis and unnecessary component replacement.
Removal
The following instructions cover the removal of alter-
nator (1, Figure 10-17) from a Komatsu engine. Radi-
ator (2) has been removed from the truck in some
pictures to clearly show the removal process. How-
ever, the radiator does not need to be removed to
remove the alternator.
Liquid Threadlockers
Loctite 222 Low Strength Threadlocker is an anaero-
bic sealant. This low-strength threadlock is used for
small screws less than 6 mm (.25 in.) in diameter.
The parts can be separated using hand tools.
Henkel Corporation
1001 Trout Brook Crossing
Rocky Hill, Connecticut 06067 USA
Phone: 860-571-5100
Internet: www.loctite.com
ALTERNATOR DISASSEMBLY
NOTE: Disassemble the alternator only as far as
necessary to replace any defective part(s).
FIGURE 10-29.
36. Wiring Harness 37. Voltage Regulator
The following replacement parts are mandatory:
spiral rings (5, 50), O-rings (63), lock nuts (14),
bearings (9, 62), and all lock washers. All small
hardware is included in a kit. Refer to the Parts
book.
FIGURE 10-30.
38. Screw 39. Bellville Washer
FIGURE 10-33.
FIGURE 10-31.
65. Fan 67. Nut
NOTE: The setting of this switch can depend on the 66. Bellville Washer
type of battery being used. Refer to the Battery
section for additional information.
Fan Removal
1. Remove fan guard (68) by removing six Allen
head screws (69) using a 3 mm Allen wrench. When removing nut (67), the use of an air impact
wrench is recommended.
FIGURE 10-32.
FIGURE 10-34.
68. Fan Guard 70. Grommet Washer
69. Allen Head Screw
NOTE: DO NOT lose the metal portion of grommet 3. Remove and discard spiral ring (50) from fan
washers (70). (65).
FIGURE 10-35.
Pulley Removal
1. Remove pulley (3, Figure 10-24) from the drive
end by removing nut (1) using an air impact
wrench and a 30 mm socket. Also, remove
washer (2) and woodruff key (49).
FIGURE 10-37.
20. Drive End Housing 64. Anti-Drive End
58. Shell Housing
FIGURE 10-36.
1. Nut 49. Woodruff Key
2. Washer
FIGURE 10-40.
FIGURE 10-38.
14. Lock Flange Nuts 64. Anti-Drive End
Housing
The alternator weighs approximately 32 kg (70 NOTE: Removal may require the use of a three jaw
lbs). Be careful when moving or positioning the gear puller.
alternator to prevent personal injury.
FIGURE 10-41.
58. Shell 74. Three Jaw
64. Anti-Drive End Gear Puller
Housing
FIGURE 10-39.
FIGURE 10-43.
48. Rotor Shaft 62. Bearing
51. Ring Carrier
FIGURE 10-45.
FIGURE 10-48.
46. Screw 48. Rotor Shaft
47. Rotor
FIGURE 10-46.
FIGURE 10-47.
FIGURE 10-50.
FIGURE 10-52.
FIGURE 10-53.
FIGURE 10-51.
FIGURE 10-56.
FIGURE 10-54.
11. Hex Jam Nuts 20. Drive End Housing
6. Remove and discard nine lock flange nuts (14)
using a 9 mm socket.
FIGURE 10-61.
FIGURE 10-59.
6. Screw 21. Control Unit Cover
12. Remove the two field coil leads from plug (30), 14. Lift drive end housing (20), along with rotor (47)
and remove the orange seal from the field coil and rotor shaft (48), off of shell assembly (58).
leads. This may require two people; one to lift the
housing, and the other to guide the phase leads
out of the housing.
FIGURE 10-63.
20. Drive End Housing 30. Plug
FIGURE 10-65.
20. Drive End Housing 48. Rotor Shaft
47. Rotor 58. Shell Assembly
FIGURE 10-66.
4. Pulley Bushing 20. Drive End Housing FIGURE 10-68.
4. Bushing 5. Spiral Ring
FIGURE 10-67.
4. Pulley Bushing 75. Expandable Pliers FIGURE 10-69.
20. Drive End Housing 77. Hydraulic Press
FIGURE 10-70.
FIGURE 10-72.
9. Front Bearing 48. Rotor Shaft
10. Flat Retainer Ring 9. Front Bearing
FIGURE 10-71.
FIGURE 10-73.
8. Beveled Retainer 9. Front Bearing
Ring
FIGURE 10-76.
46. Screw 47. Rotor
FIGURE 10-74.
The rotor retaining screws have been installed
Drive End Rotor Removal with a thread lock compound (Loctite). DO NOT
1. If necessary, remove drive end rotor (47) from use air impact tools to remove screws (46). Use
rotor shaft (48), using the following steps. only hand tools to carefully remove these
screws. Using air tools can cause the screws to
break, resulting in damage.
FIGURE 10-75.
FIGURE 10-78.
FIGURE 10-77.
53. Screws 60. Field Coil
8. Engage the recessed areas of the tool with the NOTE: In some instances, removal of the field coil
field coil bobbin ears. Rotate the tool clockwise may be easier by placing the anti-drive end of the
approximately five degrees to release the field alternator in an upward position and pulling the field
coil from the stator tabs. coil out of the stator.
FIGURE 10-82.
FIGURE 10-81.
FIGURE 10-84.
ALTERNATOR ASSEMBLY
Before starting the installation procedure, ensure all
the parts are available and in good condition.
Replace any damaged parts before assembly.
FIGURE 10-91.
FIGURE 10-92.
FIGURE 10-90.
FIGURE 10-95.
FIGURE 10-94.
FIGURE 10-97.
FIGURE 10-98.
FIGURE 10-101.
FIGURE 10-99.
NOTE: Precisely align the alignment marks on both
stators and the shell. If they are not aligned, remove
the stator(s) and reinstall.
FIGURE 10-102.
FIGURE 10-104.
FIGURE 10-103.
FIGURE 10-107.
FIGURE 10-105.
6. Install eight field coil screws coated with a
59. Stator Tabs 60. Field Coil thread locking compound (such as Loctite 222
or equivalent). Tighten the screws to 2 N·m (20
in. lb).
4. Place field coil removal/installation tool XA3320
on top of the field coil.
FIGURE 10-108.
FIGURE 10-106.
FIGURE 10-109.
FIGURE 10-111.
8. Install eight field coil screws coated with a 10. Flat Retainer Ring 76. Snap Ring Pliers
thread locking compound (such as Loctite 222
or equivalent). Tighten the screws to 2 N·m (20
in. lb).
FIGURE 10-110.
FIGURE 10-114.
FIGURE 10-112.
5. Spiral Ring 44. Pulley Bushing
9. Front Bearing 20. Drive End Housing
FIGURE 10-113.
FIGURE 10-115.
8. Beveled Retainer 76. Snap Ring Pliers
Ring 5. Spiral Ring 20. Drive End Housing
FIGURE 10-116.
FIGURE 10-118.
FIGURE 10-119.
58. Shell Assembly 73. Support Stand
FIGURE 10-120.
14. Lock Flange Nuts 61. Studs 11. Jam Nuts 20. Drive End Housing
FIGURE 10-123.
FIGURE 10-126.
FIGURE 10-129.
FIGURE 10-128.
FIGURE 10-130.
FIGURE 10-133.
FIGURE 10-131.
6. Screws 7. Cover Plate
2. Install anti-drive end rotor (47) onto shaft
assembly (48). Align the previously-scribed
14. Apply Dow Corning® 1-2577 low VOC RTV, or mark on the face of the rotor with the center of
equivalent, onto the cover before installing. the screw hole.
Install control unit cover (21). Apply thread lock
compound (Loctite) with five Torx screws (6)
using a T20 Torx bit. Tighten to 3 N·m (30 in.
lb).
FIGURE 10-134.
47. Anti-Drive End Rotor 48. Shaft Assembly
FIGURE 10-132.
6. Screws 21. Control Unit Cover
FIGURE 10-137.
FIGURE 10-135.
46. Screw 47. Rotor 50. Spiral Ring 51. Carrier Ring
FIGURE 10-138.
63. O-Rings 64. Anti-Drive End
FIGURE 10-136. Housing
46. Screw 47. Rotor
FIGURE 10-141.
FIGURE 10-139.
14. Lock Flange Nuts 64. Anti-Drive End
50. Spiral Ring 51. Carrier Ring Housing
Assembly
FIGURE 10-143.
50. Spiral Ring 65. Fan
FIGURE 10-145.
9. Install the fan onto the rotor shaft with Bellville
washer (66) and nut (67). Use an air impact 68. Fan Guard 70. Grommets
wrench and a 24 mm impact socket to tighten 69. Allen Head Screws
the nut to 6 N·m (50 ft lb).
.
NOTE: Verify the metal grommet washers are still in
grommets (70).
FIGURE 10-144.
FIGURE 10-146.
1. Lock Nut 49. Woodruff Key
2. Flat Washer
FIGURE 10-148.
Regulator Installation
38. Screws 39. Bellville Washers
1. Set the selectable voltage set point switch on
the back side of the regulator to the correct
position.
3. Connect wiring harness (36) to voltage regula-
tor (37).
FIGURE 10-147.
FIGURE 10-149.
36. Wiring Harness 37. Voltage Regulator
FIGURE 10-152.
FIGURE 10-153.
22. Thermal Switch
FIGURE 10-151.
6. Screws 26. Stud Assembly
21. Control Unit Cover
FIGURE 10-154.
23. Hex Head Bolt 25. Flat Washer
24. Bellville Washer
6. Identify and mark the wiring terminals for proper FIGURE 10-156.
reassembly. These terminals must be reinstalled
in the same location as they were removed.
The order of the connections from top to bottom is:
rectifier terminal (1)
rectifier terminal (1),
B+/sense terminal (2),
thermal switch terminal (3),
flat washer,
Bellville washer, and
bolt
FIGURE 10-157.
FIGURE 10-155.
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18
Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18
Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18
Continued
FIGURE 11-7. ORBCOMM CONTROLLER Komatsu will notify the person who performed
the controller replacement by e-mail when the
1. OrbComm Controller 3. Connector CN1B new controller has been activated and no more
2. Connector CN1A 4. Antenna Connector manual downloads will have to be performed.
Removal
1. Turn the key switch OFF. Wait three minutes to
allow the VHMS controller to process and store
data.
2. Disconnect the battery using the battery discon-
nect switch.
3. Disconnect the wiring harnesses from the inter-
face module.
4. Remove the mounting hardware and remove
the interface module.
Installation
1. Install the interface module. Attach all wire har-
nesses to the interface module.
2. Refer to the VHMS Software instructions to
install the flashburn program on a laptop PC.
3. Connect the laptop PC to IM diagnostic port (1,
Figure 11-4).
4. Turn the key switch ON, but do not start the
engine. FIGURE 11-8. INTERFACE MODULE
5. Run the flashburn program to install the operat- 1. Interface Module 3. Connector IM2
ing system into the interface module. Make sure 2. Connector IM1 4. Connector IM3
the correct operating system is installed for the
model of truck that is being serviced. Refer to
the VHMS Software section for more details on
programming the interface module.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5
NECESSARY TOOLS
INTERFACE MODULE
FLASHBURN PROGRAM
Installation
The Flashburn program is used to install the applica-
tion code into the interface module controller.
1. Save the file EJ3055-2.exe to local drive on a 6. Be sure the power is off to the interface module.
laptop PC. Then click [Next].
2. Double click on the “EJ3055-2.exe” file to 7. Select the correct COM port. Then click [Next].
extract the files to a directory (such as C:\temp).
8. Select the correct “.KMS” file. Then click [Next].
3. Inside that directory, double click on
“Setup.exe” to install the Flashburn program. Flashburn will now install the application code into
4. Follow the on screen prompts to install the pro- the interface module.
gram.
Setting Summary
8. Verify that all the setting information is correct
and click [Apply].
10. If this is the first time this laptop PC has con- 1. Open Windows Explorer by right-clicking on the
nected to the machine, you will need to down- Start button and choosing Explore.
load its definition file by clicking the [OK] button. 2. In the left frame, the computer's file structure
will be displayed. The right frame will show the
11. Verify that a manual snapshot (MFAO) has
details for the folder that is highlighted in the left
been recorded. The display should show an
frame.
item named “Snapshot” with the code MFAO
and text “Manual Trigger”. 3. In the left frame, navigate to the download files.
7. Verify that the data showing is the data to be 9. Enter the correct Time Zone, Date and Time
loaded and then click the [Next] button. information. Check [DST (Summer Time)] if the
machine's location uses Daylight Savings Time.
Click the [Apply] button.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-3
Structure and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-14
Communications Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-14
Coaxial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-14
Necessary Equipment:
• Checkout procedure
• System schematic
• Laptop personal computer (PC)
• VHMS Technical Analysis Toolbox software FIGURE 13-2. INTERFACE MODULE
• VHMS Setting Tool software
1. Interface Module 3. Connector IM2
• Interface Module Real Time Data Monitor
software 2. Connector IM1 4. Connector IM3
Necessary Equipment:
• Checkout procedure
• System schematic
• Laptop personal computer (PC)
• VHMS Technical Analysis Toolbox software
• VHMS Setting Tool software
• Tera Term Pro software
• Serial cable (RS232)
(male DB9 connector on one end, female
connector on the other end)
Preliminary
1. Turn the key switch to the OFF position to stop
the engine. With the key switch OFF, verify the
seven segment LED display on the VHMS con-
troller is off.
2. Turn the key switch to the ON position, but DO
NOT start the engine.
3. Allow the VHMS controller to boot up. Watch
the red, two digit LED display on the VHMS
controller to show a circular sequence of seven
flashing segments on each digit. After a short
time the two digit display should start counting
up from 00 - 99 at a rate of ten numbers per
second.
4. Attach the VHMS serial cable to the machine's
VHMS diagnostic port (2, Figure 13-3), and the
10. Review the settings for accuracy.
other end to the laptop PC’s serial port.
5. Double-click on the VHMS Technical Analysis •If everything is correct, click the [Exit] button.
Tool Box icon on the computer's desktop. The checkout procedure is complete.
6. Enter the appropriate User Name and Pass- •If a setting is not correct, click the [Back] button,
word and click the [OK] button. select the appropriate category and reset the
information to the correct settings. Then
7. Check for any active fault codes. If any are proceed to the next step.
found, these circuits should be analyzed to
determine the cause of the fault and they must
be repaired before continuing.
8. Start the VHMS Setting Tool program by click-
ing on the icon on the laptop PC screen.
Communications Networks
Each RS232 network uses three wires: transmit,
receive, and ground. Both transmit and receive are
voltage signals, referenced individually to the ground
wire. The shield for the cable is grounded at one end
only.
Each CAN network uses two wires: CAN_High &
CAN_Low. The communications signal is a voltage
differential measured between CAN_High and
CAN_Low. The cable shields are connected at each
module through a high pass filter and grounded at
one point only on the truck. Both ends of each net-
work have termination resistors.
Coaxial Cable
The coaxial cable carries the Radio Frequency (RF)
communications signal between the OrbComm
modem and the antenna. The coaxial cable consists
of an inner conductor and an outer shield (connected
to the connector shell) that are separated by a non-
FIGURE 13-7. ORBCOMM CONTROLLER conductive dielectric material.
1. OrbComm Controller 3. Connector CN1B In an RF application such as VHMS, the communica-
2. Connector CN1A 4. Antenna Connector tions signal sent over coaxial cable is very suscepti-
ble to changes in the cable. Physical damage, as
well as contaminants such as water, may affect the
ability of the cable to properly transmit the RF signal.
Bending the coaxial cable into a small loop may also
damage the inner conductor.
12. After the “data store in progress” LED has been • VHMS controller replacement
off for one minute, turn the key switch OFF. Wait • OrbComm controller replacement
three minutes before turning the key switch ON.
• Engine or alternator replacement
Customer Information
• Enter the customer information. All fields are
required.
Distributor Information
• Enter the distributor information. All fields are
required.
• All distributors are required to have one contact
person who is responsible for coordinating
VHMS, Payload, Komtrax and Fleet Manager
activities for all branches.
FOR: 730E, 830E, 930E & 960E DUMP TRUCKS Distributor and
Branch
Person performing
initialization
Item Result
No. To be checked when Check Item Yes No
11. With engine running, perform quick While recording data, the white LED should be
PM with manual snapshot switch. illuminated, indicating snapshot is in recording
stage.
12. Key switch OFF Red LED turns off?
VHMS DATA DOWNLOAD
1. Download data to laptop PC What time did download start (use wrist watch)?
Select all files, and is download complete?
Is download start time correct?
2. Download Data Check Settings correct?
SMR correct?
Manual snapshot recorded and no data missing?
Manual snapshot data recorded in fault history,
key switch ON/OFF and engine on/off records are
saved in machine history file?
3. Send download data to Komatsu Send download data to KAC Service Systems
Support at
ServicePrograms@komatsuNA.com
Customer Information
Company Name
Site Name
Customer Employee Contact
Mailing Address
Phone Number
Fax Number
E-mail
Distributor Information
Distributor Name
Distributor Service System Support Administrator Name and E-mail
Distributor Branch
Distributor Branch Employee Contact and E-mail
Distributor 4 + 2 Code
Machine Information
Machine Model - Type
Machine Serial Number
Customer Unit Number
Engine Serial Number
Transmission / Alternator Serial Number
VHMS Controller Part Number
VHMS Controller Serial Number
Orbcomm Controller Part Number
Orbcomm Controller Serial Number
Setting Tool Information
Setting Date (MM:DD:YYYY)
Setting Time (HH:MM:SS)
GMT (Time Zone)
Daylight Savings Time (DST) (Yes/No)
Service Meter Reading (SMR)
GCC code (Orbcomm satellite)
Orbcomm Activation Date
Reason for Form Submittal (Check One)
Factory Installed VHMS Initialization
Retrofitted VHMS Initialization
VHMS Controller Replacement
Major Component (Engine/Transmission Replacement)
Customer or Distributor Change
Setting Tool Information Change
INDEX
NOTE: Propulsion system electrical schematics are located in Section “R” of this manual.
Self-Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-46
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-46
The alternator supplies three phase AC power for the The PSC, which is mounted in the main control
gate driver power converters and rectifier diode cabinet, determines the optimum engine operating
modules. The rectifier diode modules convert the AC speeds based on what the operator requests,
power to DC power, then supply that DC power to propulsion system requirements, and efficient fuel
two AC power inverters via the DC link. Each AC usage. Interfaces between the PSC and the truck
power inverter inverts the rectified DC voltage, brake system allow the PSC to provide proper
delivering variable voltage, variable frequency power retarding, braking and wheel slide control.
to each of the AC induction traction motors.
NOTE: Refer to Figure 2-1 for the following
description. The PSC interfaces with the Truck Control Interface
(TCI), which is mounted in the same card rack as the
The two AC induction traction motors, each with its
PSC. System status and control signals are
own inverter, are connected in parallel across the
transmitted and received between these two
rectified output of the alternator. The inverters
components to access real time data and event
change the rectified voltage back to AC by turning on
information that is stored in the PSC. This data is
and off (chopping) the applied DC voltage.
displayed on the Diagnostic Information Display
The output AC voltage and frequency are controlled (DID) panel located in the cab behind the operator's
to produce optimum slip and efficiency in the traction seat.
motors. At low speeds, the rectified alternator output
(DC link or DC bus) voltage is chopped with patterns
called pulse width modulation (PWM) inverter
operation. At higher speeds, the DC link voltage is
applied to the traction motors using square wave
inverter operation. The voltage of the DC link is
dependent upon the Propulsion System Controller
(PSC) and engine RPM during propulsion. The DC
link voltage will vary between 600 and 1600 volts.
000 NO FAULT None Displayed when all faults have been reset
002 GROUND FAULT No power A ground fault has been detected:
For voltage < 1000 V, detection threshold is 166 mA
For voltage >= 1000 V, detection threshold ramps from
166 mA at 1000 V down to approximately 70 mA at
approximately 1500 V.
003 FAILED DIODE No power Failed diode(s) in main rectifier
004 GFCO OPEN and not in REST None GF Cutout Switch is open with the system not in REST.
005 DRIVE SYSTEM OVERTEMP
:01 auxiliary phase control
:02 auxiliary inverter
:03 afse
:04 alternator
:05 left stator
:06 left rotor
:07 right stator
No Propel Temperature exceeds a limit for a sufficient time.
:08 right rotor
:09 chopper IGBT
:10 chopper diode
:11 left IGBT module
:12 left diode
:13 right IGBT module
:14 right diode
:15 rectifier diode
006 BOTH INVERTERS COMMUNICATION FAILED No power Lost communication with both inverters
008 DC LINK OVERVOLTAGE No power DC link voltage exceeds limit for a sufficient time.
:01 not in retard Occurs while not in retard, exceeds propel voltage limit
:02 in retard Occurs while in retard, exceeds retard voltage limit
:03 instantaneous Occurs instantaneously in propel or retard, exceeds link
voltage limit
009 ALT FIELD OVERCURRENT Alternator field current exceeds limit.
:01 normal No power Exceeds current limit over time
:02 instantaneous Exceeds current limit with no persistence
:03 persistent With persistence due to low engine speed
011 RETARD LEVER BAD
:01 voltage too high None Incorrect input from retard lever
:02 voltage too low
012 RETARD PEDAL BAD
:01 voltage too high None Incorrect input from retard pedal
:02 voltage too low
013 LINKV TEST FAILED No power Incorrect link volts
021 TCI COMM. FAULT PSC received no serial data from TCI over period of time.
:01 Message missing
:02 Bad tick
:03 Bad CRC No propel
:04 Overflow
:05 Bad start
:06 Bad stop
022 PERSISTENT TCI COMM FAULT No serial data received from TCI and truck is stopped for
No power
10 seconds.
023 TERTIARY OVERCURRENT Current in alternator field tertiary winding exceeds limit
No propel
over time.
024 PSC CONFIG FILE INCORRECT Incorrect or missing PSC configuration file
:01 no file No configuration file selected
:02 bad CRC No power
:03 wrong version Wrong configuration file version
:04 overspeeds incorrect Incorrect overspeed values
025 AUX INVERTER FAULT Auxiliary blower system fault
:01 not ok or no speed feedback Auxiliary speed feedback indicates no or incorrect blower
No power
speed.
:02 numerous shutdowns Auxiliary OK goes low twice when speed command is
greater than running speed.
026 CAPACITOR OVERPRESSURE No power Excessive filter cap pressure
:01 INV1 No power INV1 capacitor
:02 INV2 No power INV2 capacitor
027 PSC PANEL CONNECTOR A panel connector B, C, or D is not properly connected.
:01 CNFB
No power
:02 CNI/CNX (3500 HP, 150 TON)
:03 Aux blower connector
030 GF CONTACTOR Speed limit GF command/feedback don't agree.
031 BATTERY BOOST CIRCUIT
:01 GFR failed to open GFR command/ feedback don't agree.
Speed limit
:02 GFR failed to close
:03 SCR3 failed
032 RP CONTACTOR
:01 RP1 Speed limit & engine
RP command/ feedback don't agree.
:02 RP2 speed/RP
:03 RP3
033 RETARD CIRCUIT Speed limit & engine
speed/RP
035 ESS INPUT Speed limit Engine speed sensor is out of range.
633 BBRAM CORRUPTED SYS Event Battery backed RAM has failed.
634 TRUCK OVERLOADED - RESTRICTIVE NO PROPEL The over-payload signal is on, operation restricted.
635 TRUCK OVERLOADED - NON-RESTRICTIVE SYS Event The over-payload signal is on, propulsion allowed.
636 AUX INVERTER An auxiliary blower control failure has occurred.
:01 buss volts low Low DC bus was detected during powerup.
:02 buss volts high High DC bus was detected during powerup.
:03 overcurrent Overcurrent condition was detected during operation.
:04 battery loss Loss of blower control battery voltage has occurred.
:05 high dc buss when running High DC bus voltage was detected during operation.
:06 high dc buss after pc powerup High DC bus voltage was detected after phase controller
powerup.
:07 Low dc buss after pc powerup Low DC bus voltage was detected after phase controller
SYS Event
powerup.
:08 high dc buss when running High DC bus voltage was detected during operation.
:09 overcurrent after pc powerup, current overload Overcurrent condition was detected after phase
controller power up.
:10 current overload Sustained current overload exists.
:11 low dc buss overcurrent Overcurrent due to low DC bus voltage
:12 low dc buss current overload Sustained current overload due to low DC bus voltage
:13 gate drive trip IGBT protection circuit detected an overload.
:14 no input voltage Zero input voltage was detected.
638 ENGINE CRANKING TIMEOUT SYS Event Engine is cranking longer than allowed.
639 ENGINE START REQUEST WHILE RUNNING Engine start request signal occured while engine RPM
SYS Event
greater than 600 RPM, and longer than 3 seconds.
640 ACCEL PEDAL TOO HIGH No Propel Accelerator pedal voltage is high.
641 ACCEL PEDAL TOO LOW SYS Event Accelerator pedal voltage is low.
696 UNEXPECTED TCI CPU RESET SYS Event TCI CPU reset without request.
698 DATA STORE SYS Event A data snapshot has been manually initiated.
Initiated Tests
These tests are performed when requested by
EVENT LOGGING AND STORAGE
maintenance personnel. The truck must be in the
Test state for these tests to run. This software function is responsible for the
recording of event information. There are two basic
• Maintenance Tests - The purpose of these tests
levels of event storage: event history buffer and data
is to facilitate verification of system installation
packs. The event history buffer provides a minimum
and wiring, particularly the “digital” interfaces
(relays, contactors, etc). set of information for a large number of events, while
data packs provide extensive information for a limited
• Self-Load Test - Self-load testing is a means by number of events.
which the truck’s diesel engine can be checked
for rated horsepower output. The following requirements apply to both data packs
and the event history buffer:
• Fault information is maintained until overwritten;
Periodic Tests it is not cleared out following a reset. This allows
the user to examine data associated with events
These automatic tests are run continuously during
that have been reset, as long as there have not
the operation of the truck to verify certain equipment. been so many new events as to necessitate
reuse of the storage space.
• If a given event is active (logged and not reset),
logging of duplicate events (same event and sub-
ID numbers) will not be allowed. If the event is
reset and subsequently reoccurs, it may be
logged again. Likewise, if an event reoccurs with
a different sub-ID from the original occurrence,
the event may be logged again.
A data pack is defined as an extended collection of To Record and Save a Data Pack to a Disk
information relevant to a given event.
PSC:
NOTE: The concepts of lockout, soft reset, and 1. With the PTU serial cable attached to the PSC
accept limit do not apply to data packs. port, type c:\ACNMENU and press {enter}.
Thirty (30) data packs are stored with each 2. Select “PTU TCI and PSC” and press {enter}
containing 100 frames of real time snapshot data. 3. Type your name and press {enter}.
Snapshot data is defined as a collection of key data
parameter values for a single point in time). The 4. Type your password and press {enter}.
purpose of each data pack is to show a little “movie” 5. Cursor to “Special Operation” and press {enter}.
of what happened before and after a fault. 6. Cursor to “Event Data Menu” and press {enter}.
The time interval between snapshots is default to 50 7. Cursor to “View Data Packs” and press {enter}.
ms, but each data pack may be programmed via the 8. Type FLTR number to be recorded and press
DID (or PTU) from 10 ms to 1 sec. (In multiples of 10 {enter}.
ms). The “TIME 0:00 frame #” at which the fault is 9. Watch the lower right of the screen as 100
logged is default to frame #60, but each data pack is frames are recorded. Press the F2 key.
programmable from 1 to 100.
10. Cursor to “Record Screen” and press {enter}.
In the above default cases, data is stored for 3
seconds (2.95 second actual) before the fault and 2 11. Assign a file name for the data pack.
seconds after the fault. 12. Press {escape} until back to the DOS “C:>”
A data pack status structure is assigned to each data prompt.
pack plus any programmable settings. This status 13. Insert a blank disk in the appropriate drive.
structure is used by the TCI (or PTU) to check for
14. Type the following command: copy c:\geoh-
available data (event number, id, and status, should
vac\ptuaccur\f2data\filename
be set to zero if data pack is not frozen), as well as
for control of the data packs. NOTE: Insert the name assigned to the file in Step 11
in place of “filename" in the command in Step 14.
If a data pack is unfrozen (not holding any particular
fault data), it is continually updated each 100 frames, 15. Press {enter} to copy the file to the disk.
organized in a circular queue, with new real time
snapshot data. When a fault occurs, the frame
number at which the event occurred is used as a
reference to mark the end of the data pack, and data
is collected until the data pack is full. Only when the
data pack is full will the event number, id and status
be updated in the status structure.
FIG.
NO. COMPONENT FUNCTION
AFSE 2-4 Alternator Field Static Exciter Regulates current in the alternator field based on firing
Panel pulses from the PSC.
AMBTS 2-6 Ambient Temperature Sensor Provides ambient air temperature input to the control
group.
ANALOG I/O CARD System analog input/output card Provides signal conditioning for analog signals to and
from the TCI and PSC.
BAROP 2-4 Barometric Pressure Sensor Provides altitude input for control electronics.
BATFU1, 2 2-4 System Fuse Provides overload protection for control equipment.
BATTSW Battery Disconnect Switch Connects and disconnects the 24 VDC truck batteries.
BDI 2-4 Battery Blocking Diode Works in conjunction with BFC and BLFP to maintain
battery voltage to CPU.
BFC 2-4 Battery Line Filter Capacitor Additional capacitance for BLFP to prevent nuisance CPU
resets.
BFCR 2-4 Battery Filter Resistor Added to replace Battery line filter that was removed.
BM1, 2 Grid Blower Motors 1 and 2 DC motors driving blowers to provide cooling air for the
retarding grids.
BM1I / BM2I 2-3 Current Sensing Modules Monitors current flowing through grid blower motors #1
and #2.
CCF1, 2 2-3 DC Link Filter Capacitors Absorbs and releases current to the DC link for the grid
resistors when a current spike occurs.
CCLR1, 2 2-3 Capacitor Charge Resistor Connected across the DC link to provide a voltage
Panels 1 and 2 attenuated sample of the DC link voltage to the Capacitor
Charge Indicating lights.
CCL1, 2 2-4 Capacitor Charge Indicating Illuminated when 50 volts or more is present on the DC
Lights 1 and 2 link (the DC bus connecting the Alternator output,
Chopper Module/Resistor Grid circuits and traction
Inverters).
CD1, 2 2-3 Chopper Diodes 1 and 2 Controls the DC voltage applied to the grids during
retarding.
CF11, 22, 21, 22 2-3 DC Link Filter Capacitors Absorbs and releases current to the DC link for the
Traction Motors when a current spike occurs.
CGBM1, 2 2-3 Blower Motor Capacitors Limit the rate of current increase when starting to optimize
motor commutation.
CMAF 2-4 Alternator Field Current Sensing Detects amount of current flowing through the Alternator
Module field winding.
CMT 2-4 Alternator Tertiary Current Detects amount of current flowing through the Alternator
Sensing Module tertiary winding.
CM1, 2 2-3 Chopper IGBT Phase Module 1 Controls the DC voltage applied to the grids during
and 2 retarding.
FIG.
NO. COMPONENT FUNCTION
CM11A - 12C Current Sensing Modules, Phase Detects amount of current flow through the A, B and C
1A, 1B and 1C phases of Traction Motor 1.
CM21A - 22C Current Sensing Modules, Phase Detects amount of current flow through the A, B and C
2A, 2B and 2C phases of Traction Motor 2.
CPR 2-4 Control Power Relay Picks up when the Key Switch and Control Power Switch
are closed.
CPRD 2-4 Dual Diode Module Allows two separate voltages to control the CPR coil.
CPRS 2-4 Control Power Relay Suppresses voltage spike when CPR coil is de-energized.
Suppression Module
CPS 2-4 Control Power Switch Energizes CPR coil.
DCN BUS/DCP BUS 2-6 DC Link (-) and (+) Bus The DC bus connects the Alternator output, Chopper
Module/Resistor Grid circuits, and Traction inverters.
DID Diagnostic Information Display Provides maintenance personnel with the ability to
monitor the operational status of certain truck systems
and perform system diagnostic test.
DIGITAL I/O CARD Digital Input/Output Card Receives contactor, relay and switch feedback signals
and provides drive signals to relays, contactors, indicator
lamps, etc. Located in PSC and TCI.
FDR 2-6 Filter Discharge Resistor Resistor divider network connected across the DC link,
provides secondary discharge link for the DC link. Normal
discharge is through RP1.
FIBER OPTIC Fiber Optic Assembly Provides voltage and electrical noise isolation for control
ASSEMBLY and feedback signals between the PSC and Phase/
Chopper Modules.
FP 2-6 Filter Panel Filters electrical noise on 3 phases of Alternator output.
GDPC1 2-4 Gate Driver Power Converter 1 Converts 19 to 95 VDC from the Gate Drive Power Supply
to 25 kHz, 100 VRMS, square wave power to drive
Inverter 1 IGBT Phase and Chopper Modules.
GDPC2 2-4 Gate Driver Power Converter 2 Converts 19 to 95 VDC from the Gate Drive Power Supply
to 25 kHz, 100 VRMS, square wave power to drive
Inverter 2 IGBT Phase and Chopper Modules.
GF 2-5 Alternator Field Contactor Connects the AFSE to the Alternator field.
GFBR 2-4 Resistor Provides a small load across the contactor feedbacks to
help keep the contactors clean.
GFCO 2-4 Generator Field Contactor Cutout Disables Alternator output.
Switch
GFM1, 2 Gate Firing Module Receives pulses from the Analog I/O card in the PSC,
amplifies the pulses, and then splits the pulses to drive
two SCR circuits in the AFSE. Located on AFSE panel.
GFR 2-5 Alternator Field Relay Picks up with GF contactor and applies B+ to the AFSE
(battery boost) during initial acceleration phase.
GFRS 2-5 Alternator Field Relay Coil Suppresses voltage spikes when GF coil is de-energized.
Suppression Module
GFS 2-5 Suppression Module Suppresses voltage spikes in coil circuit when GF
contactor is de-energized.
GRR 2-6 Ground Resistor Panel Detects power circuit grounds.
GRR9, 10 2-4 Resistors Used with GRR to detect power circuit grounds.
FIG.
NO. COMPONENT FUNCTION
ICP 2-4 Integrated Control Panel The ICP is the main controller for the AC drive system.
The ICP is composed of the PSC, TCI and inverter cards.
Inverter 1 Central Processing Generates Phase Module turn-on/turn-off commands for
INV1 TMC CARD Unit Card and Input/Output Card the Inverter 1.
Monitors voltages and currents from various areas for
Inverter 1. Monitors Traction Motor 1 speed.
Inverter 2 Central Processing Generates Phase Module turn-on/turn-off commands for
INV2 TMC CARD Unit Card and Input/Output Card the Inverter 2.
Monitors voltages and currents from various areas for
Inverter 2. Monitors Traction Motor 2 speed.
KEYSW Key Switch Connects battery voltage to CPR and control circuits
when closed. (Located on instrument panel.)
LINK1 2-6 Link Current Sensing Module Detects amount of current flow through the DC link.
FIG.
NO. COMPONENT FUNCTION
R1 2-5 Battery Boost Resistor Limits surge current in the Alternator field circuit when
GFR contacts first close.
SS1, 2 Traction Motor Speed Sensors Each speed sensor provides two output speed signals,
proportional to the Traction Motor's rotor shaft speed.
SYS CPU Card System Central Processing Unit Provides control of propulsion and dynamic retarding
Card functions, battery backed RAM, real-time clock,
downloadable code storage, and an RS422 serial link.
TCI Truck Control Interface Is a part of the ICP Panel. Provides the main interface
between the various truck systems, controls, and
equipment and is used in conjunction with the DID by
maintenance personnel.
TH1 2-5 Alternator Field Thyrite (Varistor) Discharges the Alternator field when the AFSE is first
turned off.
VAM1 2-3 Voltage Attenuation Module Attenuates the three high voltage outputs applied to each
phase winding of Traction Motor 1 to a level acceptable
for use by the Analog I/O card in the ICP.
VAM2 2-3 Voltage Attenuation Module Attenuates the three high voltage outputs applied to each
phase winding of Traction Motor 2 to a level acceptable
for use by the Analog I/O card in the ICP.
VAM3 2-6 Voltage Attenuation Module Attenuates the high voltage outputs between the main
alternator and the rectifier panel, and between the rectifier
panel and the inverters to a level acceptable for use by
the Analog I/O card in the ICP.
VAM4 2-5 Voltage Attenuation Module Attenuates the high voltage outputs between the AFSE
and the main alternator to a level acceptable for use by
the Analog I/O card in the ICP.
Installation
1. Install the pedal assembly using the mounting
cap screws, lockwashers and nuts.
2. Connect the pedal wiring harness to the truck
wiring harness. FIGURE 2-7. TYPICAL ELECTRONIC PEDAL
3. Use the DID panel to calibrate the pedal
1. Cable Clamp 3. Potentiometer
potentiometer according to the instructions in
2. Wiring Harness
the AC Drive System Electrical Checkout
Procedure.
CALIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-25
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-25
TCI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-26
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-34
DANGEROUS VOLTAGE LEVELS ARE PRESENT • If weld repairs are required, the welding
WHEN THE ENGINE IS RUNNING AND CONTINUE ground electrode should be attached as close
TO EXIST AFTER SHUTDOWN IF THE REQUIRED as possible to the area to be welded. NEVER
SHUTDOWN PROCEDURES ARE NOT FOLLOWED. weld on the rear of the Electrical Control
Before attempting repairs or working near Cabinet or the retard grid exhaust air louvers.
propulsion system components, the following Power cables and wiring harnesses should be
precautions and truck shutdown procedure must protected from weld spatter and heat.
be followed:
• Prior to welding, disconnect Engine Control
• DO NOT step on or use any power cable as a System (ECS) harnesses and ground wire
handhold when the engine is running. (MTU engine). If equipped with DDEC or
• NEVER open any electrical cabinet covers or Komatsu engine, disconnect ECM harnesses.
touch the Retarding Grid elements until all GE cards should be pulled forward far enough
shutdown procedures have been completed. to disconnect card from backplane connector.
• ALL removal, repairs and installation of • Some power cable panels throughout the
propulsion system electrical components, truck are made of aluminum or stainless steel.
cables etc. must be performed by an electrical They must be repaired with the same material
maintenance technician properly trained to or the power cables may be damaged.
service the system.
• Power cables must be cleated in wood or After the truck is parked in position for the repairs, the
other non-ferrous materials. Do not repair truck must be shut down properly to ensure the safety
cable cleats by encircling the power cables of those working in the areas of the deck, electrical
with metal clamps or hardware. Always cabinet, traction motors, and retarding grids. The
inspect power cable insulation prior to following procedures will ensure the electrical system is
servicing the cables and prior to returning the properly discharged before repairs are started.
truck to service. Discard cables with broken
insulation.
• IN THE EVENT OF A PROPULSION SYSTEM
MALFUNCTION, a qualified technician should
inspect the truck and verify the propulsion If a problem occurs in the AC drive system that
system does not have dangerous voltage prevents use of normal shutdown procedures,
levels present before repairs are started. ADDITIONAL PRECAUTIONS ARE NECESSARY to
ensure that dangerous drive system voltages are
not present when tests or repairs are performed.
APPROX.
CIRCUIT LOCATION NOTES
VALUE
11B1 * ∞ Measure at the 12VDC insulator in the auxiliary control cabinet.
Measure at the 24VDC insulator in the auxiliary control cabinet.
11 * ∞
All devices listed for the 11A circuit reading must be off.
15V TB21 ∞
71GE TB22 120Ω
439 TB25 ∞
10V TB28 ∞
11SL TB28 ∞ Engine service lights must be turned off.
11ST TB28 ∞
15PV TB29 ∞
11S TB30 ∞ Ground level engine shutdown switch must be deactivated.
The following devices must be turned off:
• Brake cabinet service light
• Operator cab dome light
11A TB30 ∞ • Hazard lights
• Headlights
• Ground level engine shutdown switch
• Left and right side engine service lights
712 TB32 ∞ Auxiliary control cabinet service lights must be turned off.
71 TB32 ∞
11KS * ∞ Measure at the key switch.
12M ∗ >10Ω Measure at AID Module terminal B-13.
12F ∗ >200Ω Measure at AID Module terminal B-12.
4. Remove the old battery and install the new To select the Configuration File, click “Browse”,
battery. Make sure that it is positioned for proper then “Up One Level”, then select the file that
polarity. Reinstall the screws. matches your truck’s wheels.
Make sure that the link voltage is drained down Make sure that the link voltage is drained down and
before servicing the propulsion system or the engine is not running before performing the
performing tests. following procedures.
1. Connect the serial communication cable from the 1. Connect the serial communication cable from the
PTU to the PSC port (DIAG1) on the DID panel PTU to the top ports on the ICP panel (CNG for
located on the back wall of the operator cab. inverters 11 and 12, CNH for inverters 21 and 22).
2. Make sure that the directional control lever is in 2. Turn GF cutout switch (2, Figure 3-1) to the
PARK and the rest switch is in the REST position. CUTOUT position.
3. Turn control power switch (1, Figure 3-1) and the To program the inverters:
key switch ON.
Click START > Programs > GEOHVPTU_2.0 >
To program the PSC CPU card: AC TOOLS > wPTU AC v21.01
Click START > Programs > GEOHVPTU_2.0 > Select “Normal” mode {enter}
AC TOOLS > wPTU AC v21.01 Type password “ok75e” {enter}
Select “Normal” mode {enter}
Click “Program Panel”.
Type password “ok75e” {enter}
Select the GE Panel to download.
Click “Program Panel”.
Click “Begin Download”.
Select the GE Panel to download.
After the download is complete, click “Exit” when
To select the Configuration File, click “Browse”, you see “Press exit to continue”.
then “Up One Level”, then select the file that
matches your truck’s wheels. CPU RESET
Click “Open”. After any programming is done, turn the control power
switch to OFF. Wait for the green LEDs on the power
Click “Begin Download”.
supply turn off, then turn the control power switch to
After the download is complete, click “Exit” when ON. This allows for synchronization of all CPU
you see “Press exit to continue”. communication links.
PSC Digital Input Checks Click START > Programs > GEOHVPTU_2.0 >
AC TOOLS > wPTU AC v21.01
1. Open circuit breakers 1 and 2 for gate driver
power converters 1 and 2. Select “Normal” mode {enter}
2. Connect the serial communication cable from the Type password “ok75e” {enter}
PTU to the PSC port (DIAG1) on the DID panel Under “Real Time”, double-click “PSC Real Time
located on the back wall of the operator cab. Data”.
3. Make sure that the directional control lever is in Verify that the analog values are similar to the
PARK and the rest switch is in the REST position. example in Figure 3-3. Also, make sure that the
correct truck ID is at the top of the screen and
4. Turn control power switch (1, Figure 3-1) and the
“COMMLINK” signal under “Modes” reads OK.
key switch ON.
The following normal power-on digital inputs
should be highlited: KEYSW, PSOK, CNX,
CPSFB and CNFB.
BRAKEON will be highlited with wire 44R (TB26)
jumpered to 712 (TB22). The wires do not have
to be removed.
GFNCO should be highlited with the GF cutout
switch in the NORMAL position.
2 RP2 RP2 Contactor Verify that RP2 picks up and RP2FB is highlighted.
3 RP3 RP3 Contactor (If installed) If installed, verify that RP3 picks up and RP3FB is highlighted.
4 GFR GFR Contactor Verify that the GFR relay picks up.
Verify that the GF contactor picks up and GFFB is highlighted on the PTU. The
5 GF GF Contactor
GF Cutout Switch must be in the NORMAL (up) position to check.
Move the GF Cutout Switch to the CUTOUT (down) position. Verify that the GF
6 GF GF Cutout Switch Safety Check contactor does not pick up and GFFB is not highlighted on the PTU. Return the
GF Cutout Switch tothe NORMAL (up) position.
With CPRL highlighted, turn off the Control Power Switch and verify that control
7 CPRL Control Power Relay
power is not lost. Turn the switch back on.
With AFSE highlighted, verify 24 volts to ground on the “+25” terminal on the
8 AFSE Alternator Field Static Exciter
AFSE terminal board.
9 FORT Forward Travel Direction Verify that circuit 72FD changes from 24VDC to 0VDC when FORT is activated.
10 REVT Reverse Travel Direction Verify that circuit 79RD changes from 24VDC to 0VDC when REVT is activated.
Check Engine Caution Lamp - Jumper circuit 419M @ TB30 to ground to illuminate the lamp in the overhead
2 ENGCAUTION
panel. ENGCAUTION on the PTU should be highlighted.
CONTROLON
3 Control Power ON & Engine Warm-Up - DO NOT CHECK AT THIS TIME.
WARM-UP
Engine Service Light - Jumper 528A @ TB32 to ground to illuminate the blue indicator lamp on the back of the
4 ENGWARN
center console.
Engine Shutdown Switch - Pull up on switch on center console. Verify that circuit 439 @ TB25 changes from
5 ENGKILL
24VDC to 0VDC. Push down the switch to reset the system.
Body Up Switch (activated when body is down) - Place a washer on body-up switch. Verify that circuits 63L &
6 BODYDWN
71F change from 0VDC to 24VDC and the lamp in the overhead panel is OFF.
Rest Switch - Move the Rest Switch to the REST position. Verify that the internal lamp on the Rest Switch
7 RESTSW
illuminates when in the REST position.
Reverse Request - Move the selector lever to the REVERSE position. The parking brake will release, circuit
8 REVREQ
52PBO will be 24VDC, and circuit 52CS will be 0VDC.
Forward Request - Move the selector lever to the FORWARD position. The parking brake will release, circuit
9 FORREQ
52PBO will be 24VDC, and circuit 52CS will be 0VDC.
Neutral Request - Move the selector lever to the NEUTRAL position. The parking brake will release, circuit
10 NEUREQ
52PBO will be 24VDC, and circuit 52CS will be 0VDC.
Parking Brake Switch - Move the selector lever to the PARK position. PRKBRKSW on the PTU should be
11 PRKBRKSW highlighted. (NOTE: The parking brake solenoid is controlled by the VHMS Interface Module. See VHMS/
Interface Module Checkout Procedure to fully test this function.)
12 RSC Retard Speed Control Switch - Pull up the switch on the center console.
13 MIDPAYLD Truck at 70% Payload - Jumper 73MS @TB25 to ground. (NOTE: RB2 circuit breakers must be OFF if installed.)
14 FULLPAYLD Truck Fully Loaded - Jumper 73LS @TB25 to ground. (NOTE: RB2 circuit breakers must be OFF if installed.)
16 RESET Override/Fault Reset Switch - Push the switch on the center console.
Lamp Test Switch - Push the switch on the dash panel. All warning/status lights in the overhead panel should
17 LAMPTEST illuminate except for the bottom two rows, the backup horn sounds, and the retard lights at the rear of the truck
and on top of the cab turn on.
18 DATASTORE Data Store Switch - Push the switch on the back of the center console.
19 AXLEP Axle Pressure Switch - Jumper across the air pressue switch in the rear axle housing.
LOCATION
STEP INPUT DESCRIPTION
(Fig. 3-11)
Battery Separate Relay - Measure 24 VDC from circuit 21BSR @ TB28 to
1 BATSEPC
ground. With BATSEPC highlighted on the PTU, press {enter}. Verify 0 VDC.
2 LINKONLT Link Energized Light on the back of the center console will illuminate.
3. Turn control power switch (1, Figure 3-1) and the Click “LOGIN to wPTU Toolbox”.
key switch ON. Under the “Special Tasks” heading, double-click
Click START > Programs > GEOHVPTU_2.0 > “Erase PSC Events”.
AC TOOLS > wPTU AC v21.01 Click “YES”.
Select “Normal” mode {enter} Double-click “PSC Event Summary”.
Type password “ok75e” {enter} Only two events should be listed and active:
Event 91 (Inverter 1 Cutout) and Event 92
Under “Real Time”, double-click “PSC Real Time
(Inverter 2 Cutout). Investigate any other events
Data”.
that are listed.
Verify the values in Table VI.
2. Ensure that all blower motor and alternator Under “Real Time”, double-click “PSC Real Time
brushes are installed correctly. Data”.
Verify that ENGSPD in the “Analog” field shows
3. Install locks on the contactor box door and left
the correct alternator speed value.
side compartment door of the control cabinet. The
right side compartment will be accessed. 9. Leave the PTU connected to the PSC port for
further checks. Use the emergency stop switch on
4. Use the DID panel to cutout both inverters:
the center console of the operator cab to stop the
a. Press F4 - MENU > F3 - Inv Cutout > engine.
F1 - Inv #1 > F4 - Toggle.
The display will show “Inverter #1 = cut-out”. Battery Boost Check
1. Connect an AC voltmeter to circuits 74X (TB22) 2. Move GF cutout switch (2, Figure 3-1) to the
and 74Z (TB22). CUTOUT (down) position.
2. Ensure that the GF cutout switch is in the 3. Verify that all link voltage lights are OFF.
CUTOUT (down) position and the rest switch is 4. Connect a voltmeter across resistor R1 located in
ON. the right side compartment of the control cabinet.
3. Start the engine and operate at low idle. a. Connect the positive lead to BAT
Verify approximately 4VAC on the meter. b. Connect the negative lead to F101.
Verify that the tachometer in the operator cab
5. Start the engine.
reads approximately 700 RPM.
6. Move the GF cutout switch to the NORMAL (up)
4. Remove the voltmeter.
position.
5. Ensure engine speed control by varying the
7. Turn the rest switch OFF.
position of the accelerator pedal.
The voltmeter will momentarily show a reading
6. To check the PSC alternator speed feedback, of approximately 18VAC, then drop to zero.
connect the serial communication cable from the
PTU to the PSC port (DIAG1) on the DID panel 8. Turn the rest switch ON.
located on the back wall of the operator cab. 10. Move the GF cutout switch to the CUTOUT
7. Make sure that the directional control lever is in (down) position.
PARK and the rest switch is in the REST position. 11. Use the emergency stop switch on the center
8. Turn control power switch (1, Figure 3-1) and the console of the operator cab to stop the engine.
key switch ON. 12. Verify that all link voltage lights are OFF. Remove
the voltmeter.
6. Let up on the accelerator pedal just enough so Manual Offset HP Output Adjustment:
that contactor RP2 drops out but contactor RP1 is 12. If it isnecessary to troubleshoot HP problems, use
still picked up. This should occur at approximately the following procedure:
1375 rpm.
With loadbox initiated, enter a + or - offset value
NOTE: Some trucks are not equipped with contactor in the “HP Offset” field.
RP3. Click the “HP Offset” box.
7. Depress the accelerator pedal to pick up
13. Perform the load test again.
contactors RP1, RP2 and RP3. This should occur
at approximately 1550 rpm. Return the offset to 0.0
8. Warm up the engine until the engine coolant Click the “HP Offset” box.
temperature stabilizes. Then fully depress the Click “EXIT LDBX” to exit the Self Load Engine
accelerator pedal to pickup all the RP contactors. Test screen.
The CHOP value on the PTU should be be 25% 14. Allow the engine to cool down until the engine
at approximately 1900 rpm. temperature and pressure gauges show normal
9. Record the PTU screen while viewing the screen operating values.
during full load. 15. Turn the rest switch ON.
Under the “Save” menu, select “Single 16. Turn the key switch OFF. Allow approximately 90
Snapshot”, then click “Save”. seconds for the steering accumulators to bleed
To view the recorded screen, under the “View” down.
menu, select “Screen Relay”, the highlight the 17. Remove the jumper from the fan clutch control
file and click “Open”. circuit
18. Record all data to create a truck record for future
comparison.
Before storing used tires, clean thoroughly and Manual tire removal and installation is possible, but
inspect for damage. Repair as necessary. When a due to the size and weight of the components, spe-
truck is placed in storage, it should be blocked to cial handling equipment is desirable. Consult local
remove the weight from the deflated tires. If stored tire vendors for sources of equipment designed
truck cannot be blocked, check air pressure and especially to remove, repair, and install large off-
inspect tires twice a month for proper inflation pres- highway truck tires.
sure. If the studs in the front wheel hub require replace-
ment, use a special stud installer tool and tighten
studs to 732 N·m (540 ft lbs) torque.
1. Shift directional control lever to PARK, then
block rear wheels to prevent movement of truck.
Installation
NOTE: Clean all mating surfaces before installing
wheel assembly.
1. Attach tire handler (or lifting device) to inner
dual and install inner dual onto wheel motor
hub. Use care not to damage tire inflation
extension line.
NOTE: During inner wheel installation be sure air
inflation line lays in channel on wheel hub assembly.
2. Using a lifting device, install spacer (6, Figure 2-
4) onto wheel motor hub. Tap spacer up against
FIGURE 2-3. TIRE LIFTING SLING
inner dual. Attach tire handler to outer dual and
(BODY REMOVED)
position onto wheel motor hub.
Tire Removal 1. Clean the rim base, bead seat band, and
flanges with a wire brush. Remove all paint from
knurling on bead seat band and back section.
Procedure
1. The truck must have been in operation for at
least one hour prior to taking an oil sample to
ensure that all contaminants are in suspension. OIL DRAIN AND REFILL PROCEDURE
2. Take the oil sample within five minutes of stop- 1. Position the drain plug at the lowest position.
ping the truck. Remove the drain plug and drain the oil from
the front wheel hub. Inspect and reinstall the
3. Clean the area around the magnetic plug before drain plug.
removing the plug.
2. If necessary, rotate the wheel hub to position
4. Obtain the oil sample at the lowest point possi- the fill plug at 12 o’clock.
ble inside the wheel hub.
3. Remove the fill plug.
5. Complete the oil sample form immediately and
submit it with the oil sample for analysis. 4. Fill wheel hub assembly with SAE 80W-90 oil.
5. When properly filled, the floating ball in the sight
NOTE: For more information regarding oil sampling, gauge will be at its highest position.
refer to the Komatsu Oil Wear Analysis (KOWA)
manual. 6. Replace the fill plug.
NOTE: The oil may need to be changed more
frequently, depending on mine conditions and the
results of the oil sample tests.
Bearing Replacement
Removal 1. Remove cap screws (2, Figure 3-13) and lock-
1. With engine shut down and key switch OFF, washers (3). Remove bearing retainer (4).
allow at least 90 seconds for the accumulator to 2. Press bearing (1) out of bore in steering cylin-
bleed down. Turn the steering wheel to make der or tie rod end.
sure no hydraulic pressure is present. Block 3. Press new bearing into bore.
front and back of rear wheels.
4. Install bearing retainers with cap screws and
2. Disconnect hydraulic lines at the steering cylin- lockwashers. Tighten cap screws to standard
ders. Plug all line connections and cylinder torque.
ports to prevent contamination of hydraulic sys-
tem.
Installation
1. Be certain mating surfaces of axle housing (1, Assembly
Figure 4-3), and pivot eye (4) are clean and not 1. Setup an appropriate tool to press bearing car-
damaged. rier (3, Figure 4-2) into the bore of the pivot eye
2. Lift pivot eye into position on front of axle hous- structure (1). Be certain the bearing carrier is
ing. Insert several cap screws (2) and flatwash- pressed fully into the pivot eye bore, flush with
ers (3) to align the parts. Remove the lifting sides. Lube groove in bearing carrier outer
device. diameter must align with lube fitting hole in pivot
3. Install the remaining cap screws and flatwash- eye structure.
ers. Tighten alternately until the pivot eye is NOTE: With parts to correct size, the fit of the
properly seated. Tighten cap screws to 2007 bearing carrier into the bore of the pivot eye structure
N-m (1480 ft lbs) final torque. may be: 0.025 mm - 0.08 mm (0.0010 in. - 0.0030 in.)
interference fit.
Freezing the bearing carrier will ease installation.
Installation
1. Start the pin (7) in through the front of the frame FIGURE 4-4. ANTI-SWAY BAR INSTALLATION
mount (10) and one of the spacers (3). Rotate (Typical, Both Ends)
the pin to align the retaining cap screw (1) hole 1. Retainer Cap Screw 6. Lockwasher
with the hole in the mounting bracket. 2. Locknut 7. Pin
2. Raise the anti-sway bar (9) into position and fin- 3. Bearing Spacer 8. Bearing
ish pushing the pin (7) through to the far side of 4. Snap Ring 9. Anti-Sway Bar
the spherical bearing. Position the other spacer 5. Cap Screw 10. Mounting Structure
(3) and finish pushing the pin into the other
mounting ear. If necessary, realign the pin with
the mounting bracket retainer cap screw hole.
Install retaining cap screw (1) and locknut (2).
Install cap screw (5) and lockwasher (6) if
removed. Tighten cap screws (1 & 5) to stan-
Cleaning and Inspection
dard torque.
3. Repeat above procedure to install remaining 1. Inspect bearing bores of anti-sway bar. If bores
pin, spacers, and retainer cap screw and lock- are damaged, repair or replace anti-sway bar.
nut. Start the pin into the bore of the rear axle 2. Inspect bearing spacers (3) for damage or
housing from the rear of the truck. wear.
4. Attach lubrication lines.
5. Remove blocks or stands from under frame.
Assembly
6. Charge suspensions if necessary. Refer to Sec-
tion "H" for suspension charging. 1. Press in new bearings.
2. Install snap rings.
2. Loosen hose clamps and disconnect wheel 10. Reconnect wheel motor cooling air duct and
motor cooling flexible air duct from connection clamp securely.
on front center of housing. 11. Install wheels and tires.
3. Mark and disconnect lube and brake lines from
center case.
4. Mark electrical cables for identification and dis-
connect at wheel motors. Loosen cable grips
and pull cables free.
5. Remove rear tires as covered in this section.
6. Remove wheel motors as covered in this sec-
tion.
7. Block up truck frame and remove rear HYD-
RAIR® suspensions as outlined in Section H.
8. Remove pivot pin as outlined previously in this
Section.
9. Remove anti-sway bar as outlined earlier in this
Section.
10. Move housing from under truck for repair or
replacement.
Installation
1. Position axle housing under frame.
2. Align pivot pin bores and install pivot pin. FIGURE 5-1. WHEEL MOTOR REMOVAL AND
3. Install anti-sway bar. INSTALLATION
4. Install rear suspensions, as covered in Section (Shown with the body removed.)
H, Suspensions.
5. Install wheel motors.
SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-5
Removal
1. Park unloaded truck on hard level surface.
Block wheels and apply 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 cov-
ered in Section G.
2. Remove boot clamp and boot from around sus-
pension. Disconnect pressure sensor.
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”).
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
FIGURE 4-3. CHARGING VALVE 6. Remove the center hose from manifold (6).
7. Open inlet valve (4) until the pressure has
1. Valve Cap 6. Valve Body dropped below the pressure listed in Figure 4-2,
2. Seal 7. O-Ring and then close the valve.
3. Valve Core 8. Valve Stem 8. Install the center hose to manifold (6).
4. Swivel Nut 9. O-Ring
5. Rubber Washer 9. Charge the suspensions to the pressure listed
in Figure 4-2. DO NOT use an overcharge of
nitrogen to lift the suspensions off of the charg-
ing blocks.
10. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes in order to allow
the pressures in the suspensions to equalize.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
1. Actuator Cap
2. Adjustment Collar
3. Actuator Base
4. Actuator Plunger
5. Wiper Seal
6. Poly-Pak Seal Assembly
7. Valve Body
8. Glyde Ring Assembly
9. Plunger Return Spring
10. Regulator Springs (B1)
11. Regulator Springs (B2)
12. Spring Seat
(B2 Parts 13-16)
(Front Brake)
13. Spool Return Spring
14. Regulator Spool
15. Regulator Sleeve
16. Reaction Plunger
1. Actuator Base
2. Brake Valve
3. Orfice Set-Screw
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-25
Rebuild Criteria
If any one of the following conditions exist, the brake
valve should be removed and repaired:
• Excessive cam rock in pedal actuator.
• Any sign of external leakage.
• Internal leakage at the tank port must be less
than 100 cc/minute with the valve in the released
position and system pressure supplied to the
"P1" and "P2" inlet ports.
• Tank port leakage must be less than 250 cc/
minute with valve pilot or manual applied at 20
685 kPa (3,000 psi) system pressure.
• Failure of the pedal to return to full release
position.
• Valve holds pressure when in the neutral
position.
• Varying output pressure with the pedal fully
depressed.
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. FIGURE 3-1. ACCUMULATORS AND BRAKE
NOTE: Minor repairs and service adjustment may not MANIFOLD
require the removal of the brake valve. 1. Rear Brake Accumulator
2. Charging Valve
3. Front Brake Accumulator
4. Charging Valve
5. Brake Lock Shuttle Valve
Before disconnecting pressure lines, replacing 6. Brake Lock Pressure Reducing Valve (PR1)
components in the hydraulic circuits, or install- 7. Park Brake Reducing Valve (PR2)
ing test gauges, always bleed down hydraulic 8. Brake Lock Solenoid
steering and brake accumulators. The steering 9. Park Brake Solenoid
accumulators can be bled down with engine shut 10. Park Brake Test Port
down, turning the key switch OFF and waiting 90 11. Bleed Down Valve (Front Brake Accumulator)
seconds. Confirm the steering pressure is 12. Automatic Apply Valve
released by turning the steering wheel - No front 13. Bleed Down Valve (Rear Brake Accumulator)
wheel movement should occur. Open bleed down 14. Accumulator Test Port (LAP1)
valves (10 & 12, Figure 3-1) located on the brake 15. Brake Manifold
manifold and allow both accumulators to bleed 16. Low Brake Accumulator Pressure Switch
down. 17. Park Brake Pressure Switch
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.
NOTE: Shut off valves (8) for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1 Cylinder must be capable of a 10 cubic inch maximum displacement.
NOTE: B2 Cylinder must be capable of a 20 cubic inch maximum displacement.
1. Brake Valve 7. Nylon Bearing 13. Pad 18. Spring Pivot (Lower)
2. Retainer Clip 8. Pivot Shaft 14. Nut 19. Spring
3. Pivot Shaft 9. Insert 0.025 in. Shim 15. Cap Screw 20. Spring Pivot (Top)
4. Bushings 10. Jam Nut 16. Electronic Retard 21. Set Screw
5. Shims 11. Cap Screw Pedal Assembly 22. Jam Nut
6. Retainer Clip 12. Pedal Structure 17. Brake Pedal Actuator
Assembly
Removal
1. Securely block the wheels to prevent possible
roll-away.
2. Turn key switch OFF and allow 90 seconds for
steering system accumulators to bleed down.
3. Bleed down brake accumulators by rotating the
manual bleeddown valves NV1 (13, Figure 3-
24) and NV2 (11) counterclockwise.
4. Confirm brake accumulators are bled down by FIGURE 3-24. ACCUMULATORS AND BRAKE
applying the Brake Lock switch (key switch ON, MANIFOLD
engine shut down) and applying service brake 1. Rear Brake Accumulator
pedal. The service brake light should not come 2. Charging Valve
on. 3. Front Brake Accumulator
5. Close the bleeddown valves by rotating clock- 4. Charging Valve
wise. 5. Brake Lock Shuttle Valve
6. Remove the valve guard and Dyna-seal from 6. Brake Lock Pressure Reducing Valve (PR1)
top of accumulators. 7. Check Valve (CV3)
8. Brake Lock Solenoid
7. Depress valve core to release gas precharge
9. Park Brake Solenoid
pressure from accumulators.
10. Park Brake Test Port
8. If a brake manifold cartridge is faulty or leaking 11. Bleed Down Valve (Front Brake Accumulator)
oil externally, remove the cartridge. Inspect O- 12. Automatic Apply Valve
ring and O-ring seat in the manifold. Replace O- 13. Bleed Down Valve (Rear Brake Accumulator)
ring or defective part(s). 14. Accumulator Test Port (LAP1)
15. Brake Manifold
16. Low Brake Accumulator Pressure Switch
17. Park Brake Pressure Switch
Disassembly
1. Mark all plugs, valves and cartridges before
removal to insure proper assembly.
2. Remove plugs, valves and cartridges.
NOTE: Check Valve (7, Figure 3-24) and Reducing
Valve (6) both have an orifice disc located below
them. Do not mix these up, as the orifices are
different sizes.
1. Park truck on a level surface, then turn engine · Record on data sheet.
and key switch OFF. Place wheel chocks on 9. Turn brake lock switch OFF. Measure the lining
both sides of all wheels to prevent truck from to disc clearance with feeler gauge and record
moving during this procedure. the clearances.
2. Fully open each brake accumulator bleeddown · Record on data sheet.
valve and precharge both accumulators to 9653
kPa (1400 psi). Allow gas temperature to
approach ambient temperature before complet-
ing precharge process.
· Record on data sheet. If there is no clearance between a brake lining
and the disc, the brake will drag and overheat the
NOTE: For best performance, charge accumulators brake components, which may result in reduced
in the ambient conditions in which the machine will braking capability. Refer to ARMATURE SPEED
be operating. REAR DISC BRAKE chapter to service the brake
3. Close both accumulator bleeddown valves. caliper.
4. Install pressure gauges at: NOTE: If the rear brake calipers were just installed, a
a. Front Brake Test Port "BF" (brake cabinet) - parking brake adjuster may be out of adjustment
34,475 kPa (5000 psi) gauge. which can cause a brake lining to drag. Refer to
ARMATURE SPEED REAR DISC BRAKE chapter to
b. Rear Brake Test Port "BR" (brake cabinet) -
service the brake caliper.
34,475 kPa (5000 psi) gauge.
c. Low Accumulator Pressure Test Port "LAP1"
(brake manifold) - 34,475 kPa (5000 psi) 10. Move directional control lever to PARK.
gauge. 11. Return the pressure gauge to the BF or BR
5. Move directional control lever to PARK position. location from which it was removed.
Release brake lock.
6. Start engine. Observe rising brake pressures as
system charges. Brake pressure should begin
to fall when Auto Apply Valve releases. Brakes
should release at approximately 14,479 ± 690
kPa (2100 ± 100 psi) front and 10,894 ± 517
kPa (1580 ± 75 psi) rear.
· Record on data sheet.
7. If a brake caliper or brake line was replaced, the
brakes need to bled before proceeding. Partially
depress brake pedal and bleed air from bleed-
ers located at each brake caliper.
24. Shut engine down. Allow 90 seconds for the 28. Turn engine off. Allow the steering accumulator
steering accumulator to bleed completely down. to bleed completely down. Turn key switch ON.
Disable steering pressure switch from the brake Slowly open the rear brake accumulator bleed
warning circuit by unplugging the diode down valve and observe LAP1 pressure.
between circuits 33 and 33F. (This is diode 22 Record LAP1 pressure at set points for low
on diode board 1.) Turn key switch ON. After brake warning lamp and auto apply brake pres-
two minutes, record the low accumulator pres- sures. Also record front and rear brake pressure
sure (LAP1 port). If LAP1 pressure is below after auto apply.
17,927 kPa (2,600 psi), then leakage in the sys- · Record on data sheet.
tem is excessive and the source of the leakage
needs to be identified and repaired. NOTE: Verify that the low brake pressure lamp and
buzzer, and auto apply set points are within a 690
· Record on data sheet. kPa (100 psi) of those recorded in steps 25 and 26.
25. Slowly open the front brake accumulator bleed 29. Close the rear brake accumulator bleed down
down valve and observe LAP1 pressure. The valve.
Low Brake Pressure lamp and buzzer must
30. Enable the steering pressure switch by plugging
actuate at 15,859 ± 517 kPa (2300 ± 75 psi).
in the diode removed between circuits 33 and
· Record on data sheet. 33F.
26. Brake pressures should begin to rise (Auto 31. Start the engine to recharge hydraulic system.
Apply) when LAP1 reaches 14,479 kPa (2,100 Allow engine to run until low brake accumulator
± 100 psi). Close front brake accumulator bleed pressure stabilizes at or above 22,064 kPa
down valve. (3,200 psi).
· Record on data sheet. 32. Shut engine down. Do not allow steering accu-
mulator to bleed down. Make repeated slow,
complete brake applications with pedal until
auto apply comes on. Record the number of
brake applications prior to auto apply.
· Record on data sheet.
33. Remove all jumper wires, and gauges. This
concludes the brake check out procedure.
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open. Close valve, check precharge.
Accumulator precharge is low. Recharge accumulator.
Leak in one circuit. Check plumbing.
Malfunction in brake valve. Remove, disassemble, clean, reassemble; or
replace.
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. Remove, disassemble, clean, reassemble; or
replace.
Damage in brake valve assembly. Repair or replace brake valve assembly.
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component. Check all steering and brake system components.
Accumulator precharge too high or too low. Check accumulator precharge.
Brake Valve plumbed incorrectly. Correct plumbing.
Internal leakage in brake valve assembly. Replace brake valve assembly.
Pump is worn. Rebuild or replace pump.
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Leak in charge system. Check charge system.
Accumulators precharge too high or too low. Check accumulator precharge.
Brake Valve plumbed incorrectly. Correct plumbing.
Internal leakage in brake valve assembly. Replace brake valve assembly.
Pump is worn. Rebuild or replace pump.
STEP 2 _______________ Front brake accumulator charged to 9653 kPa (1400 psi).
_______________ Rear brake accumulator charged to 9653 kPa (1400 psi).
STEP 6 _______________ Front brake pressure when auto apply releases - approx. 14,479 ± 690 kPa
(2100 ± 100 psi).
_______________ Rear brake pressure when auto apply releases - approx. 10,894 ± 517 kPa
(1580 ± 75 psi).
Parking Brake
STEP 8 _______________ Park brake release pressure - 17,238 ± 690 kPa (2500 ± 100 psi).
Brake System
STEP 12 _______________ Rear brake pressure when front brake pressure begins to rise - 310 - 1413 kPa
(45 - 205 psi).
STEP 13 _______________ Rear brake pressure when stop lights illuminate - 517 ± 34 kPa (75 ± 5 psi).
STEP 14 _______________ Front brake pressure, pedal applied - 20,685 ± 1034 kPa (3000 ± 150 psi).
_______________ Rear brake pressure, pedal applied - 10,894 ± 517 kPa (1580 ± 75 psi).
Brake Lock
STEP 19 _______________ Low brake lock pressure warning alarm actuation - 6895 ± 172 kPa (1000 ± 25 psi).
STEP 22 _______________ Rear brake pressure when brake lock is applied - 10,343 ± 690 kPa
(1500 ± 100 psi).
STEP 28 _______________ LAP1 pressure when low brake pressure warning occurs - 15,859 ± 517 kPa
(2300 ± 75 psi). Should be within 690 kPa (100 psi) of Step 25.
_______________ LAP1 pressure when auto apply occurs - 14,479 kPa (2,100 ± 100 psi).
Should be within 690 kPa (100 psi) of Step 26.
_______________ Front brake pressure after auto apply occurs.
_______________ Rear brake pressure after auto apply occurs.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-9
Disassembly Assembly
1. Remove bleeders (2, Figure 5-3) and end caps When assembling pistons (11, Figure 5-3) into the
(7 and 8) from each end of each brake caliper housings (1), lubricate all cylinder walls, threads,
housing (1). seals, piston seal surfaces, etc., with clean C-4
2. Remove linings from the caliper assembly. hydraulic oil.
NOTE: A shallow container may be necessary to 1. Install new piston seals (12) and backup rings
receive any remaining fluid that will drain from (13) in housings.
cavities. Do not reuse fluid. 2. With housing lying on mounting face, gently
3. Carefully remove the piston dust shields (10) push each piston past piston seal until seated in
from behind the groove lip in the housing and bottom of cavities.
from the grooved lips on the piston. 3. Install new or reusable dust shields (10).
4. Mark each piston and corresponding brake cali- NOTE: Do not allow lubricant to contact dust shields.
per housing position and pull piston out of the 4. Install all fittings (4 & 5) and bleeder (2) in cor-
housing. Do not interchange parts. rect position in housings.
5. Remove O-ring seals (12) and backup ring (13)
5. Apply Loctite® 271 to threads of cap screw (6).
from the piston cavity using small flat non-
Install linings (9) and end caps (7 & 8) with bolts
metallic tool having smooth round edges.
(6) and tighten to 546 N·m (403 ft lbs) torque.
6. Refer to Caliper Cleaning and Inspection on the
6. Refer to Rear Disc Brakes in this Section and
following page for detailed instructions regard-
perform Bench Test before installing caliper.
ing condition and usability of parts.
7. After bench test is performed, refer to Installa-
tion for procedures for installing calipers on
brake adapter.
• REAR BRAKES MUST BE DISCONNECTED NOTE: The Override Switch on the instrument panel
WHEN BURNISHING THE FRONT BRAKES. must be depressed and held by the operator in order
Front brakes require burnishing to propel with the brakes applied.
independently from rear brakes in order to 3. Apply front brakes at full pressure until discs
control disc temperatures reach or just exceed 316° C (600° F). Hold in
• EXTREME SAFETY PRECAUTIONS SHOULD override switch to maintain propulsion to obtain
BE USED WHEN MAKING HIGH-ENERGY/ disc temperature. Check temperature after 182
HIGH-SPEED BRAKE STOPS ON ANY meters (200 yards).
DOWNGRADE.
4. Let discs cool to 121° C (250° F) and repeat
Safety berms or adequate run off ramps are
necessary for any stopping performance procedure two more cycles.
tests. 5. Allow front discs to cool to 121° C (250° F).
• Heavy smoke and foul odor from brake 6. RECONNECT rear brakes:
linings is normal during burnishing a. Relieve pressure in hydraulic system accord-
procedures. ing to previous “WARNING” instructions.
b. Remove cap nuts and reinstall tube (1).
Tighten tube nuts to standard torque.
c. Close accumulator bleed valve (7) handles.
7. Start engine and check for leaks. Bleed brakes
according to bleeding procedures.
8. Insure all brakes are functioning properly.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-7
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-13
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) . . . . . . . J6-14
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-29
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-30
REAR BRAKES 2. With engine off, key switch OFF, wait 90 sec-
onds for steering accumulators to bleed down.
Each rear wheel service brake assembly consists of Open both brake accumulator drain valves.
two discs, each with a four piston caliper and a lining
3. Remove crossover tubes (4, Figure 6-1) from
on each side of the disc. Both discs are attached by
upper service brake caliper. Remove crossover
adapters to the wheel motor armature.
tubes on lower brake assembly.
A constant brake-release clearance between pistons 4. Remove two center caliper mount cap screws
and linings, and lining and disc, is maintained by an (6, Figure 6-2) from outboard caliper and install
automatic adjustment feature of the piston subas- two 7/8-9 NC X 14 in. studs.
sembly. As the lining wears, the position of grips on a
5. Slowly remove the four remaining caliper mount
return pin advances to allow maximum piston force to
cap screws. The brake lining is under spring
be applied to lining. Upon brake release, the piston is
pressure, and it will extend out as the cap
retracted by a return spring for the amount of the pre-
screws are loosened. Do not let the brake lining
determined clearance.
pull away from the caliper housing.
CALIPER AND DISC 6. Use small diameter wire and wrap it around the
brake lining and caliper. This will keep the brake
Removal lining from pulling away from the caliper and
over-extending the brake wear adjuster.
NOTE: If the caliper is being removed to be serviced,
it is not necessary to install the wire. If the caliper is
being removed to gain access to other parts, and the
Do not loosen or disconnect any hydraulic brake
caliper does not need service, the wire must be
line or component until engine is stopped, key
installed. If the brake lining pulls away from the
switch is OFF and drain valves on brake accumu-
caliper, the caliper must be disassembled to reset the
lators are opened and steering accumulators are
brake wear adjuster.
bled down. Turn steering wheel to be sure steer-
ing accumulator is completely bled down. 7. Remove the caliper half. Each caliper half
weighs approximately 45 kg (100 lbs).
1. Park truck in level ground. Block all the wheels
on both sides to prevent the truck from moving. 8. Support outer disc (12) and remove disc mount
cap screws (11) and washers. Slide disc from
outboard adapter (10). Shims (7) will be found
between disc and adapter. Remove bushing
(8). Mark all shims so they will be installed in
the same location during assembly.
9. Use small diameter wire and wrap it around the
brake lining and inner caliper half (5).
10. Remove the shoulder bolt and spring (1, Figure 13. Use a pick or suitable tool to remove the parking
6-8), loosened in Step 5, from the parking pis- piston boots from each caliper housing.
ton cavity.
14. Use suitable snap ring pliers to remove the
parking piston adjusting collar retaining snap
ring (1, Figure 6-10) from inside the groove of
the parking piston. Remove the adjusting collar.
Clean Parts
For Ground or Polished Metal Parts:
Use a cleaning solvent or kerosene or diesel fuel to
clean ground or polished metal parts or surfaces.
Item 11. Drill and ream for slip fit with 0.375 in dowel,
three holes equal space on two inch diameter.
Adjuster Force
FIGURE6-36.
1. Parking Piston Cap 2. Spanner Wrench
Holes
• Cracks on the Linings. Replace the linings that • Verify that the dust boots are soft and flexible.
have larger or deeper cracks than the small, tight • Disassemble the caliper and replace the dust
cracks on the surface of the lining which are boots that are hard or damaged.
normal when the caliper is used under high
temperature conditions. These cracks are
referred to as heat check cracks.
Brake Disc
• Refer to Brake Disc Inspection in this chapter. If
the disc is worn beyond the wear limits, replace
the disc.
Extreme safety precautions should be used when Do not exceed 800°F (427°C) disc temperatures
making high-energy/high-speed brake stops on during burnishing.
any downgrade. Safety berms or adequate run off 3. Allow the brake discs to cool to approximately
ramps are necessary for any stopping perfor- 121°C (250°F) between cycles.
mance tests.
4. Repeat steps 2 and 3.
1. Temporarily disconnect the FRONT brakes
5. If linings smoke or smell during the second
using the following procedure:
cycle, continue to repeat burnishing cycle until
a. Observe safety precautions on the previous smoke and smell are gone or are significantly
page. Bleed down the steering accumulators reduced.
with engine off, and turn the key switch OFF 6. Reconnect front brakes:
and wait 90 seconds. Confirm the steering
pressure is released by turning the steering a. Relieve pressure in hydraulic system
wheel - No front wheel movement should described in Steps 1a and 1b.
occur. b. Remove cap nuts and reinstall tube (5).
b. Open the two valves (7, Figure 6-38) at the Tighten tube nuts to standard torque.
bottom of the brake accumulators (inside c. Close accumulator bleed valve (7) handles.
brake cabinet) to bleed down the two brake 7. Start engine and check for leaks.
accumulators.
8. Ensure all brakes are functioning properly and
c. Disconnect “BF” hydraulic tube (5, Figure 6- have cooled to approximately 121°C (250°F)
38) at both ends inside brake control cabinet. before releasing truck.
Install a #8, 0.75 x 16UNF-2B, 37° flare Cap
Nut (WA2567, or equivalent) on each fitting
where tube was removed. Tighten caps to
standard torque to prevent leakage. Cap or
plug tube to prevent contamination.
NOTE: This will disconnect the hydraulic
supply from the operator's brake pedal to the
front brakes. There will be a noticeable loss
of “braking action” at the pedal. However,
this method of temporarily disabling the
brakes will still permit the application of
Brake Lock, in the event of an emergency.
d. Close accumulator bleed valves handles (7).
2. Drive empty truck on level terrain at speeds of 5
to 10 MPH while applying (dragging) the brakes
using sufficient pressure to make engine work FIGURE 6-38. BRAKE MANIFOLD AND
until the disc temperatures reach or just exceed COMPONENTS
316°C (600°F).
1. “BR” Hydraulic Tube 5. “BF” Hydraulic Tube
2. Rear Brake Accu- 6. Brake Lock Shuttle
mulator Valve
3. Brake Manifold 7. Brake Accumulator
4. Front Brake Accu- Bleed Valves
mulator
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L2
STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7
FIGURE 2-1. HYDRAULIC PUMPS AND TANK (VIEWED FROM BELOW TRUCK)
1. Hydraulic Tank 3. Steering / Brake Pump 5. Hoist Circuit Hydraulic
2. Hoist Cylinder 4. Hoist Circuit Filters Pump
The hoist pump (5, Figure 2-2) is a tandem gear type The steering accumulators (9) provide an adequate
pump. The pump is mounted behind the main alter- volume of pressurized oil to allow the truck to be
nator and driven by a drive shaft connection between steered to a safe area if a malfunction occurs in the
the pump and the accessory drive output of the alter- pump. (Brake system accumulators store a supply of
nator. The pump has a total output of 870 l/min (.230 oil to allow several brake applications if the steering/
GPM) at 1900 RPM. brake pump malfunctions. Refer to Section J for
detailed information.)
STEERING/BRAKE PUMP
The Steering/Brake system pump (3) is mounted on
the rear of the hoist system pump and coupled to the
hoist pump driveshaft. This pump has an output of
246 l/min (65 GPM) at 1900 RPM. Output from this
pump provides oil for the truck steering system as
well as the service brake system.
TANK
The hydraulic tank provides a common supply of oil
for the hoist, steering, and brake systems. The
hydraulic tank service capacity is 901 l (238 gal).
Oil leaving the hydraulic tank (1) passes through two
100 mesh wire strainers before entering the hydraulic
pumps. Oil level should be checked periodically and
be visible in the bottom sight glass when the body is
down and the engine is running. If filling is required,
use only clean, filtered type C-4 hydraulic oil.
Removal
1. Turn key switch OFF and allow at least 90 sec-
onds for the steering accumulator to bleed
down.
Be prepared to contain approximately 901 l (238 gal.)
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 removing the drain
plug (2, Figure 3-17) located on the bottom of
the tank.
1. O-Ring 8. Setscrew
2. Plug 9. Filter Element
3. Filter Head 10. Bowl
4. O-Ring 11. Bleed Plug
5. Indicator Switch 12. O-Ring
6. O-Ring 13. Bottom Plug
7. Backup Ring
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-15
Low Precharge Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-15
FLOW AMPLIFIER
The flow amplifier (Figure 4-2) is located on the left
inside frame rail just forward of the bleed down mani-
fold. The flow amplifier is required in the steering cir-
cuit due to the large volume of oil displacement
required for steering. The flow amplifier uses the
amount of flow from the steering control valve to
determine the amount of amplified flow to send from
the bleed down manifold to the steering cylinders.
Reference Figures 4-3 through 4-6 for oil flow paths
during the neutral, steering and external shock load
conditions.
FIGURE 4-7.
1. Bleed Down Solenoid 5. Return Relief Valve (500 10. Bleed Down Manifold 15. Hoist Pilot Valve Return
2. Brake Quick Dis- psi) 11. Return Line Line
connect 6. Flow Amplifier 12. From Steering Filter 16. Supply to Brakes
3. Accumulator Supply 7. Unloader Valve Line 13. Check Valve (Piloted) 17. Return from Flow Ampli-
4. Low Steering Pressure 8. Check Valve 14. Outlet to Flow Amplifier fier
Switch 9. Relief Valve (4000 psi)
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-5
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-32
Control Piston Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-32
Valve Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-32
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-32
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-36
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-36
Compensator Block and Unloader Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-36
Stroke Adjuster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-36
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-36
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-36
Control Piston Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-38
Valve Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-39
FIGURE 5-2. CHARGING VALVE 3. Loosen small hex nut (4, Figure 5-2) three com-
plete turns. Remove valve cap (1). Install charg-
1. Valve Cap 6. Valve Body ing manifold assembly and bleed off all nitrogen
2. Seal (Large Hex Nut) pressure.
3. Valve Core 7. O-Ring 4. Disconnect electrical leads at the pressure
4. Swivel Nut 8. Valve Stem switch located on top of the accumulator.
(Small Hex Nut) 9. O-Ring 5. Disconnect and plug the hydraulic line (3, Fig-
5. Rubber Washer ure 5-4) at the bottom of the accumulator.
Disassembly
1. Once the accumulator has been removed from
the equipment, the accumulator body should be
secured in a vise, preferably a chain vise. If a
standard jaw vise is used, brass inserts should
be used to protect the hydraulic port assembly
from damage. Clamp on wrench flats only
FIGURE 5-4. ACCUMULATOR MOUNTING
when using a jaw vise to prevent accumulator
1. Accumulators 3. Hoses (to Bleeddown from turning.
2. Clamps Manifold)
2. Remove bleed plug (12, Figure 5-5) on hydrau-
lic port assembly. Using a spanner wrench,
remove lock ring (10) from the hydraulic port
assembly. Use an adjustable wrench on the
flats located on the port assembly to prevent
port assembly from rotating.
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).
Driveshaft Group
NOTE: Be sure punch marks on cylinder bearing (26,
Figure 5-25) will face toward shaft end of pump.
9. Insert cylinder bearing (26) straight into pump
housing. Be sure bearing is positioned so bear-
ing retainer pins (17, Figure 5-24) can be
inserted in the case and into the bearing.
10. Install O-rings (18) on pins (17) and install pins.
11. An arbor press is required to install shaft bear-
ing (2) onto driveshaft (1). IMPORTANT - press
FIGURE 5-27. STROKE ADJUSTER ASSEMBLY ONLY on the inner race of the bearing. Press
bearing until it contacts the shoulder on drive-
1. Stem 3. Gland shaft.
2. O-Ring 4. Jam Nut 12. Use a long 153 mm (6 in.) 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.
4. Use a long brass bar and a mallet (or an arbor 13. Place seal retainer (21) over seal (24) inside the
press), to install saddle and bearing assembly pump housing (20). Lubricate shaft seal with
into pump housing. Tap or press ONLY on the clean hydraulic oil.
area of the saddle that is exposed between the 14. Install entire driveshaft assembly through the
saddle bearings (DO NOT tap on bearing sur- front of the pump housing. A mallet will be
faces). Saddle is fully seated when a distinct required to install the driveshaft through shaft
metallic sound is heard when installing saddle seal (2).
into pump housing.
15. Once the driveshaft assembly is fully seated
within the pump housing, install snap ring (3).
1. Hoist Cylinders
2. Hoist valve
3. Pilot Operated Check Valve
4. Hoist Up Limit Solenoid
5. Filter
6. Hoist pilot valve
7. Filter
8. Return from Flow Amplifier valve
9. Hoist Pump
10. Hydraulic Tank
11. Quick Disconnects
12. Counterbalance Valve Manifold
Hydraulic Tank Hoist pump output flows to two remote mounted high
pressure filters located on the lower inboard side of
The hydraulic tank supplies hydraulic oil for the hoist,
the fuel tank. The filter elements are rated at 7
steering, and brake circuits. The tank is located on
micron. The filter assembly is equipped with a
the left hand frame rail forward of the rear wheels.
bypass valve which permits oil flow if the filter ele-
The service capacity is 901 l (238 gal). Refer to Sec-
ment become plugged. Flow restriction through the
tion P for the correct type hydraulic oil recommended
filter element is sensed by a pressure differential
for use in the hydraulic system.
switch.
Oil used in the hoist circuit flows through two 100
This switch will turn on an over-
mesh wire suction strainers to the inlet housing of the
head panel mounted, yellow
hoist pump. Air drawn into the tank during operation
warning light to indicate filter
is filtered by dual air filters located on the top of the
service is required. The light is
tank. Oil level can be checked visually at sight
labeled “Filter Monitor” and will
glasses located on the face of the tank. Oil level
come on when restriction
should be checked periodically and be visible in the
reaches approximately 241 kPa
bottom sight glass when the body is down and the
(35 psi). Actual filter bypass will
engine is running.
result when the filter element
Hoist Pump restriction reaches approxi-
mately 345 kPa (50 psi).
The hoist pump is a tandem gear type pump driven
by an accessory drive at the rear of the traction alter-
nator. The pump has a total output of 908 lpm (240
gpm) at 1900 RPM. The hoist pump also drives the
steering and brake supply pump located at the rear
of the hoist pump. Hoist pump output is directed to
two remote mounted high pressure filters. Maximum
hoist pump output pressure is 17237 kPa (2500 psi).
Separate spools control oil flow to each end of the • Check poppets
cylinders. The valve consists of two identical inlet The pilot ports are located in the top spool section
sections, a spool section, and a separator plate. cover. These ports provide connections for pilot lines
The hoist valve precisely follows differential pressure from the hoist pilot valve. Each pilot port has a corre-
input signals generated by the hoist pilot valve. sponding work port.
(Refer to Figures 7-6 through 7-10.) The work ports provide for line connections between
The inlet sections of the hoist valve consist of the fol- the spool section and the hoist cylinders. One main
lowing components: spool for each work port is spring centered at both
ends to close the work port from the high and low
• Flow control and main relief valve (system relief). pressure cores when there is no flow to the pilot
• Low pressure relief valve. ports.
Installation
1. Attach a suitable lifting device to the hoist valve.
Move the hoist valve into position with the sepa-
rator plate (8, Figure 8-1) located to the rear.
Secure in place with cap screws, nuts and lock-
washers. Tighten cap screws to standard
torque.
Note: Be certain hoist valve assembly is positioned
with separator plate (8, Figure 8-1) towards rear of
truck when valve is lowered onto mounting plate.
FIGURE 8-1. HOIST VALVE INSTALLATION 2. Using new O-rings at the flange fittings, connect
hydraulic lines. Tighten flange cap screws to
standard torque. Refer to Figure 8-1 for hydrau-
1. Hoist Pilot Valve Supply 5. Power Down Line
2. Power Up Line 6. To Hoist Pilot Valve lic line location.
3. Inlet From Filters 7. Return To Tank
4. Return To Tank 8. Separator Plate
SPOOL SECTION
Disassembly
NOTE: It is not necessary to remove the inlet
sections (4, Figure 8-2) to accomplish spool section
(3) 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. Remove cap screws and remove spool section
cover (2, Figure 8-2). Remove and discard O-
rings (4 & 5, Figure 8-8).
3. Remove poppet (1, Figure 8-7), remove and
discard O-ring (3).
NOTE: The poppet (1) is equipped with a small steel
ball. Do not misplace.
FIGURE 8-14. HOIST PILOT VALVE ASSEMBLY FIGURE 8-15. TIE ROD NUT TORQUE
1. Spool Housing 4. O-ring 1. Nut 4. Tie Rod
2. Check Poppet 5. Outlet Housing 2. Tie Rod 5. Outlet Housing
3. Spring 3. Nut
Installation
SS1145 – Plate
(2.50" x 2.50" x 0.25" thick)
Quill Installation
1. The plugs (3, Figure 8-20) and the check balls
(4) in the quill should be checked during any
cylinder repair to insure the plugs are tight and
ball seats are not damaged. Refer to Installation
of Check Balls and Plugs in Quill.
2. Secure cap assembly (1) in a sturdy fixture.
Make certain threads in cap and threads on quill
are clean and dry (free of oil and solvent).
3. Using Loctite “LOCQUIC” Primer “T” (TL8753,
or equivalent), spray mating threads of both cap
assembly (1) and quill assembly (2). Allow
primer to dry 3 to 5 minutes.
4. Apply Loctite Sealant #277 (VJ6863, or equiva-
lent) to mating threads of both cap assembly
and quill assembly.
5. Install quill and use SS1143 tool to tighten quill
to 1356 N·m (1000 ft lbs) torque. Allow parts to
cure for 2* hours before exposing threaded
areas to oil.
* Note: If “LOCQUIC” primer “T” (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
6. Tack weld quill in 2 places as shown in Figure
8-20.
7. Remove all slag and foreign material from tack
weld area before assembly of cylinder.
Hookup
Be certain there is an adequate, clear area to dump
the loaded box. When the good truck is in position,
shut down the engine and allow the hydraulic system
to bleed down. Be certain pressure has bled off
before connecting hoses.
1. With the good truck parked as close as possible
to the disabled truck, attach a hose from the
power up quick disconnect (3, Figure 8-23) to
the power down circuit of the disabled truck.
(Hose must be rated to withstand 17237 kPa
(2500 psi) or greater pressure. FIGURE 8-26. PUMP MODULE, HOSE HOOKUP
(Model 830E Shown)
NOTE: The power down circuit will use a smaller
diameter hose (tube) than the power up circuit. 1. Hoist Valve
2. Overcenter Manifold
2. Connect another hose from the power down
3. Power Up Quick Disconnect; Connect to
quick disconnect (4) to the power up circuit of power down circuit of “disabled” truck
the disabled truck. 4. Power Down Quick Disconnect; Connect to
NOTE: If both trucks are a Model 830E, the hoses power up circuit of “disabled” truck
will be installed at the quick disconnects shown in
Figure 8-23 and will be crossed when connected.
BLEEDDOWN MANIFOLD
Adjustment of the relief valves is not necessary or
recommended. Relief valves are factory preset. Do
not attempt to rebuild or repair if relief valves are
defective. Replace as a unit. The steering pressure
switch and check valves are also replaced only as
units.
1. Bleeddown Solenoid
2. Quick Disconnect, Brake System
3. To Steering Accumulators
4. Low Steering Pressure Switch
5. Relief Valve - 3447 kPa (500 psi)
6. Flow Amplifier
7. Feedback Pressure to Unloader Valve
8. Check Valve
9. Relief Valve - 27,579 kPa (4000 psi)
10. Bleeddown Manifold Valve Assembly
11. Tank Return Line
12. Supply (From Filter)
13. Check Valve (Piloted)
14. Supply to Flow Amplifier
15. Hoist Pilot Valve Return to Tank
16. Brake System Supply
17. Return From Flow Amplifier
Broken or worn linkage between Check for loose fitting bearings at anchor
Excessive free play at cylinder and steered wheels. points in steering linkage between cylinder
steered wheels and steered wheels.
Leaky cylinder seals. Replace cylinder seals.
Binding or misalignment in steering Align column pilot and spline to steering
column or splined column or splined control valve.
input connection.
High back pressure in tank can Reduce restriction in the lines or circuit by
Binding or poor center- cause slow return to center. Should removing obstruction or pinched lines, etc.
ing of steered wheels not exceed 2068 kPa (300 psi).
Large particles can cause binding Clean the steering control unit. If another
between the spool and sleeve. component has malfunctioned generating
contaminating materials, flush the entire
hydraulic system.
Large particles in spool section. Clean the steering control unit.
Steering control valve Insufficient hydraulic power. Check hydraulic oil supply.
locks up Severe wear and/or broken cardan Replace pin or the steering control unit.
shaft pin.
Steering wheel oscil- Lines connected to wrong ports. Check line routing and connections.
lates or turns by itself Parts assembled incorrectly. Reassemble correctly.
Steering wheels turn in Lines connected to wrong cylinder Correct cylinder port line connections.
opposite direction ports.
when operator turns
steering wheel
Trapped air inside steering pump. Bleed trapped air. Refer to “Pressure Check
And Adjustment Procedure”, this Section.
Broken pump drive shaft. Replace pump drive shaft.
No pump output Excessive circuit leakage. Check for loose fittings, broken or cracked
tubes.
No oil to pump inlet. Check hydraulic tank oil level. Make sure
shut-off valve is open.
Low pump pressure. Check or adjust compensator pressure set-
ting.
Compensator valve, seat, spring or Repair or replace compensator.
packing failure.
Worn or scored pistons and bores. Repair or replace pistons or pump housings.
Maximum volume stop limiting Turn volume stop screw counterclockwise.
pump stroke. Tighten jam nut.
Worn or damaged piston shoes, Repair or replace defective parts.
Low pump output swashblock or swashblock wear
plate.
Worn or grooved cylinder wear Repair or replace defective parts.
plate and/or port plate.
Restricted inlet. Clear restriction. Make sure suction line
shut-off valve is open. Clean suction
strainer.
Insufficient inlet oil. Check for proper hydraulic tank oil level and
make sure suction line shut-off valve is
open.
Control piston seals broken or dam- Repair or replace broken parts.
Unresponsive or slug-
aged.
gish control
Swashblock saddle bearings worn Repair or replace broken parts.
or damaged.
Faulty output circuit components. Repair or replace relief valve or pressure
compensator valve.
Worn piston pump. Repair or replace worn parts.
Worn or grooved cylinder wear Repair or replace worn parts.
Loss of pressure plate and/or port plate: wear plate
and/or port plate separation from
cylinder, each other or valve plate.
Worn pistons, shoes or piston Repair or replace worn parts.
bores.
Stuck piston (position 2, Figure 10- Disassemble and check piston movement.
Slow or hard steer
5).
Heavy steering wheel Dirty throttle-check valve, (position Disassemble and clean the throttle check
movement with a simul- 3) or dirty orifice screw (position 4). valve and/or the orifice screw.
taneous opening of the
relief valve
Leaky shock valve or suction valve, Disassemble, clean and check shock and
Free Wheeling (no end (position 6). suction valves.
stop) Setting pressure of shock valve too Adjust the shock valve pressure setting.
low, (position 6).
Leaky relief valve in the priority Clean and perhaps replace the relief valve.
Inability to Steer (No valve, (position 1).
Pressure Build-up)
Defective steering control unit. Replace the steering control unit.
Air in “LS” line. Bleed the “LS” line.
Hard point when begin- Spring compression in the priority Replace priority valve spring.
ning to turn the steering valve too low.
wheel Clogged orifice in the “LS” or “PP” Clean the orifice.
port (positions 7 & 8).
Relieve pressure before disconnecting hydraulic NOTE: Each hoist pump section supplies oil to a
lines. Tighten all connections securely before separate inlet section on the hoist valve. Each inlet
applying pressure. section on the hoist valve contains a power up relief
Hydraulic fluid escaping under pressure can valve. If the either relief pressure is not within
have sufficient force to enter a person's body by specifications, adjust or replace the respective relief
penetrating the skin and cause serious injury and valve.
possibly death if proper medical treatment by a 5. If power up relief pressure is not correct, adjust
physician familiar with this type of injury is not pressure as follows:
received immediately. a. Move hoist control lever to the “power down”
position and allow body to completely rest on
Hoist System Relief Pressure Adjustment
frame rails. Shut down engine.
1. Install two 0-35,000 kPa (0-5000 psi) pressure
b. Relieve all hydraulic pressure from hoist sys-
gauges (one to each diagnostic coupler located
tem.
at each outlet port on the hoist pump).
2. Start engine and run at low idle. NOTE: One relief valve is located under each inlet
valve cover.
Pressure at both hoist pumps should be
approximately 517 kPa (75 psi) or less with c. Remove small external tube and cap screws
oil temperature at 29°C (70°F). (1, Figure 10-6) from inlet section cover (2)
3. To allow full extension of the hoist cylinders, where the relief valve needs serviced.
disconnect the hoist up limit solenoid from the Remove cover from hoist valve and spring
wiring harness located in the hydraulic cabinet (3) from relief valve.
behind the operators cab. d. Loosen jam nut on relief valve (4) and turn
screw in (clockwise) to increase pressure or
out (counter-clockwise) to decrease pres-
sure.
Be sure there is adequate (safe) overhead clear-
ance before raising body to full up position.
Preparation: 1. Start the engine. At low idle, raise the body and
as it extends to the third stage, read the pres-
Note: The ports and valves referred to in the sure on the gauge connected to the “TR” port.
following procedures are labelled on the (All counterbalance valve pressures are read/
counterbalance manifold valve body. adjusted while hoist cylinders are in third stage.)
1. With the engine shut down, the body resting on a. If pressure is 20 684 kPa (3000 psi) or
the frame, the hoist valve in the FLOAT position above, stop hoisting immediately.
and hydraulic system pressure bled down, Pressure is adjusted too high and must be
loosen locknut on adjustment stem of needle lowered. Go to Counterbalance Valve
valve (9, Figure 10-9) on counterbalance mani- Adjustment and perform adjustment proce-
fold (2). Turn adjustment stem fully clockwise. dure.
2. Remove fitting from “PILOT VENT” port (8) on b. If pressure is below 20 684 kPa (3000 psi),
counterbalance manifold. This port will remain increase engine speed by approximately 300
open to atmosphere during adjustment; do not rpm and observe pressure on gauge.
allow dirt to enter open port.
Note: It is suggested a clean SAE #4 (1/4") hydraulic
hose is installed in the open port and the hose
pointed downward.
3. Install a 35,000 kPa (5000 psi) gauge at test
port “TR” (7) on counterbalance manifold.
(Gauge will measure rod end pressure; the
pressure controlled by the counterbalance
valve.)
• Angle groove on
face of pressure plate Verify correct filter elements are being used.
Abrasive wear caused by fine parti-
• Lube groove
cles in oil supply — Dirt (fine contami- Check hoist and steering cylinders for dents,
enlarged and edges
nants, not visible to the eye). scoring, or seal damage.
rounded
• Dull area on shaft at
root of tooth Entire hydraulic system may require com-
plete cleaning (See Flushing Procedure in
• Dull finish on shaft the following pages).
in bearing area
• Sandblasted gear
bore in housing
Visible damage in the Entire hydraulic system may require com-
following areas: plete cleaning (See Flushing Procedure in
• Scored pressure Abrasive wear caused by metal parti- the following pages).
plates cles — Metal (coarse contaminants,
visible to the eye).
• Scored shafts Check other hydraulic system components
• Scored gear bore for possible source of contaminants.
External damage to
Incorrect installation. Remove and repair as required.
pump
Check pump driveshaft.
Damage on rear of
Check cross and bearings for smooth oper-
drive gear and rear Defective pump driveshaft.
ation.
pressure plate only
Check for adequate joint lubrication.
Check hydraulic tank oil level.
Aeration - cavitation Verify correct oil viscosity.
Eroded pump hous-
ing or pressure plate • Restricted oil flow to pump Check for restriction or air leak at pump inlet
• Aerated oil line.
Check for loose fittings, clamps etc.
Excessive wear on Check hydraulic oil level.
pressure plate and/or Lack of oil. Check pump inlet hoses for obstructions or
end of gear leaks.
• Housing scored
heavily Thoroughly clean and flush hydraulic sys-
Damage caused by metal object -
• Inlet peened and tem.
battered Object not removed during a previous
Check other system components for possi-
failure repair.
• Foreign object ble source of metallic object.
caught in gear teeth
• Pressure plate black
• O-rings and seals Check hoist system relief valve settings.
brittle Excessive heat. Verify correct hydraulic oil level.
• Gear and journals Verify correct oil viscosity.
black
• Broken shaft
Check relief valve pressure.
• Broken housing or Excessive pressure.
Verify relief valve is functioning properly.
flange
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-3
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Placing the Electric Detection & Actuation System Into Service . . . . . . . . . . . . . . . . . . . . . . . M2-9
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-10
Control Module
(Figure 2-4)
Provides the electrical connections necessary
between the power lead and the linear detection
wire to the power lead supplying electrical power,
via the squib, to the actuator. Also provides a visual
check of power availability - pressing the switch but-
ton will illuminate the green indicator light if electri-
cal power is available in the system. FIGURE 2-4. CONTROL MODULE
FIGURE 2-11. LINEAR DETECTION WIRE Do Not install squib to power lead at this time
CONNECTOR (Figure 2-13).
! CAUTION !
Remove jumper to prevent fire suppression sys-
FIGURE 2-14. INSTALL JUMPER tem from discharging when squib is installed in
electric detection and actuation system.
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 (Fig-
ure 2-14) 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 2-15).
Test module light should immediately illumi-
nate. This test confirms that the wire is prop-
erly installed and will function as designed. If
test module light does not illuminate on test
module, refer to the "Troubleshooting" sec- FIGURE 2-16. REMOVE JUMPER ASSEMBLY
tion.
FIGURE 2-19.
Daily
The machine operator should manually test system
power by pushing the button and noting illumination
of indicator light. This confirms battery power is avail-
able. If light is not illuminated, refer to "Troubleshoot-
ing" covered in this section.
FIGURE 2-23. ATTACH INDICATOR LIGHT 14. Install actuation cartridge back into lower actua-
ASSEMBLY (Test Module) tor body and tighten firmly by hand.
TROUBLE: Green Indicator Light on Control Module Does Not Go On When Button is Depressed.
Detection wire too close to heat source Check for broken points of security, move away from
heat source, and recharge
Test jumper assembly left in place after testing Remove jumper, reinstall plugged end of line connector
and recharge
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M7-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M7-3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M7-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M7-4
Maintenance
To check for operation of the heating units, the outlet
water hoses should feel warm to the touch.
1. Check all electrical connections to insure proper
connections are made.
2. Check for a burned out heating element. (Do
not remove heating unit from the truck.) FIGURE 7-1. COOLANT HEATER
a. Remove the two Phillips head screws and 1. Thermostat 4. Heating Element
slide end cover out of the way. 2. Heater Assembly 5. Cover
b. Connect a voltmeter at the two electrical ter- 3. Water Outlet Port 6. Terminals
minals and check for operating voltage (220
to 230 volts) while coolant temperature is
below 48°C (120°F). If correct voltage is
present, the heating element is defective and
should be replaced.
3. If correct voltage (measured above) is not read
at heating element terminals, the thermostat is
defective and should be replaced.
THERMOSTAT
Removal
1. Disconnect the external power source at the
plug in receptacle.
NOTE: It is not necessary to remove the thermostat
assembly from the heater.
2. Remove the two screws and slide cover out of
the way.
3. Disconnect the two electrical leads.
4. Loosen the two setscrews and remove the tem- FIGURE 7-2. THERMOSTAT ASSEMBLY
perature sensing unit. 1. Cover 3. Housing
2. Temperature 4. Setscrew
Sensing Unit
Installation
1. Install a new temperature sensing unit and
secure in place with two setscrews.
2. Connect the electrical leads.
3. Move cover into position and secure in place
with screws.
4. Plug in the external power source.
After allowing time for the element to warm up, outlet
hoses should feel warm to the touch.
ROLL-OUT ASSEMBLY
Part Number Description Use
EJ2627 Roller Assy. Power Module
Remove & Install
EYE BOLT
Part Number Description Use
TG1106 Eye Bolt, 0.75-10
UNC Misc. lifting
WA4826 Eye Bolt, 1.25-7 requirements
UNC
TORQUE ADAPTER
Part Number Description Use
TZ2734 3/4 in. Torque Miscellaneous
Adapter
HANDLE
Part Number Description Use
TZ2733 Tubular Handle Use with
PB8326 &
TZ2734
SEAL INSTALLER
Part Number Description Use
TY2150 Seal Installation Installation of
Tool Front Wheel
Bearing Face
Seals
HARNESS
Part Number Description Use
EF9160 Harness Payload Meter
Download. Refer
to Section M.
TUBE
Part Number Description Use
TZ5146 Tube Miscellaneous
Refer to Section G, Drive Axle, Spindles, and Wheels, for information on using the spindle tool to properly
remove the spindles from the machine.
RADIATOR SHUTTERS 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-3
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-3
Electrical Circuit:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-5
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-8
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-10
1. Radiator Shroud
2. Oil Supply
3. Pressure Reducing Valve
4. Pressure Reducing Valve
5. Shutter Solenoid Valve
6. To Cylinder Head End
7. To Cylinder Rod End
8. Electrical Harness (To RH
Frame Junction Box)
9. To Shutter Disable Switch
box
10. Oil Return to Tank
Hose
11. Shutter Actuator
Cylinder
Cause Remedy
YES Go to
11 Electri- electrical
cal prob- trouble-
lem shooting
YES
NO
Contin-
ued on
next page
Cause Remedy
Pressure Replace
YES
reducing pressure
valve (2) reducing
is defec- valve (2)
Install tee fitting between
oil supply hose (1) and
tive
pressure reducing valve
(2). Connect pressure
gauge with a 0-35,000
kPa (0-5000 psi) range
to tee fitting. Pressure
should be 20,684 -
24,131 kPa (3000-3500
psi) the same as steering
system standby
pressure.
Perform
trouble-
Hydraulic shooting
NO
Supply to proce-
shutters is dures in
incorrect appropri-
ate shop
manual to
correct
truck
hydraulic
system
Cause Remedy
Repair cir-
NO
Open cir- cuit 712R.
cuit in
712R from
key switch
PLMIII uses a speed signal to calculate speed, dis- The circuit board inside the payload meter housing is
tance, and other performance data. This input is criti- made from multi-layer, dual-sided surface-mount
cal to the proper operation of the system. PLMIII electronics. There are no field serviceable compo-
receives this signal from the speedometer/operator nents inside. The electronics are designed to with-
display on the dashboard. The same signal displayed stand the harsh operating environment of the mining
to the operator is used by the system. Distance cal- industry. Opening the payload meter housing will
culations are made based on the rolling radius of the result in voiding the warranty.
tires for a particular truck.
Communications Ports
Body-Up Switch The payload meter has two RS232 serial communi-
The body-up input signal is received from a magnetic cations ports and two CAN ports. Connections for the
switch located on the inside of the truck frame, for- two serial ports are available inside the payload
ward the pivot pin of the truck body. This is the same meter junction box. The two CAN ports are available
switch typically used for input to the drive system. for future electronics systems.
When the body is down, the switch closes and com- Serial port #1 is used to communicate with the dash-
pletes the circuit to 71-control power. 24vdc indicates board display. It is also used to connect to the laptop
the body is down. Open circuit indicates that the computer. The display gauge will remain blank when
body is up. the PC is using the serial port. This port initially oper-
ates with serial settings at 9600,8,N,1. These set-
Brake Lock Switch tings change automatically to increase the
The brake lock is used to lock the rear brakes on the communications rate when the PC is using the port.
truck. It is necessary for the accurate calculation of This serial port uses a 3-wire hardware connection.
swingloads during the loading process. Without the Serial port #2 is used to communicate to other on-
brake lock applied, the payload meter will not calcu- board electronics like Modular Mining's Dispatch®
late swingloads during the loading process. Without system or the scoreboard from Komatsu. This port
the brake lock, the payload meter will assume that uses a 3-wire hardware connection. Connections to
the truck was loaded using a continuous loader and this serial port need to be approved by Komatsu.
flag the haul cycle record. All other functions will be Several protocol options are available and detailed
normal regardless of brake lock usage. The brake technical information is available depending on
lock input comes from the switch located on the dash licensing.
panel. The brake lock switch connects the circuit to
ground. Open circuit indicates brake lock off. Ground
indicates brake lock on.
TCI Outputs
The GE drive system on the 930E/960E requires
information from the payload meter regarding the
loaded condition of the truck. There are three outputs
from the payload meter to GE to indicate the relative
load in the truck. 24 vdc on the 73MSL circuit indi-
cates that the load is 70% of rated load. 24 vdc on
the 73FSL circuit indicates the truck is 100% loaded.
The 73OSL circuit is not currently used.
2. Hold the “SET” button until the display clears. “SELECT” switch until rr= is displayed.
• Inclinometer - To display the truck incline, press
The units for the display are controlled by the config- scroll, ----930E---.
uration of the payload meter. If the payload meter is
set to display metric units, the pressures will be dis-
played in tenths of kg/cm2. For example, if the dis- If the PLMIII encounters memory problems, it will dis-
play shows 202 the actual value is 20.2 kg/ play ER88 where 88 is the specific memory
error. In this very rare circumstance, the system
cm2. If the payload meter is set to display short tons, should be turned off for 30 seconds and restarted.
the pressures will be displayed in psi (lbs/in2). Multi-
ply by 14.2 to convert kg/cm2 to psi. (example -- 1kg/
cm2 x 14.2 = 14.2 psi). There is no way to detect the
units setting for the gauge without the PC software.
Table 2:
Fault Code Name Description
1 Left front pressure high Input current > 22 ma
2 Left front pressure low Input current < 2 ma
3 Right front pressure high Input current > 22 ma
4 Right front pressure low Input current < 2 ma
5 Left rear pressure high Input current > 22 ma
6 Left rear pressure low Input current < 2 ma
7 Right rear pressure high Input current > 22 ma
8 Right rear pressure low Input current < 2 ma
9 Inclinometer high Input voltage < 0.565 vdc
10 Inclinometer low Input voltage > 5.08 vdc
11 Speed input failure Not Used
12 Brake lock input failure Not Used
13 Body-up input failure Payload meter detected dumping activity without receiving a body up signal
16 Memory write failure Indicates possible memory problem at power start up. Cycle power and recheck.
17 Memory read failure Indicates possible memory problem at power start up. Cycle power and recheck.
18 Rear right suspension flat Payload meter detected an undercharged suspension condition on the rear right suspension.
19 Rear left suspension flat Payload meter detected an undercharged suspension condition on the rear left suspension.
20 Time change Payload meter time was changed by more than 10 minutes. The Alarm Set time indicates
original time. The Alarm Clear time indicates the new time.
21 Tare value reset The user manually forced the payload meter to reset the haul cycle empty (tare) sprung
weight. This forced the meter into the tare_zone state and lost all data for the previous haul
cycle.
22 Excessive carryback The payload meter detected an empty carryback load in excess of the user-defined carryback
threshold on two consecutive haul cycles.
26 User switch fault - SELECT Select switch on for more than 2 minutes, may indicate short to ground
27 User switch fault - SET Set switch on for more than 2 minutes, may indicate short to ground
System Configuration
PLMIII needs to be configured for operation when it
is first installed on the truck. This process requires
several steps and uses the laptop computer to make
the necessary settings. The setup procedure can be
broken down into several steps:
Time Units
Minutes and Seconds Example:
Five minutes and thirty-two seconds = 5:32
Decimal Minutes Example:
Five minutes and thirty-two seconds = 5.53
Connection Menu
The data analysis tools allow the user to monitor the Sorting on Truck Unit Number
performance of the payload systems across the fleet.
The truck unit number is the truck unit number
Analysis begins when the "View Payload Data" but-
entered into the payload meter when it was config-
ton is pressed. This starts an "all trucks, all dates, all
ured at installation. The query can be set to look for
times" query of the database and displays the results
all trucks or one particular truck number. When the
in the Payload Summary Form.
program begins, it searches through the database for
The user can change the query by changing the all the unique truck numbers and creates a list to
dates, times, or trucks to include in the query for dis- select from.
play.
Choosing one particular truck number will limit the
Haul cycles in the data grid box at the bottom can be data in the displays, summaries and reports to the
double-clicked to display the detailed results of that one selected truck. To create reports for truck num-
haul. ber 374, select 374 from the pull-down menu and hit
the "Query Database and Display" button.
Creating a Query
The program defaults to show all trucks, all types, all
dates and all times for the initial query. The display Sorting on Truck Type
can be narrowed by selecting which trucks or types
The truck type is the size of the truck from the family
to view and for what dates and times.
of Komatsu trucks. This allows the user to quickly
The query items are added in the "AND" condition. If view results from different types of trucks on the
the user selects a truck # and date range, the query property. For example, a separate report can be gen-
will sort the data for that truck number AND the date erated for 830E and 930E trucks.
range.
6:00
3. Change the “To” date to July 31, 2000.
4. Press the "Query Database and Display" to
view the results.
12:00
date range. Times are entered in 24:00 format. To Query : Date: 1/5/00 to 1/8/00
Haul Cycles Included in the Query
view the haul cycle reports from the first shift for truck Daily Shift Time: 6:00 to 18:00
Time
Date
Reports can be generated and viewed on the screen
0:00
Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000
or printed. These reports are generated from the
query displayed on the Payload Summary Screen.
From the example in "Sorting on Time Range", the
report printed would only contain data from truck 374
6:00
during the month of July 2000, from 8:00 AM to 5:00
PM.
12:00
It is important to carefully select the query data and
press the "Query Database & Display" button before
printing a report.
18:00
24:00
CSV Export
• Truck number The second series of data below the haul cycle data
• Haul cycle start date is the alarms. The alarm columns, left to right are:
• Haul cycle start time
• Payload
• The alarm type
• Swingloads
• The date the alarm was set
• Operator ID
• The time the alarm was set
• Warning Flags
• Alarm description
• Carry Back
• The date the alarm was cleared
• Total Haul Cycle time
• The time the alarm was cleared
• Empty Running Time
• Empty stop time
• Loading time
Compressed
• Loaded running time
• Loaded stopped time
• Dumping time
• Loading start time
• Dumping start time
• Loaded haul distance
• Empty haul distance
• Loaded maximum speed
• Time when loaded maximum speed occurred
• Empty maximum speed
• Time when loaded maximum speed occurred
• Maximum + frame torque
• Time when the maximum + frame torque
occurred This export function allows the data from one laptop
• Maximum - frame torque to be transferred to another computer. This can be
• Time when the maximum - frame torque useful when a service laptop is used to download
occurred
multiple machines and transfer the data to a central
• Maximum sprung weight calculation
• Time when the maximum sprung weight computer for analysis. This can also be used to copy
calculation occurred haul data from a particular truck onto a diskette for
• Left Front Tire-kilometer-hour analysis.
• Right Front Tire-kilometer-hour The file format is a compressed binary form of the
• Average Rear Tire-kilometer-hour
displayed query. The file can only be imported by
• Frame serial number
another computer running the PDM Software.
• If these errors persist after reprogramming, the primary and secondary processors then the payload meter
must be replaced.
• If the speedometer works but the operator displays remain blank, confirm payload connections at “No Payload
Display When Key Switch is Turned ON”.
• Confirm that the truck operator uses the brake lock switch (NEUTRAL) during loading. Without this input, the
payload meter will not properly recognize swingloads.
• Confirm bulbs in payload lights by using lamp check mode.
• Confirm 15 A breaker CB-B in payload junction box.
• To continue troubleshooting, turn on all the payload lights using the lamp check mode of the Payload Data
Manager software.
• Confirm the body up switch signal. When the body up signal is not properly received during dumping, the
payload meter may maintain the lights after the body is lowered.
• Confirm the payload light wiring using the procedures in "Load Lights Don't Light During Loading".
The payload meter senses when the load is dumped without receiving a body-up signal. When the load quickly
drops below 50% without the body up signal, Alarm 13 is set. The alarm will be cleared when a normal dump cycle
is detected. A normal dump cycle will be detected when the body up signal is received, the load drops quickly and
the body down signal is received.
Alarm 19
Payload meter detected an undercharged suspension condition on the rear left suspension.
The suspension may be in need of servicing. Refer to Section H in the shop manual for information on charging the
suspensions.
Alarm 22
The payload meter detected an empty carryback load in excess of the user-defined carryback threshold on two
consecutive haul cycles.
Stop the truck and clean any stuck material from the truck body.
This diagram shows the general location of connectors, terminal boards and miscellaneous connections.
the button and the Operator ID will be dis- dashboard. In= will be displayed. Release
played. This value should be 0. the button and the inclinometer value will be
displayed. This value is in degrees. The incline
10. Press and hold the “SELECT” button on the
will depend on how the truck is set during
dashboard. tL= will be displayed. Release assembly. Values between ±3° are acceptable.
the button and the total tons will be displayed. It is not necessary to zero this reading by
This value should be 0. adjusting the attitude of the inclinometer in the
buddy seat.
11. Press and hold the “SELECT” button on the
dashboard. LC= will be displayed. Release
17. Press and hold the “SELECT” button on the
the button and the number of loads will be dis- dashboard. PL= will be displayed. Release
played. This value should be 0. the button and the current payload will be dis-
played.
12. Press and hold the “SELECT” button on the
dashboard. Lf= will be displayed. Release
18. Connect a laptop to the PLMIII system. Typically
an EF9160 download cable is used. The pay-
the button and the left-front pressure will be dis- load meter connector is behind the buddy seat
played. This value should be in metric units. on the back wall on the side of the PLMIII
The nominal value should be 23.4 kg/cm2 mounting bracket. The laptop must have the
(332psi). Values between 17.6 and 29.2 kg/ Payload Data Manager software installed.
cm2 (250 psi and 416 psi) are acceptable. 19. Run the PC software.
13. Press and hold the “SELECT” button on the 20. From the main menu, select "Connect to Pay-
dashboard. rf= will be displayed. Release load Meter".
the button and the right-front pressure will be
displayed. This value should be in metric units.
The nominal value should be 23.4 kg/cm2
(332psi). Values between 17.6 and 29.2 kg/
cm2 (250 psi and 416 psi) are acceptable.
14. Press and hold the “SELECT” button on the
dashboard. Lr= will be displayed. Release
the button and the left-rear pressure will be dis-
played. This value should be in metric units.
The nominal value should be 23.4 kg/cm2
(332psi). Values between 17.6 and 29.2 kg/cm2
(250 psi and 416 psi) are acceptable.
Flashburn
49. Close all screens and disconnect the laptop
from the PLMIII system. 1. Power Before programming, power must be
OFF turned off to the target device. Be sure
the power is turned off before continuing.
2. Select
Port
3. Select
File
4. Power
ON
Inclinometer
Date
Truck
Signature
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-4
LED Monitor Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-4
Tank Fill Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-5
Filling Procedure (Remote fill feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-5
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
Every 10 Hours, or once each shift: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
Every 500 Hours: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-7
Circuit Breaker or Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-7
1. Engine Oil Pan (Sump) 4. Pumping Unit (1 & 2) A. Oil Suction Line
2. Oil Tank 5. Air Relief Valve B. Oil Return Line
3. Oil Filter 6. Suction Tube C. Engine Oil Level
OPERATOR CAB
INDEX
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-18
1. Turn the key switch to the OFF position and a. Attach a recycle/recovery station at the air
allow at least 90 seconds to bleed the steering conditioning compressor service valves.
accumulator. Turn the steering wheel to be sure (Refer to "Heater/Air Conditioning System" in
no pressure remains. this section for detailed instructions.)
2. Block truck securely, and open the brake accu- b. Evacuate air conditioning system refrigerant.
mulator bleed down valves on the accumulators c. Remove the air conditioner system hoses
located in the cabinet mounted on the rear of routed to the cab from the receiver/drier and
the cab. Allow sufficient time for accumulators compressor. Cap hoses and fittings to pre-
to bleed down completely. vent contamination.
3. Open the battery disconnect switches located at
10. Attach a lifting device to the lifting eyes provided
one end on the battery box.
on top of the cab.
4. Disconnect hydraulic hoses routed to frame
from fittings at rear of cab under brake cabinet
(3, Figure 2-2). (It is not necessary to discon-
nect hoses (2) attached to, and routed under
the cab.) Cap all fittings and plug hoses to pre-
vent contamination. The cab assembly weighs approximately 2270 kg
(5000 lbs). Be sure lifting device is capable of lift-
5. Disconnect wire harnesses at connectors (5) ing the load.
located under hydraulic cabinet.
11. Remove the cap screws and washers from each
6. Remove cable and hose clamps as needed for
mounting pad (1, Figure 2-1) at the corners of
cab removal
the cab.
NOTE: The tool group shipped with the truck
contains the following tools which may be used to
remove the inner cap screws, as clearance is limited:
• PB8326 - 1-1/2" offset wrench
• TZ2733 - Tubular Handle
• TZ2734 - 3/4" torque wrench Adaptor
12. Check for any other hoses or wiring which may 2. After cab is positioned, insert the remaining cap
interfere with cab removal. screws and hardened washers. (32 total).
Tighten the cap screws to 950 N·m (700 ft lbs)
13. Lift the cab assembly off the truck and move to
torque.
an area for further service.
3. Route wire harnesses to the electrical connec-
14. Place blocking under each corner of the cab to
tors on the rear corner of the cab (5, Figure 2-
prevent damage to floor pan and hoses before 2). Align cable connector plug key with recepta-
cab is lowered to the floor. cle key and push plug onto receptacle. Carefully
thread retainer onto receptacle and tighten
Installation
securely. Install clamps if removed during cab
1. Lift cab assembly and align mounting pad holes removal.
with tapped pads. Insert at least one cap screw 4. Remove caps from hydraulic hoses and tubes
and hardened washer at each of the four pads and reinstall. Reinstall hose clamps as required.
prior to lowering cab onto the truck.
5. Install heater hoses and clamps on fittings on
NOTE: The tool group shipped with the truck underside of cab. Connect other end of hose to
contains the following tools which may be used to fittings at shutoff valves on engine. Open heater
remove the inner cap screws, as clearance is limited: shutoff valves. Connect air cleaner restriction
• PB8326 - 1-1/2" offset wrench indicator hoses.
Removal
1. If overhead space is available, raise body to Door Adjustment
allow access to door with overhead hoist.
If adjustment is necessary to insure tight closure of
Secure body in raised position with safety
door, loosen striker bolt in the door jamb, adjust, and
cables.
retighten.
2. Lower door glass far enough to allow insertion
of lifting sling when door is removed. A rubber sealer strip is mounted with adhesive
around the perimeter of the door assembly to
3. Remove door panel for access to power win-
exclude dirt and drafts. This sealer strip should be
dow motor harness connector. Disconnect
kept in good condition and replaced if it becomes
motor and remove cab harness from door.
torn or otherwise damaged.
4. Remove the retainer clip and bolt clip from the
travel limiting strap.
FIGURE 3-4. DOOR JAMB BOLT ADJUSTMENT a. Remove hair pin clip (1, Figure 2-6) and bolt
(2) from the door check strap closest to the
1. Washer 3. Frame
door.
2. Striker Bolt 4. Seal
b. Remove 2 cap screws (3), which hold the
door strap bracket to the door.
3. Loosen and vertically align (center) the door
jamb bolt with this mark and tighten it firmly c. Disconnect wiring harness (4) to the window
enough to hold it in place but still allow some regulator.
slippage. d. Open the door as far as possible in and
4. Carefully try to close the door (4) and determine remove the internal door panel.
if this has helped the "springing" problem. If the e. Before removing all door panel mounting
door latches but not firmly enough, follow proce- screws, support the panel to prevent the
dures listed previously in "Step A". If the door assembly from dropping. Remove 15 mount-
latch does not catch, move the bolt outwards ing screws (5).
and try again. When corrected, follow adjust-
ment procedures listed in "Step A" to ensure a
good seal. By design, if both seals are in good
condition, proper adjustment of the outside seal
will ensure good contact on the inside seal to
prevent dust and moisture from entering the
cab.
FIGURE 3-8.
FIGURE 3-7.
FIGURE 3-9.
FIGURE 3-10.
1. Screws 2. Rubber Felt Insert
FIGURE 3-12.
1. Window Frame 2. Window Bracket
FIGURE 3-11.
1. Screws
FIGURE 3-13.
1. “L” Shaped Brackets
FIGURE 3-15.
Installation
1. Install the seal material around the door open-
ing in the cab. Start at the bottom center of the
cab opening and work the seal lip over the edge
of the opening. Go all the way around the open-
ing. Be sure that the seal fits tight in corners. A
soft face tool may be used to work the seal up FIGURE 3-16.
into the corners.
2. Continue going all the around the opening. 1. Door Opening Seal 3. Door Assembly Seal
When the ends of the seal meet at the starting
bottom center of the cab opening, it may be
necessary to trim off some of the seal.
NOTE: The ends of the seal material need to be
square-cut to assure a proper fit.
3. Fit both ends so that they meet squarely, then
while holding ends together, push them firmly
into the center of the opening.
FIGURE 3-17.
Adhesive-bonded Windows
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
WIPER ARM
Removal
1. Note the parked position of wiper arm (1, Figure
3-2).
2. Lift the wiper arm cover and remove nut (2) and
washer (3).
3. Disconnect the washer hose, and remove the
wiper arm.
Installation
1. Place the wiper assembly into position in the
wiper compartment.
2. Install cap screws (3, Figure 3-3) with lock
washers (4) and flat washers (5) and tighten
cap screws.
3. Install washer (5, Figure 3-2) and nut (6) on
each wiper shaft and tighten finger-tight.
Tighten the nuts to 18-20 N·m (160-177 in. lbs)
torque. Do not overtighten. The threads on
the shafts are easily stripped when improp-
erly tightened. Install cap (4) over nut (6).
4. Align the linkage and attach to the wiper motor
drive arm using retainer (8, Figure 3-3).
NOTE: When the motor is parked, the drive arm will
be in the 3 o’clock position as shown in Figure 3-3.
FIGURE 3-3. PARK POSITION 5. Install the wiper arms. Refer to Wiper Arm
Installation. Ensure the wipers arms operate
A. Park Position (7°) 5. Flat Washer
properly and park in the proper position after
1. Wiper Motor 6. Wiper Arm
installation is complete.
2. Wiper Blade 7. Nozzle
3. Cap Screw 8. Retainer
4. Lock Washer 9. Hose
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.
Adjustment
The following adjustments must be made while sit-
ting in the seat.
1. Headrest: Move up, down, fore, or aft by mov-
ing headrest (1, Figure 3-5) to desired position.
2. Armrests: Rotate adjusting knob until armrest
is in desired position.
3. Backrest: Lift handle (3) to release and select
backrest angle; release control handle to set.
4. Seat Belt: Operator should always have seat
belt (4) buckled in place and properly adjusted
whenever vehicle is in motion.
5. Seat Slope: Lift lever (5) and hold to adjust the
slope of seat. Release lever to lock adjustment.
6. & 7 Air Lumbar Support: Each rocker switch
(6 or 7) controls an air pillow. Switch (7) controls
the lower air pillow and switch (6) controls the
upper air pillow. To inflate, press on top of
rocker switch and hold for desired support, then
release. To deflate, press on bottom of rocker
switch and hold for desired support, then
release. Adjust each pillow for desired support.
8. Seat Suspension: Move rocker switch (8) up to
increase ride stiffness and down to decrease
ride stiffness.
9. Horizontal Adjustment: Lift control lever (9)
and hold. Bend knees to move seat to a com-
fortable position; release control lever to lock
adjustment
10. Seat Height: Lift lever (12) and hold to adjust FIGURE 3-5. OPERATOR’S SEAT ADJUSTMENT
the height of the seat. Release lever to lock CONTROLS
adjustment.
1. Headrest
2. Armrest Adjustment
3. Backrest Adjustment
4. Seat Belt
5. Seat Slope Adjustment
6. Upper Air Pillow Lumbar Support
7. Lower Air Pillow Lumbar Support
8. Suspension Adjustment
9. Horizontal Adjustment
10. Mounting Cap Screws and Hardware
11. Seat Tether Cap Screw
12. Seat Height Adjustment
Actuators
Two rotary actuator motors (8, 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
A failure to switch one of the above modes of opera-
tion may be caused by a faulty actuator.
Test
Visually inspect the flappers (11, 44‘) and linkage for
the function being diagnosed. Make certain the flap-
per is not binding or obstructed, preventing move-
FIGURE 4-3. CAB FILTER LOCATION
ment from one mode to the other.
Verify voltage (12 VDC) is present at the actuator 1. Access Cover 2. Cab Filter
when the toggle switch is closed or absent when the
toggle switch is opened.
If the correct voltages are present during operation of
the switch, disconnect the actuator from the flapper
and verify actuator force is comparable to a known
(new) actuator. If not, replace with a new actuator.
21° C (70° F) 820 - 1300 kPa (120 - 190 psi) 70 - 138 kPa (10 - 20 psi)
27° C (80° F) 950 - 1450 kPa (140 - 210 psi) 70 - 173 kPa (10 - 25 psi)
32° C (90° F) 1175 - 1650 kPa (170 - 240 psi) 105 - 210 kPa (15 - 30 psi)
38° C (100° F) 1300 - 1850 kPa (190 - 270 psi) 105 - 210 kPa (15 - 30 psi)
43° C (110° F) 1450 - 2075 kPa (210 - 300 psi) 105 - 210 kPa (15 - 30 psi)
NOTE: All pressures in this chart are for reference, only. Weight is the only absolute means of determining
proper refrigerant charge.
Reclaimed Refrigerant
REPLACING OIL Reclaimed refrigerant has been filtered through a
Component Oil to add more thorough filtering process and has been pro-
cessed to the same standards of purity as virgin
Condenser 60-90 ml (2-3 ounces) refrigerant. Because of this, reclaimed refrigerant is
acceptable for use in all systems, not just mobile.
Evaporator 30 ml (1 ounce) The reclaiming equipment used for this process is
Receiver-Drier 60 ml (2 ounces) expensive, and therefore, not common among nor-
mal maintenance shops. Equipment such as this is
Accumulator 60 ml (2 ounces) more commonly found in air conditioning specialty
shops.
Compressor 207 ml (7 ounces)
Block Valve
Adding oil is not necessary
(Expansion)
Always read the container label to verify the contents Usually, a 50% charged system is enough to find
are correct for the system being serviced. Note the most leaks. If the system is empty, connect the mani-
containers for R-134a are painted light blue. fold gauge set to the system and charge at least 1.6
kg (3.5 lbs) of refrigerant into the system.
Pulley Alignment
1. Install alignment tool (EL8868) onto the pulleys
to check the alignment. Refer to Figure 4-15. If
misalignment of the pulleys exceeds 3 mm
(0.13 in.), the position of the compressor must
be adjusted.
FIGURE 4-14. DEFLECTION MEASUREMENT
Belt Tension Check
NOTE: This procedure has been written for use with
4. Find the approximate center of the belt between
belt tension tool (XA3379), shown in Figure 4-13.
the two pulleys. Place the tip of the tool onto the
Other tension tools may differ in functionality.
outer face of the belt and apply pressure, as
shown in Figure 4-14. The tool must be
perpendicular to the belt. Push on the tool until
the bottom edge of the deflection scale O-ring is
even with the outer face of the adjacent drive
belt. If only one belt is used, rest a straight edge
across both pulleys to serve as the indicating
plane.
5. The O-ring on the force scale indicates the
force used to deflect the belt. The belt must
deflect 5.3 mm (0.21 in.) under a force of 1.6 ±
0.1 kg f (3.44 ± 0.11 lbf). If not, adjust the belt
accordingly and recheck the tension.
FIGURE 4-19.
FIGURE 4-20.
FIGURE 4-21.
FIGURE 4-23.
1. Pulley Puller 3. Puller Pilot
2. Pulley Assembly
Pulley Installation
FIGURE 4-24.
FIGURE 4-25.
1. Bearing Installer 2. Universal Handle
1. Drive Plate Installer 2. Spacer
1. Place the pulley assembly into position on the
compressor. Use bearing installer (1, Figure 4-
24), universal handle (2), and a hammer to
lightly tap the pulley assembly onto the com-
pressor until it seats. Use of the installer or the 2. Place the clutch assembly into position on the
equivalent ensures that the force driving the compressor. Align the square key with the key-
bearing into position acts on the inner race of way on the shaft.
the bearing. Applying force to the outer race of
3. Thread drive plate installer (1, Figure 4-24) onto
the bearing will result in bearing damage.
the shaft of the compressor. Spacer (2) should
be in place under the hex nut on the tool.
0 76.0 (29.92)
NOTE: The chart indicates the expected gauge readings at altitude to obtain the optimal vacuum.
Indications:
Low side pressure - VERY LOW
High side pressure - VERY LOW
Discharge air is warm.
No bubbles observed in sight glass, may show oil
streaks.
- Pressure sensing switch may have compressor Add refrigerant (make sure system has at least
clutch disengaged. 50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
-
enable the compressor to operate, if the com-
- Refrigerant excessively low; leak in system. pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
A/C operation and do system performance test.
Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is warm.
The low pressure switch may have
shut off the compressor clutch.
Leaks Found:
Add refrigerant (make sure system has at least
50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable the compressor to operate, if the com-
pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
Indications:
Low side pressure - Normal
High side pressure - Normal
Discharge air is only slightly cool.
(In a cycling type system with a
thermostatic switch, the switch may not cycle
the clutch on and off, so the low pressure
gauge will not fluctuate.)
Indications:
Low side pressure - HIGH
High side pressure - HIGH
Discharge air is only slightly cool.
Indications:
Low side pressure - VERY LOW or in a Vacuum
High side pressure - HIGH
Discharge air only slightly cool.
Expansion valve body is frosted or sweaty.
Indications:
Low side pressure - HIGH
High side pressure - Normal
Air from vents in the cab seems warm
or only slightly cool.
Indications:
Low side pressure - LOW
High side pressure - Normal to HIGH
Discharge air is only slightly cool.
Look for sweat or frost on high side hoses
and tubing. The line will be cool to the touch
near the restriction.
Indications:
Low side pressure - HIGH
High side pressure - LOW
Compressor operates noisily.
Indications:
Low side pressure - Normal
High side pressure - Normal
Low side pressure may cycle within a smaller
range as the compressor clutch cycles
more frequently than normal. This may indicate
the thermostat is set too high.
Indications:
Low Side High
High Side High
Discharge air may be warm.
High pressure hoses and lines are very hot.
Date:____________Hour Meter:________________
NOTE: Compressor should be run at least 5 minutes
(40°F minimum ambient temperature) every month,
Maintenance Interval in order to circulate oil and lubricate components.
COMPONENT (months)
Maintenance Interval
3 6 12 Done
COMPONENT (months)
1. Compressor
3 6 12 Done
Check noise level
5. Expansion Valve X
Check clutch pulley
Inspect capillary tube (if
Check oil level used) for leakage, damage,
Run system 5 minutes looseness
Check belt tension 6. Evaporator
(80-100) lbs; V-belt
Clean dirt, bugs, leaves, etc.
Inspect shaft seal for leakage from fins (w/ compressed air)
Check mounting bracket Check solder joints on inlet/
(tighten bolts) outlet tubes (leakage)
Check clutch alignment w/ Inspect condensation drain
crankshaft pulley (within
7. Other Components
0.06 in.)
Check discharge lines
Perform manifold gauge
(hot to touch)
check
Check suction lines
Verify clutch is engaging
(cold to touch)
2. Condenser
Inspect fittings/clamps/hoses
Clean dirt, bugs, leaves, etc.
Check thermostatic switch for
from coils (w/compressed air)
proper operation
Verify engine fan clutch is
Outlets in cab: 40°F to 50° F
engaging (if installed)
Inspect all wiring connections
Check inlet/outlet for
obstructions or damage Operate all manual controls
through full functions
3. Receiver-Drier
Check inlet line from
condenser (should be hot to
touch)
Replace, if system is opened
4. Accumulator
Check the inlet line from the
evaporator. It should be cool
to cold.
Replace the accumulator
each time the system is
opened.
Horn Button
Multi-function turn signal switch (4, Figure 5-2) is
Horn (2, Figure 5-2) is actuated by pushing the but- used to activate the turn signal lights, the windshield
ton in the center of the steering wheel. Ensure that wipers, and to select either high or low beam head-
the horn operates before moving the truck. Observe lights.
all local safety rules regarding the use of the horn as
a warning signal device before starting the engine Turn Signal Operation
and moving the vehicle.
Move the lever upward to signal a right turn.
Low Speed
FIGURE 5-2. STEERING WHEEL & CONTROLS High Speed
1. Steering Wheel 3. Tilt/Telescope Lever Depressing the button at the end of the
2. Horn Button 4. Multi-Function Turn lever will activate the windshield washer.
Signal Switch
DIAGNOSTIC PORTS
The diagnostic ports shown in Figure 5-5 are located FIGURE 5-5. DIAGNOSTIC PORTS
on the back wall of the cab next to the D.I.D. Panel.
1. VHMS Diagnostic Port 5. PSC Diagnostic Port
VHMS Diagnostic Port 2. IM Diagnostic Port 6. Engine Diagnostic Port
3. Payload Meter (CENSE)
Diagnostic port (1, Figure 5-5) is used to download Diagnostic Port 7. Engine Diagnostic Port
truck operation data from the VHMS controller. 4. TCI Diagnostic Port (QUANTUM)
This light is reserved for future use. This amber light will illuminate if
any of the circuit breakers in the
relay circuit control boards are
tripped. The relay circuit boards
are located in the electrical con-
trol cabinet.
Interface Module
Interface module (3, Figure 5-10) receives data from
FIGURE 5-12. DIAGNOSTIC PORTS
the sensors installed on the truck and sends this
(D.I.D. PANEL AT REAR OF CAB)
information to the VHMS controller. There is a small
green LED light on the face of the controller. With the 1. IM Diagnostic Port
key switch ON, the light should be blinking. If the light 2. VHMS Diagnostic Port
is continuously illuminated, there is a problem in the
controller.
When a new interface module controller is installed
on the truck, new software has to be installed inside
the controller. IM-Diag connector (1, Figure 5-12) is
used to connect the interface module to a laptop PC
for installing software.
INDEX
830E SERVICE CAPACITIES Due to differences in gear ratio and component evo-
lution/design, wheel motor service intervals may be
Crankcase: Liters U.S. unit number and/or mine specific. Because of the
(including 4 oil filters) Gallons wide variety of factors involved, it is necessary to
Komatsu SDA16V160 or consult your area Komatsu representative for all
280 74 wheel motor service intervals and instructions. Gen-
SSDA16V160 Engines
eral intervals for oil service and sampling are listed in
Cooling System: 568 150 the interval charts.
Komatsu SDA16V160 or
SSDA16V160 Engine COOLANT LEVEL CHECK
Hydraulic System: 947 250
Refer to “Hydraulic Tank Service” Inspect the coolant sight gauge. If coolant cannot be
seen in the sight gauge, it is necessary to add cool-
Wheel Motor Gear Box 38 10 ant to the system before truck operation. Refer to the
(each side) procedure below for the proper filling procedure.
Fuel Tank (Diesel Fuel Only) 4542 1200
FIGURE 2-4.
1. Filter Cover 2. Cab Filter
*These checks are required only after the initial 50 hours of operation (such as: the commissioning of a new
truck, or after a new or rebuilt component installation).
FIGURE 2-5.
*These checks are required only after the initial 100 hours of operation (such as: the commissioning of a new
truck, or after a new or rebuilt component installation), check:
FIGURE 2-6.
*This check is 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:
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5
System Priming
The system must be full of grease and free of air
pockets to function properly. After maintenance, if
the primary or secondary lubrication lines were
replaced, it will be necessary to prime the system to
eject all entrapped air.
1. Fill lube reservoir with lubricant, if necessary.
2. To purge air from the main supply line, remove
the main supply line at the grease canister.
Connect an external grease supply to the line.
3. Remove plugs from each injector group in
sequence (right front, left front, and rear axle).
4. Using the external grease source, pump grease
until grease appears at the group of injectors
and re-install the pipe plug. Repeat for remain-
ing injector groups.
5. Remove the caps from each injector and con-
nect an external grease supply to the zerk on
the injector and pump until grease appears at
the far end of the individual grease hose or the FIGURE 3-4. FILTER ASSEMBLY
joint being greased.
1. Housing 6. Spring
2. Bypass Indicator 7. Bowl
3. O-Ring 8. O-Ring
Filter Assembly 4. Backup Ring 9. Plug
The filter assembly element (5, Figure 3-4) must be 5. Element
replaced if the bypass indicator (2) shows excessive
element restriction.
Injector Adjustment
FIGURE 3-6. TYPE SL-1 INJECTOR
The injectors may be adjusted to supply from 0.13 -
1. Adjusting Screw 11. Spring Seat
1.31 cc (0.008 - 0.08 in3) of lubricant per injection 2. Locknut 12. Plunger
cycle. The injector piston travel distance determines 3. Piston Stop Plug 13. Viton Packing
the amount of lubricant supplied. This travel is in turn 4. Gasket 14. Inlet Disc
controlled by an adjusting screw in the top of the 5. Washer 15. Viton Packing
injector housing. 6. Viton O-Ring 16. Washer
Turn the adjusting screw (1, Figure 3-6) counter- 7. Injector Body Assy. 17. Gasket
clockwise to increase lubricant amount delivered and 8. Piston Assembly 18. Adapter Bolt
clockwise to decrease the lubricant amount. 9. Fitting Assembly 19. Adapter
10. Plunger Spring 20. Viton Packing
When the injector is not pressurized, maximum injec-
tor delivery volume is attained by turning the adjust-
NOTE: The piston assembly (8) has a visible
ing screw (1) fully counterclockwise until the
indicator pin at the top of the assembly to verify
indicating pin just touches the adjusting screw. At the
injector operation.
maximum delivery point, about 9.7 mm (0.38 inch)
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 4.8 mm
(0.19 inch) threads are showing. The injector will be
set at minimum delivery point with about 0.22 mm
(0.009 inch) 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.
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 lu-
bricant 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 pas-
sage (4) and measuring chamber (1).
The injector piston (2) and slide valve
(5) remain in this position until lubri-
cant pressure in the supply line (6) is
vented.
STAGE 4.
After venting, the injector spring ex-
pands, 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).
Load Connected To Printed circuit board failure or key- Remove and replace.
Terminals 3 & 4 pad failure.
Energized, But “PUMP
ON” LED Does Not Light
Bearing Points
Excessively Lubricated
Injector output adjustment setting Readjust to lower setting.
too high.
Timer/controller cycle time setting Set to longer cycle time or reevaluate lube
too low. requirements.
System too large for pump output. Calculate system requirements per plan-
ning manual.
Daily Lubrication System Inspection 4. Inspect all bearing points for a bead of lubricant
around the bearing seal.
1. Check grease reservoir level.
It is good practice to manually lube each bear-
Inspect grease level height after each shift of
ing point at the grease fitting provided on each
operation. Grease usage should be consistent
Injector. This will indicate if there are any frozen
from day-to-day operations.
or plugged bearings, and will help flush the
• Lack of lubricant usage would indicate an bearings of contaminants.
inoperative system. Excessive usage would 5. System Checkout
indicate a broken supply line.
a. Remove all SL-1 injector cover caps to allow
2. Check filter bypass indicator when filling reser-
visual inspection of the injector cycle indica-
voir. Replace element if bypassing.
tor pins during system operation.
3. Check all grease hoses from the SL-1 Injectors
b. Start truck engine.
to the lubrication points.
c. Actuate the lube system test switch (6, Fig-
a. Repair or replace all damaged feed line
ure 3-1). The hydraulic motor and grease
hoses.
pump should operate.
b. Ensure that all air is purged and all new feed
d. With the grease under pressure, check each
line hoses are filled with grease before send-
SL-1 injector assembly.
ing the truck back into service.
The cycle indicator pin should be retracted
4. Inspect key lubrication points for a bead of lubri- inside the injector body.
cant around seal. If a lubrication point appears
dry, troubleshoot and repair problem. e. When the system attains 17,237 kPa (2500
psi), the pump should shut off and the pres-
250 Hour Inspection sure in the system should drop to zero, vent-
ing back to the grease reservoir.
1. Check all grease hoses from the SL-1 Injectors
to the lubrication points (see, Figure 3-2). f. With the system vented, check all of the SL-1
injector indicator pins; all of the pins should
a. Repair or replace all worn / broken hoses.
be visible. Replace or repair injectors, if
b. Ensure that all air is purged and all new feed defective.
line hoses are filled with grease before send-
g. Reinstall all injector cover caps.
ing the truck back into service.
2. Check all grease supply line hoses from the h. Check timer operation.
pump to the SL-1 injectors. NOTE: With the engine on, the lube system should
a. Repair or replace all worn / broken supply activate within five minutes. The system should build
lines. 13,790 - 17,237 kPa (2000 - 2500 psi) within 25-40
seconds.
b. Ensure that all air is purged and all new sup-
ply line hoses are filled with grease before i. If the system is working properly, the
sending the truck back into service. machine is ready for operation.
3. Check grease reservoir level. j. If the system is malfunctioning, refer to the
troubleshooting chart.
a. Fill reservoir if low. Check filter bypass indi-
cator when filling reservoir. Replace element
if bypassing.
1000 Hour Inspection
b. Check reservoir for contaminants. Clean, if
required. 1. Check pump housing oil level. Refill to bottom
of level plug with SAE 10W-30 motor oil if nec-
c. Check that all filler plugs, covers and essary
breather vents on the reservoir are intact and
free of contaminants.
M
Manifold,
Bleeddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Counterbalance Valve . . . . . . . . . . . . . . . . . . . . .L7-7
H Metric Conversion. . . . . . . . . . . . . . . . . . . . . . . . . A5-1
O
Oiling and Charging Procedure, HYDRAIR® II . . . H4-3 S
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Optional Equipment
Software, Propulsion Control System . . . . . . . . . E2-26
Engine Heaters . . . . . . . . . . . . . . . . . . . . . . . . . .M7-1
Seat, Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Fire Control System . . . . . . . . . . . . . . . . . . . . . .M2-1
Payload Meter III. . . . . . . . . . . . . . . . . . . . . . . .M20-1 Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . P2-1
Radiator Shutters . . . . . . . . . . . . . . . . . . . . . . .M19-1 Solenoid
Reserve Engine Oil System . . . . . . . . . . . . . . .M31-1 Bleeddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-14
Outlet Strainer (Hydraulic Tank). . . . . . . . . . . . . . L3-17 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M8-1
Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . L7-7 Specifications
Overhead Display . . . . . . . . . . . . . . . . . . . . . . . . N5-22 HYDRAIR® II Oil . . . . . . . . . . . . . . . . . . . . . . . H4-11
HYDRAIR® II Nitrogen . . . . . . . . . . . . . . . . . . . H4-11
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
P Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Pedal
Spindle, Front Wheel Hub . . . . . . . . . . . . . . . . . . .G3-3
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Starter (Cranking) Motors . . . . . . . . . . . . . . . . . . . D2-7
Throttle, Electronic . . . . . . . . . . . . . . . . . . . . . . E2-46
Status/Warning Indicator Lights . . . . . . . . . . . . . . N5-22
Retarder, Electronic . . . . . . . . . . . . . . . . . . . . . E2-46
Steering
Pin, Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
Accumulator Charging Procedure . . . . . . . . . . . . L5-9
Plates, Warning and Caution . . . . . . . . . . . . . . . . . A4-1
Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3
Hydraulic Check-Out Procedure . . . . . . . . . . . . L10-1
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . G3-15, L5-25
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-28
Engine/Alternator Mating . . . . . . . . . . . . . . . . . C4-5
Troubleshooting Chart (Steering Circuit). . . . . L10-10
Prelub™ System . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7
Strainer, Hydraulic Tank. . . . . . . . . . . . . . . . . . . . L3-17
Pump, Hoist System . . . . . . . . . . . . . . . . . . . . . . . L3-1
Suspension, HYDRAIR® II
Pump, Steering/Brake System. . . . . . . . . L4-15, L5-28
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
Switch
R Accumulator Pressure. . . . . . . . . . . . . . . . . . . . L4-15
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4 Body-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-1 Low Steering Pressure . . . . . . . . . . . . . . . . . . . L4-15
V
Valves
Bleeddown Solenoid . . . . . . . . . . . . . . . . . . . . .L4-14
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . L4-4, L5-14
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Hoist Pilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-10
Adjustment Procedure (Power Down) . . . . . .L10-17
Hoist Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-16
Adjustment Procedure. . . . . . . . . . . . . . . . . .L10-16
Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . .L7-7
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-23
Adjustment Procedure. . . . . . . . . . . . . . . . . .L10-19
Steering Control Unit . . . . . . . . . . . . . . . . . . . . .L5-18
VHMS System . . . . . . . . . . . . . . . . . . . . . . . . . . D11-1
PX
P1 P2
Park
BR BF Brake
STOP LOW BRAKE LOCK
LIGHT APPLY SWITCH
SW Service
6895 ± 172 kPa Brake
517 ± 34 kPa
FRONT (1000 ± 25 psi)
(75 ± 5 psi)
BRAKE
CALIPERS
REAR
BRAKE
CALIPERS
BRAKE LOCK
PRESSURE BRAKE LOCK
10,342 kPa SOLENOID 9653 kPa
9653 kPa (1500 psi) N.C. (1400 psi)
(1400 psi) NITROGEN
NITROGEN SV1
ORF2 PP3
AR2 PR1 BL AF2
AR1 AF1
T1
LOW BRAKE
PRESS SW
Closes below
T3
15,858 kPa LAP2
(2300 psi) PR2
HS1 PARK BRAKE
LAP1 PRESSURE REGULATOR
17,237 kPa
(2500 psi)
SP3 PK1
ORF1 PARK BRAKE
PK2 PRESSURE
SWITCH
BRAKE Closes
MANIFOLD below
8618 kPa
CV1 LS1 CV2 CV3 (1250 psi)
PS1 SV2
NV1 AA NV2 PARK BRAKE
STEERING SOLENOID
AUTOMATIC
PRESSURE
APPLY
SWITCH SP1
14,479 ± 517 kPa
Closes SUPPLY
(2100 ± 75 psi)
below
15,858 kPa HH360 JAN 06
(2300 psi) Hydraulic Schematic
22,063 to
NOTE: Solenoids and switches shown in their STEERING 24,132 kPa
Brake System
non-energized, non-pressurized positions. BLEEDOWN 830E-AC
(3200 to
MANIFOLD 3500 psi) Effective with A30001 & UP
XS3201 JUNE 05
ELECTRIC SCHEMATIC
INDEX AND SYMBOLS
830E-AC
A30001 and UP
SHEET 1 OF 35
XS3202-3 MAY 06
ELECTRIC SCHEMATIC
GE SYSTEM BLOCK DIAGRAM
830E-AC
A30001 and UP
SHEET 2 OF 35
XS3203-2 MAY 06
ELECTRIC SCHEMATIC
MAIN PROPULSION SCHEMATIC
830E-AC
A30001 and UP
SHEET 3 OF 35
XS3204 JUNE 05
ELECTRIC SCHEMATIC
GE 24/15V PWR DISTRIBUTION
830E-AC
A30001 and UP
SHEET 4 OF 35
XS3205-1 JAN 06
ELECTRIC SCHEMATIC
G.E. INVERTER FIRING
830E-AC
A30001 and UP
SHEET 5 OF 35
XS3206-1 JAN 06
ELECTRIC SCHEMATIC
G.E. INVERTER FIRING
830E-AC
A30001 and UP
SHEET 6 OF 35
XS3207-2 JAN 06
ELECTRIC SCHEMATIC
ENGINE - I/O
830E-AC
A30001 and UP
SHEET 7 OF 35
XS3208-1 JAN 06
ELECTRIC SCHEMATIC
G.E./24V - DIGITAL I/O
830E-AC
A30001 and UP
SHEET 8 OF 35
XS3209-1 JAN 06
ELECTRIC SCHEMATIC
CONTROL PANEL - ANALOG INPUTS
830E-AC
A30001 and UP
SHEET 9 OF 35
XS3210-2 MAY 06
ELECTRIC SCHEMATIC
24V POWER DISTRIB. & CKT PROTECT
830E-AC
A30001 and UP
SHEET 10 OF 35
XS3211-2 MAY 06
ELECTRIC SCHEMATIC
OPER. CAB/OVERHEAD WARNING LIGHTS
830E-AC
A30001 and UP
SHEET 11 OF 35
XS3212-2 MAY 06
ELECTRIC SCHEMATIC
OPER. CAB/OVERHEAD WARNING LIGHTS
830E-AC
A30001 and UP
SHEET 12 OF 35
XS3213-2 MAY 06
ELECTRIC SCHEMATIC
OPER. CAB/OVERHEAD WARNING LIGHTS
830E-AC
A30001 and UP
SHEET 13 OF 35
XS3214-3 MAY 06
ELECTRIC SCHEMATIC
OPER. CAB/OVERHEAD WARNING LIGHTS
830E-AC
A30001 and UP
SHEET 14 OF 35
XS3215-1 SEP 05
ELECTRIC SCHEMATIC
AUTO LUBE SYSTEM W/WARNING
830E-AC
A30001 and UP
SHEET 15 OF 35
XS3216-2 JAN 06
ELECTRIC SCHEMATIC
OPER. CAB GAUGES, OPTION SWITCHES
830E-AC
A30001 and UP
SHEET 16 OF 35
XS3217-1 JAN 06
ELECTRIC SCHEMATIC
HEATER, AIR CONDITIONER CONTROLS
830E-AC
A30001 and UP
SHEET 17 OF 35
XS3218 JUNE 05
ELECTRIC SCHEMATIC
WORK LIGHTS AND HORN
830E-AC
A30001 and UP
SHEET 18 OF 35
XS3219-1 JAN 06
ELECTRIC SCHEMATIC
RETARD LIGHTS, BACKUP LTS & HORNS
830E-AC
A30001 and UP
SHEET 19 OF 35
XS3220-3 MAY 06
ELECTRIC SCHEMATIC
OPERATOR DRIVE SYSTEM CONTROLS
830E-AC
A30001 and UP
SHEET 20 OF 35
XS3221-1 MAY 06
ELECTRIC SCHEMATIC
RADIO, WINDOWS & WIPER CONTROL
830E-AC
A30001 and UP
SHEET 21 OF 35
XS3222-1 MAY 06
ELECTRIC SCHEMATIC
TURN SIGNAL & CLEARANCE LIGHTS
830E-AC
A30001 and UP
SHEET 22 OF 35
XS3223 JUNE 05
ELECTRIC SCHEMATIC
FOG LIGHTS AND HEAD LIGHTS
830E-AC
A30001 and UP
SHEET 23 OF 35
XS3224-1 JAN 06
ELECTRIC SCHEMATIC
OPERATOR CAB - INSTRUMENT LIGHTS
830E-AC
A30001 and UP
SHEET 24 OF 35
XS3225-2 MAY 06
ELECTRIC SCHEMATIC
KEY SWITCH & 5-MINUTE IDLE
830E-AC
A30001 and UP
SHEET 25 OF 35
XS3226-1 JAN 06
ELECTRIC SCHEMATIC
QSK-60 START CIRCUIT
830E-AC
A30001 and UP
SHEET 26 OF 35
XS3227-2 MAY 06
ELECTRIC SCHEMATIC
ENGINE CIRCUITS - CUMMINS QSK-60
830E-AC
A30001 and UP
SHEET 27 OF 35
XS3228-2 JAN 06
ELECTRIC SCHEMATIC
PAYLOAD METER 3 CIRCUITS
830E-AC
A30001 and UP
SHEET 28 OF 35
XS3229-1 JAN 06
ELECTRIC SCHEMATIC
DIAG. PORTS/DISPATCH SYSTEM
830E-AC
A30001 and UP
SHEET 29 OF 35
XS3230-1 JAN 06
ELECTRIC SCHEMATIC
PARK BRAKE & GE I/O
830E-AC
A30001 and UP
SHEET 30 OF 35
XS3231-1 JAN 06
ELECTRIC SCHEMATIC
WINDSHLD WIPER & TURN SIG. CNTRLS
830E-AC
A30001 and UP
SHEET 31 OF 35
XS3232-2 JAN 06
ELECTRIC SCHEMATIC
VHMS. INTERFACE ORBCOM MODULES
830E-AC
A30001 and UP
SHEET 32 OF 35
XS3233-1 JAN 06
ELECTRIC SCHEMATIC
BATTERY BOX
830E-AC
A30001 and UP
SHEET 33 OF 35
XS3234-2 JAN 06
ELECTRIC SCHEMATIC
CIRCUIT LOCATOR SHEET
830E-AC
A30001 and UP
SHEET 34 OF 35
XS3235-3 Jan 06
ELECTRIC SCHEMATIC
COMPONENT LOCATOR SHEET
830E-AC
A30001 and UP
SHEET 35 OF 35
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