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Komatsu 830E-AC, Shop Manual

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Komatsu 830E-AC Shop Manual Download Page 13

A02073  3/06

Major Component Description 

A2-3

SPECIFICATIONS

These specifications are for the standard Komatsu
830E-AC Truck. Customer Options may change this
listing.

ENGINE 

Komatsu SDA16V160
           (Optional SSDA16V160)
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating Cycle. . . . . . . . . . . . . . . . . . . . . .  4-Stroke
Rated Brake HP. . . . 1865 kW (2500 hp)@ 1900 rpm
Flywheel HP  . . . . .  1761 kW (2360 hp) @ 1900 rpm

Weight* (Wet)                        9 608 kg (21,182 lbs)

* Weight does not include Radiator, Sub-frame, or
Alternator

AC ELECTRIC DRIVE SYSTEM

(AC/DC Current)

Alternator   . . . . . . . . . . . .  General Electric GTA - 41
Dual Impeller, In-Line Blower  255 m

3

/min (9000 cfm)

Motorized Wheels . . .  GEB25 AC Induction Traction
                                                                                Motors

Ratio  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1
Maximum Speed*  . . . . . . . . .  64.5 km/h (40 mph)
(*w/40.00-57 Tires and 31.875:1 gear train)

*NOTE: Wheel motor application depends upon GVW, haul road
grade and length, rolling resistance, and other parameters.
Komatsu & G.E. must analyze each job condition to assure proper
application.

DYNAMIC RETARDING

Electric Dynamic Retarding . . . . . . . . . . . . . Standard
Maximum Rating . . . . . . . . . . . . . 2983 kW (4000 hp)

24 VDC ELECTRIC SYSTEM

Batteries  . . . .  4 x 8D 1450 CCA, 12 volt batteries in
                              Series/Parallel w/Disconnect Switch
Alternator   . . . . . . . . . . . 24 Volt, 260 Ampere Output
Lighting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24 Volt
Cranking Motors (2). . . . . . . . . . . . . . . . . . . .  24 Volt

SERVICE CAPACITIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . Liters. (U.S. Gal.)

Crankcase * . . . . . . . . . . . . . . . . .  280.0. . . . . (74.0)
 * Includes Lube Oil Filters
Cooling System  . . . . . . . . . . . . . . . . 568. . . . .  (150)
Fuel  . . . . . . . . . . . . . . . . . . . . . . . . 4542. . . .  (1200)
Hydraulic System . . . . . . . . . . . . . . . 946. . . . .  (250)
Hydraulic Tank . . . . . . . . . . . . . . . . . 901. . . . .  (238)
Wheel Motor Gear Box (each) . . . . . . 38. . . . . .  (10)

HYDRAULIC SYSTEMS*

Pumps

Hoist . . . . . . . . . . . . . . . . . . . . .  Tandem Gear Pump
Rated @ . . . . .  851 lpm (225 gpm) @ 1900 rpm and

. . . . . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi)

Steering/Brake . . . . . Pressure Compensating Piston
Rated @ . . . . . . .246 lpm (65 gpm) @ 1900 rpm and

. . . . . . . . . . . . . . . . . . . . . . . .18 961 kPa (2,750 psi)

System Relief Pressures

Hoist . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi)
Steering/Brakes . . . . . . . . . . .27 580 kPa (4,000 psi)
Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . .  3-Stage
Tank (Vertical/Cylindrical)  . . . . . . .  Non-Pressurized
Filtration . . . . . . . . . . . .  in-line replaceable elements
    Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh

Hoist & Steering . . . . . . . .  Full Flow, Dual In-Line, 
 . . . . . . . . . . .  High Pressure Beta 12 Rating =200

*With Quick Disconnects for powering disabled truck
and system diagnostics.

SERVICE BRAKES

Actuation  . . . . . . . . . . . . . . . . . . . . . . . .All Hydraulic

Front

   . . . . . . . . . . . . . . . . Wheel Speed, Single Disc

Inboard Mounted  . . . . . . . . . . . . . . . . .  3 Calipers
Disc Diameter, O.D. . . . . . . .  1213 mm (47.75 in.)

Rear

 . . . . . . . . . . . . . . .   Armature Speed, Dual Disc

Disc Diameter, O.D. . . . . . . . .  635 mm (25.00 in.)

Emergency Brake-

Automatically Applied (Standard)

Wheel Brake Lock

 . . . . . .  Manual Switch on Panel

. . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping)

DISC PARKING BRAKE

Each Rear Wheel . . . . .  Integral with Service Caliper

. . . . . . . . . . .Spring Applied, Hydraulically Released

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.

Summary of Contents for 830E-AC

Page 1: ...CEBM016202 Shop Manual DUMP TRUCK SERIAL NUMBERS A30001 A30035 ...

Page 2: ...NOTES ...

Page 3: ...l 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 product...

Page 4: ...f such parts may compromise the safe operation of Komatsu products and place the operator and others in danger should the part fail Komatsu is also aware of repair companies that will rework or modify an OEM 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 th...

Page 5: ...orques 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...

Page 6: ...ifies a specific potential hazard WHICH WILL RESULT IN EITHER INJURY OR DEATH if proper precautions are not taken WARNING identifies a specific potential hazard WHICH MAY RESULT IN EITHER INJURY OR DEATH if proper precau tions are not taken CAUTION is used for general reminders of proper safety practices OR to direct the reader s attention to avoid unsafe or improper practices which may result in ...

Page 7: ...UEL COOLING AND AIR CLEANER C ELECTRIC SYSTEM 24 VDC NON PROPULSION D ELECTRIC PROPULSION AND CONTROL E DRIVE AXLE SPINDLES AND WHEELS G HYDRAIR II SUSPENSIONS H BRAKE CIRCUIT J HYDRAULIC SYSTEM L OPTIONS AND SPECIAL TOOLS M OPERATOR S CAB N LUBRICATION AND SERVICE P ALPHABETICAL INDEX Q SYSTEM SCHEMATICS R ...

Page 8: ...A 4 Introduction 8 06 A00040 KOMATSU MODEL 830E AC TRUCK ...

Page 9: ...94 Index A1 1 SECTION A GENERAL INFORMATION INDEX MAJOR COMPONENTS SPECIFICATIONS A2 GENERAL SAFETY AND OPERATION A3 WARNINGS AND CAUTIONS A4 STANDARD TORQUE CHARTS AND CONVERSION TABLES A5 STORAGE PROCEDURES A7 ...

Page 10: ...A1 2 Index 02 94 A01001 NOTES ...

Page 11: ...the truck The cab provides wide visibility with an integral 4 post ROPS FOPS structure and an advanced analog operator environment It includes a tinted safety glass windshield and power operated side windows a deluxe interior with a fully adjustable seat with lumbar support a fully adjustable tilt tele scope steering wheel controls mounted within easy reach of the operator and an analog instrument...

Page 12: ...A2 2 Major Component Description 3 06 A02073 830E MAJOR COMPONENTS ...

Page 13: ...ters U S Gal Crankcase 280 0 74 0 Includes Lube Oil Filters Cooling System 568 150 Fuel 4542 1200 Hydraulic System 946 250 Hydraulic Tank 901 238 Wheel Motor Gear Box each 38 10 HYDRAULIC SYSTEMS Pumps Hoist Tandem Gear Pump Rated 851 lpm 225 gpm 1900 rpm and 17 240 kPa 2 500 psi Steering Brake Pressure Compensating Piston Rated 246 lpm 65 gpm 1900 rpm and 18 961 kPa 2 750 psi System Relief Pressu...

Page 14: ...andard tire weight 21 081 46 476 Loaded Vehicle Kilograms Pounds Front Axle 127 330 280 715 Rear Axle 258 522 569 935 Total 385 852 850 650 Nominal Payload 220 199 485 456 242 U S Ton Nominal payload is defined by Komatsu America Corporation s payload policy documentation In gen eral the nominal payload must be adjusted for the specific vehicle configuration and site application The figures above ...

Page 15: ...15 ADDITIONAL JOB SITE RULES A3 16 WHEN REPAIRS ARE NECESSARY A3 17 SPECIAL PRECAUTIONS FOR WORKING ON A 830E AC TRUCK A3 18 TRUCK OPERATION A3 21 PREPARING FOR OPERATION A3 21 WALK AROUND INSPECTION A3 21 ENGINE START UP SAFETY PRACTICES A3 25 AFTER ENGINE HAS STARTED A3 26 MACHINE OPERATION SAFETY PRECAUTIONS A3 26 MACHINE OPERATION ON THE HAUL ROAD A3 27 STARTING ON A GRADE WITH A LOADED TRUCK ...

Page 16: ...l Safety and Operating Instructions 3 06 A03030 DELAYED ENGINE SHUTDOWN PROCEDURE A3 32 EMERGENCY STEERING SYSTEM A3 33 DISABLED TRUCK DUMPING PROCEDURE A3 34 TOWING A3 35 RESERVE ENGINE OIL SYSTEM Optional A3 36 ...

Page 17: ...se of safety features may result in serious bodily injury or death Clothing And Personal Items Avoid wearing loose clothing jewelry and loose long hair They can catch on controls or in moving parts and cause serious injury or death Additionally never wear oily clothes as they are flammable Wear a hard hat safety glasses safety shoes a mask and gloves when operating or maintaining a machine Always ...

Page 18: ...s of persons you should contact in case of an emergency on hand Precautions For High Temperature Fluids Immediately after machine operation engine coolant engine oil and hydraulic oil are at high temperatures and are pressurized If the cap is removed the fluids drained the filters are replaced etc there is danger of serious burns Allow heat and pressure to dissipate before performing such tasks an...

Page 19: ... achieved if it is repaired or modified as specified by Komatsu When modifying or repairing the ROPS always consult your nearest Komatsu distributor Even with the ROPS installed the operator must always use the seat belt when operating the machine Preventing Injury From Work Equipment Never position any part of your body between movable parts such as the dump body chassis or cylinders If the work ...

Page 20: ...bstacles before starting operations Always determine the travel roads to be used at the work site Travel roads must be maintained in order to ensure safe machine travel If travel through wet areas is necessary check the depth and flow of water before crossing the shallow parts Never drive through water which exceeds the permissible water depth Fire Prevention Remove all wood chips leaves paper and...

Page 21: ... oil grease or mud Check operation of the windshield wiper condition of wiper blades and check the washer fluid reservoir level Be familiar with all steering and brake system controls warning devices road speeds and loading capabilities before operating the truck OPERATING THE MACHINE Starting The Engine NEVER ATTEMPT TO START THE MACHINE BY SHORTING ACROSS THE STARTER TERMINALS This may cause fir...

Page 22: ...nd unattended DO NOT leave the truck unattended while the engine is running 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 Traveling In The Truck When traveling on rough ground travel at low speeds ...

Page 23: ...y careful when clearing snow The road shoulder and other objects are buried in the snow and cannot be seen When traveling on snow covered roads always install tire chains Avoid Damage To The Dump Body When working in tunnels on bridges under electric cables or when entering an enclosed area where there are height limits always use extreme caution The dump body must be completely lowered before dri...

Page 24: ...es is loose It can collapse under the weight or vibration of the machine Avoid these areas whenever possible Parking The Machine Choose a horizontal road surface to park the machine If the machine must be parked on a slope put blocks under all the wheels to prevent the machine from moving When parking on public roads provide fences flags or lights on the machine to warn pedestrians and other vehic...

Page 25: ... engine and turn the key switch to the OFF position Avoid short circuiting the battery terminals through accidental contact with metallic objects such as tools across the terminals When removing or installing a battery positively identify the positive terminal and negative terminal and use precautions not to short circuit the terminals Tighten battery caps securely Tighten battery terminals secure...

Page 26: ...or cable securely 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 warning tags around the machine if necessary These tags are available from your Komatsu distributor Part N...

Page 27: ...und the doors or vents DO NOT allow any water to enter the cooling air inlet duct above the electrical control cabinet If water enters the control cabinet through any opening or crevice major damage to the electrical components may occur Never spray water into the rear wheel electric motor covers Damage to the wheel motor armatures may occur DO NOT spray water into the retarding grids Excess water...

Page 28: ... a sheet of wood to check for oil leakage If you are hit by a jet of high pressure oil consult a doctor immediately for medical attention Maintenance Near High Temperatures And High Pressures Immediately after stopping the truck the engine coolant and operating oils are at high temperature and under high pressure In these conditions opening the system or replacing filters may result in burns or ot...

Page 29: ...e resulting in danger to personnel in the area Explosions differ from punctures or tire bursts because the destructive force is extremely large Therefore the following operations are strictly pro hibited when the tire is pressurized Welding the rim Welding near the wheel or tire Smoking or creating open flames If the proper procedure for performing maintenance or replacement of the wheel or tire i...

Page 30: ..._____________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ __________________________________________________________________________...

Page 31: ...uit cards on electric drive dump trucks or any of the Alarm Indicating Device AID circuit control cards Always fasten the welding machine ground lead to the piece being welded the grounding clamp must be attached as near as possible to the weld area Never allow welding current to pass through ball bearings roller bearings sus pensions or hydraulic cylinders Always avoid laying welding cables over ...

Page 32: ... any maintenance activities will ensure that no hazardous voltages are present in the AC drive system 1 Before shutting down the engine verify the sta tus of all the drive system warning lights on the overhead display panel Use the lamp test switch to verify that all lamps are functioning properly If any of the red drive system warning lights remain on DO NOT attempt to open any cabi nets disconne...

Page 33: ...cal harnesses Welding voltage could be induced into the electrical har ness and cause damage to components Before doing any welding on the truck always disconnect the battery charging alternator lead wire and isolate electronic control components In addition always disconnect the positive and negative battery cables of the vehicle Failure to do so may seriously damage the battery and electrical eq...

Page 34: ...A3 20 General Safety and Operating Instructions 3 06 A03030 ...

Page 35: ...nce and are repeated from the same point and in the same direc tion before every shift many potential problems may be avoided or scheduled for maintenance Unsched uled downtime and loss of production can be reduced as a result Local work practices may prevent an operator from performing all tasks suggested here To the extent permitted the operator should follow this or a similar routine High volta...

Page 36: ...A3 22 General Safety and Operating Instructions 3 06 A03030 ...

Page 37: ...ion Check for leaks Ensure that the covers over the chrome piston rod are in good condition Inspect for proper greasing 15 Open the rear hatch cover turn on work light if necessary Inspect for leaks around wheel motor mounting to rear housing and also brake hoses and fittings ensure that covers on wheel motor sump are in place and that there are no rags or tools left behind Inspect condition of ha...

Page 38: ... hand rails of any foreign material such as ice snow oil or mud 29 Use the stairs and handrails while climbing from the first level to the cab deck Always mount and dismount ladders facing the truck Never attempt to mount or dismount while the truck is in motion 30 When checking the coolant level in the radiator use the coolant level sight gauge If it is neces sary to remove the radiator cap relie...

Page 39: ...it is in the RUN position and all electrical circuits except START are acti vated a Turn key switch to the RUN not START position b With the directional control lever in PARK rotate the key switch fully clockwise to the START position and hold this position until the engine starts see NOTE below The START position is spring loaded and will return to RUN when the key is released c After the engine ...

Page 40: ...ional Guidelines 1 When the truck body is raised DO NOT allow anyone beneath it unless the body up retaining cable is in place 2 DO NOT use the fire extinguisher for any pur pose other than putting out a fire If an extin guisher is discharged report the occurrence so the used unit can be refilled or replaced 3 DO NOT allow unauthorized personnel to ride in the truck DO NOT allow anyone to ride on ...

Page 41: ...se give a back up sig nal of three blasts on the horn Before starting forward signal with two blasts on the horn These signals must be given each time the truck is moved forward or backward 5 Use extreme caution when approaching a haul road intersection Maintain a safe distance from oncoming vehicles 6 Maintain a safe distance when following another vehicle Never approach another vehi cle from the...

Page 42: ...ith caution Remain at a safe distance while the truck ahead is being loaded 2 DO NOT drive over unprotected power cables 3 When approaching or leaving a loading area watch for other vehicles and for personnel work ing in the area 4 When pulling in under a loader or shovel follow the spotter s or the shovel operator s signals The truck operator may speed up loading by observing the location and loa...

Page 43: ...nough to prevent the body from lowering In this case the truck will have to be driven forward a short distance just enough to clear the material before the body can be lowered 1 Move the directional control lever to FOR WARD release brake lock depress Override button and drive just far enough forward for the body to clear the material Stop move the directional control lever to NEUTRAL apply the br...

Page 44: ...inge pins 2 With the body returned to the frame move the directional control lever to FORWARD release the brake lock and carefully leave the dump area SUDDEN LOSS OF ENGINE POWER If the engine suddenly stops there is enough hydrau lic pressure stored in the brake and steering accumu lators to allow the operation of the steering and brake functions However this oil supply is limited so it is import...

Page 45: ... brake applied indicator light in the overhead display panel is illumi nated d Allow the engine to cool gradually by operat ing at low idle for three to five minutes or if preferred activate the five minute shutdown delay timer as described on the following page 2 Place the rest switch in the ON position to put the AC drive system in rest mode Be sure the rest indicator light in the overhead panel...

Page 46: ...rn the key switch counterclockwise to the OFF position to cause the engine to stop when the timing sequence is complete When the engine stops the hydraulic bleed down timer will activate and the 24 VDC electric circuits will turn off 6 With the key switch OFF and engine stopped wait at least 90 seconds Ensure the steering circuit is completely bled down by turning the steering wheel back and forth...

Page 47: ...ional control lever to PARK This will apply the parking brake 3 Turn the key switch OFF and notify mainte nance personnel 4 If safe to do so place wheel chocks in front or behind the wheels so that truck can not roll 5 If traffic is excessive near the disabled machine mark the truck with warning flags during day light hours or use flares at night Adhere to local regulations Testing Ensure no one i...

Page 48: ...ol lever to POWER UP and then release it to place the hoist pilot valve in the HOLD position Leave in this position during entire procedure 4 Start the engine on the good truck Place the hoist control in the POWER DOWN position and increase engine rpm to high idle to dump the disabled truck If the body of the disabled truck fails to raise increase the good truck power down relief pressure as follo...

Page 49: ... vehicle only A disabled machine may be towed after the following minimum precautions have been taken 1 Shut the engine off 2 If equipped install hydraulic connections for steering and dumping between the tow vehicle the and disabled vehicle Check the disabled vehicle braking and steering systems for normal operation 3 If the disabled truck is loaded dump the entire load Never pull or tow a loaded...

Page 50: ...el until air is no longer drawn by pump 1 Pump 2 then turns off The running level is continuously adjusted at the control point by alternation between withdrawal and return of oil at the sump LED Monitor Light Steady Pump 1 is withdrawing oil from the engine sump and bringing down the oil level Regular Pulsing Pump 2 is returning oil to the engine sump and raising the oil level Irregular Pulsing O...

Page 51: ...strument panel The warning stresses the importance of read ing the operator s manual before operation A grade speed retard chart is located on the left front post of the operator s cab and provides the recom mended MAXIMUM speeds to be used when descending various grades with a loaded truck Always refer to the decal in operator s cab This decal may change with optional truck equipment such as whee...

Page 52: ...to a good frame ground Do not con nect to the negative posts of the truck battery or a ground near the battery box This hookup com pletes the circuit but minimizes danger of sparks near the batteries Sulfuric acid is corrosive and toxic Use proper safety gear goggles rubber gloves and rubber apron when handling and servicing batteries Get proper medical help immediately if required This plate is p...

Page 53: ...been operating for a time will result in the hot coolant being expelled from the radiator Serious scalding and burning may result Warning plates are mounted on the frame in front of and to the rear of both front tires All personnel are warned that the clearances change when the truck is steered and could cause serious injury Warning plates are attached to both the hydraulic tank and fuel tank to a...

Page 54: ...ions for releasing internal pressure before disconnecting any hardware Serious injury can occur if these directions are not followed A plate on the side of the hydraulic tank furnishes instructions for filling the hydraulic tank Keep the system open to the atmosphere only as long as absolutely necessary to lessen the chances of system contamination Service the tank with clean Type C 4 hydraulic oi...

Page 55: ...ediately A wheel motor oil level decal is attached to the gear cover on both electric wheel motors This decal stresses the fact that the truck must be on a level surface and parked for 20 minutes prior to checking the oil level This is necessary in order to get an accurate reading A decal plate located on the frame near the left hoist cylinder provides the operator or technician with the hook up p...

Page 56: ...low the battery dis connect switches to warn personnel not to discon nect the batteries during the first 90 seconds after turning the key switch off This decal is located on the automatic lubrication res ervoir informing the technician that the cover should never be removed for filling purposes as there is potential for dirt or debris entering the system Always fill the grease reservoir through th...

Page 57: ...allow welding current to pass through ball bearings roller bearings suspensions or hydraulic cylinders Always avoid laying welding cables over or near the vehicle electrical harnesses Welding volt age could be induced into the electrical harness and possibly cause damage to components A high voltage danger plate is attached to the door of the rear hatch cover High voltage may be present Only autho...

Page 58: ... right side of the operator cab This decal is placed near three different indicator lights In the operator cab on the rear of the center console On the front of the control box which is mounted on the right side of the main control cabinet On the outside of the left control cabinet wall that faces the right side of the operator cab See also Information decal above When any of these indicator light...

Page 59: ...tdown only This page illustrates a variety of decals which are mounted on deck mounted cabinets housings and structures which must be lifted in a specific manner and from specific points in order to safely move or lift any of these structures If any of these decals are damaged or defaced so that it is no longer legible it should be replaced immediately Maintenance personnel must follow these lifti...

Page 60: ...e WMC The WMC designates the manufacturer of the product Komatsu brand products are identified with the letters KMT MDS Character positions 4 5 6 7 and 8 identify the Machine Descriptor Section MDS The MDS code identifies general information regarding machine specifications The MDS is a code for the machine type and model CL Character position 9 identify the Check Letter CL The CL is used to verif...

Page 61: ...ings and Cautions A4 11 The lubrication chart is mounted on the right hand side of the radiator grille structure Refer to Section P Lubrication and Service in this manual for more complete lubrication instructions ...

Page 62: ...A4 12 Warnings and Cautions A04059 NOTES ...

Page 63: ...n reducing lubricants are used excessive stress and possible breakage of the fasteners may result When the torque tables specify lubricated threads for the standard torque values listed these standard torque values are to be used with simple lithium base chassis grease multi purpose EP NLGI or a rust preventive grease see list page A5 2 on the threads and seats unless specified otherwise Verify th...

Page 64: ...ust Grease 3 X from Standard Oil Company also American Oil Co Gulf Norust 3 from Gulf Oil Company Mobilarma 355 Product No 66705 from Mobil Oil Corporation Rust Ban 326 from Humble Oil Company Rustolene B Grease from Sinclair Oil Co Rust Preventive Grease Code 312 from the Southwest Grease and Oil Company NOTE This list represents the current engineering approved sources for use in Komatsu manufac...

Page 65: ...6 0 375 18 25 5 35 5 8 0 500 14 35 5 45 5 12 0 750 14 45 5 55 5 16 1 000 11 50 55 5 65 5 20 1 250 11 50 70 5 80 5 24 1 500 11 50 80 5 95 10 32 2 000 11 50 95 10 120 10 TABLE VI TORQUE CHART FOR O RING BOSS FITTINGS SIZE CODE TUBESIZE O D THREADS UNF 2B TORQUE ft lbs 2 0 125 0 312 24 4 2 3 0 188 0 375 24 5 2 4 0 250 0 438 20 8 3 5 0 312 0 500 20 10 3 6 0 375 0 562 18 13 3 8 0 500 0 750 16 24 5 10 0...

Page 66: ... 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 ...

Page 67: ... 52 125 257 7 20 68 107 225 437 49 120 248 9 15 59 104 220 428 46 115 239 12 10 50 102 215 419 43 110 230 15 5 41 99 210 410 41 105 221 18 0 32 96 205 401 38 100 212 21 5 23 93 200 392 35 95 293 23 10 14 91 195 383 32 90 194 26 15 5 88 190 374 29 85 185 29 20 4 85 185 365 27 80 176 32 25 13 82 180 356 24 75 167 34 30 22 79 175 347 21 70 158 37 35 31 77 170 338 18 65 149 40 40 40 74 165 329 15 60 1...

Page 68: ...n 0 0907 quart qt liters l 0 946 gallon gal liters l 3 785 HP horsepower Watts 745 7 HP horsepower kilowatts kw 0 745 COMMON CONVERSION MULTIPLIERS METRIC TO ENGLISH To Convert From TO Multiply By millimeter mm inch in 0 0394 centimeter cm inch in 0 3937 meter m foot ft 3 2808 meter m yard yd 1 0936 kilometer km mile mi 0 6210 sq centimeters cm2 sq in in 2 0 1550 sq centimeters cm2 sq ft ft2 0 001...

Page 69: ...DLE PERIODS 3 PREPARATION FOR STORAGE 4 REMOVAL FROM STORAGE 5 RECONDITIONING AN IDLE VEHICLE 7 ENGINE OPERATION 9 AFTER ENGINE HAS STARTED 10 ENGINE STORAGE 11 Engine Storage Short Term 11 Engine Storage Long Term 12 ELECTRIC DRIVE TRUCKS 13 TRANSMISSION PRESERVATION AND STORAGE 17 Restoring Transmission to Service 17 ...

Page 70: ...A7 2 Storage Procedures A07006 NOTES ...

Page 71: ...t These climatic aspects must be considered and appropriate actions taken when restoring a long term idle vehicle These instructions are not intended to be all inclu sive but are furnished to provide the minimum guide lines The final aim should always be to provide the operator with a safe fully productive vehicle that he can rely on SHORT TERM IDLE PERIODS There will be periods when a vehicle may...

Page 72: ...em for proper cleaning instructions 7 The cooling system should be completely drained chemically flushed and refilled with a conditioned water antifreeze solution suitable for the lowest temperature anticipated Refer to Section P Lubrication and Service for the proper anti freeze and conditioner concentrations After refilling the system always operate the engine until the thermostats open to circu...

Page 73: ... corrosion correct as necessary 2 Service the engine according to the Engine Manufacturer s Operation and Maintenance Manual 3 Clean the radiator Refer to Section C Cooling System 4 The cooling system should be completely drained chemically flushed and refilled with a conditioned water antifreeze solution suitable for the lowest temperature anticipated Refer to Fluid Specifications in Section P Lu...

Page 74: ...e and throttle linkage points are free and properly lubricated before engine start up 18 Use the Operation and Maintenance Manual for guidance on engine start and vehicle checkout Make a thorough check of all hose and line con nections for leakage when the engine is run ning 19 Before moving the vehicle cycle all hydraulic controls and steering to verify proper operation Verify proper operation of...

Page 75: ...he eyes 3 Inspect tires thoroughly for tread and side wall condition weathering cuts and cracks a Any tire suspected of being unserviceable should be dismounted and thoroughly inspected inside and out before being inflated Do not mix rim parts of different rim manufactur ers Rim parts may resemble those of a different manufacturer but the required tolerances may be wrong Use of mismatched rim part...

Page 76: ... holding devices can be installed a Check all transmission electrical connections for corrosion cleanliness and tightness Check electrical cables for weathering dam age and proper clamping b Check drive lines for worn U joints and proper hardware torque c Check the condition of the transmission mounts 7 If fuel was left in the tank it must be removed Do not attempt to use old diesel fuel a With th...

Page 77: ...er wipers If wipers are cracked or hardened the suspension must be rebuilt Recharge the suspension with new oil if old oil is deteriorated b Check exposed chrome portions of the cylin der for rust pitting and corrosion If plating is deteriorated the suspension should be removed and overhauled or replaced pitted or scored plating will rapidly cause leakage at the seals c Recharge suspensions as out...

Page 78: ...fully operational 3 Check gauges warning lights and instruments before moving the machine to insure proper system operation and proper gauge functioning Give special attention to braking and steering circuit warning lights If warning lights come on shut down the engine immediately and deter mine the cause 4 Cycle hoist controls and steering several times to remove trapped air Complete steering cyc...

Page 79: ...mpty until the engine is ready to be returned to service Put a warning tag on the engine The tag must indicate The engine does not contain oil Do not operate the engine 11 Disconnect the electrical wiring from the fuel pump solenoid 12 Turn the fuel pump manual shutoff valve coun terclockwise until it stops 13 Crank the engine slowly Spray lubricating oil into the intake manifold and the inlet of ...

Page 80: ...12 Spray preservative oil in the intake port on the air compressor 13 Use a rust preventative compound that meets Military Specification MIL C 16173C Type P 2 Grade 1 or 2 Brush or spray the compound on all of the exposed surfaces that are not painted 14 Remove the rocker lever covers Spray the rocker levers the valve stems the springs the valve guides the crossheads and the push rods with preserv...

Page 81: ...be consid ered as a minimum procedure to achieve the best possible equipment life and the lowest operating cost when the equipment is returned to service NOTE Local conditions and or experience may require ADDITIONAL procedures and or additional storage precautions Placing Equipment Into Storage Perform the following instructions when preparing General Electric equipment for storage There are thre...

Page 82: ...moisture A hole in the bottom of the hubcap will accommodate the electrical cord for the heat source in the Motorized Wheels These heat sources are to be energized continuously 11 Seal compartment doors with a weatherproof tape to prevent entry of rain snow and dirt allow breathing When Storing A Truck That Is Not Operational When a truck which is not fully operational is being stored for a period...

Page 83: ... control compartment doors and ductworks 2 Remove all screening material from ductwork 3 Remove all heat sources from Motorized Wheels control compartments and the alterna tor 4 Fill with recommended oil Refer to the Motor ized Wheel Service Manual for the type and amount oil to be used This oil should be drained and new oil should be added after 500 hours of operation 5 Clean all Motorized Wheel ...

Page 84: ... Hour After all storage protection has been removed the truck has been cleaned and inspected and repairs made as necessary the Motorized Wheel gear case has been filled with new oil the dirt seals have been completely purged with new grease and the system completely checked the truck can be placed into ser vice It is recommended however that the truck be driven unloaded at a low speed 10 mph for t...

Page 85: ...e external lines filters and the cooler 3 Run the engine for approximately five minutes at 1500 rpm with the transmission in neutral 4 Drive the vehicle Make sure the transmission shifts through all ranges Make sure the lockup clutch is working 5 Continue running the engine at 1500 rpm with the transmission in neutral until normal operat ing temperature is reached If the unit does not have a conve...

Page 86: ...A7 18 Storage Procedures A07006 NOTES ...

Page 87: ...B01022 Index B1 1 SECTION B STRUCTURES INDEX STRUCTURAL COMPONENTS B2 1 DUMP BODY B3 1 FUEL TANK B4 1 ...

Page 88: ...B1 2 Index B01022 NOTES ...

Page 89: ...SECTION B2 STRUCTURAL COMPONENTS INDEX STRUCTURAL COMPONENTS B2 3 Preparation B2 3 LADDERS B2 4 Removal B2 5 Installation B2 5 RIGHT DECK B2 5 Removal B2 5 Installation B2 6 LEFT DECK B2 6 Removal B2 6 Installation B2 7 CENTER DECK B2 7 ...

Page 90: ...B2 2 Structural Components B02029 NOTES ...

Page 91: ...ition for the repairs the truck must be shut down properly to ensure the safety of those working in the areas of the deck elec trical cabinet and retarding grids The following pro cedures will ensure the electrical system is properly discharged before repairs are started The anti slip material on the decks should be inspected and maintained for the safety of all per sonnel If weld repairs are nece...

Page 92: ...rm area Be certain this material is in good condition and replace when worn The diagonal ladder must be removed from the truck if it becomes necessary to remove the radiator or the complete power module for major repairs When removing the ladder s check to be certain all wiring and hoses which may be attached to the struc ture have been removed FIGURE 2 1 ACCESS LADDERS AND DECKS 1 Right Deck 2 Ce...

Page 93: ... be cer tain all clamps are installed and secure RIGHT DECK The procedure below describes the sequence to fol low for complete removal of all the right hand deck components If complete disassembly is not required select the appropriate steps for removal of the desired component Additional removal of equip ment wiring hoses etc may be required depending on optional factory installed and field insta...

Page 94: ...ust be properly secured in their wood or other non fer rous cable cleats If clamps are cracked and bro ken oil soaked or otherwise damaged replace them with new parts Inspect cable insulation and replace cable if insulation is damaged LEFT DECK Removal NOTE The left deck mounting arrangement is nearly identical to the right deck Refer to Section N Truck Cab for cab removal and installation instruc...

Page 95: ...ed and secure If the air conditioning system has been discharged refer to Section N Operator Comfort for the correct procedure for system service 1 Start engine and allow systems to charge Observe for any air or oil leaks Make sure all shields covers and clamps are in place 2 Service the hydraulic reservoir if required Check for proper operation of the steering and brake systems including dynamic ...

Page 96: ...B2 8 Structural Components B02029 NOTES ...

Page 97: ...BODY INDEX DUMP BODY B3 3 Removal B3 3 Installation B3 4 BODY PADS B3 5 Adjustment B3 6 BODY GUIDE B3 7 BODY UP RETENTION CABLE B3 7 BODY POSITION INDICATOR B3 8 ROCK EJECTORS B3 8 Inspection B3 8 HOIST LIMIT SWITCH B3 9 BODY UP SWITCH B3 9 ...

Page 98: ...B3 2 Dump Body B03025 NOTE ...

Page 99: ...ositioning a suspended load Before raising or lifting the body be sure there is adequate clearance between the body and over head structures or electric power lines Be sure that the lifting device is rated for at least a 45 ton capacity 1 Park truck on a hard level surface and block all the wheels Connect cables and lifting device to the dump body and take up the slack as shown in Figure 3 1 2 Rem...

Page 100: ...ative for further information Lifting eyes and hooks should be fabricated from the proper materials and rated to lift the load being placed on them Never stand beneath a suspended load Use of guy ropes are recommended for guiding and positioning a suspended load Before raising or lifting the body be sure there is adequate clearance between the body and over head structures or electric power lines ...

Page 101: ... m 300 ft lbs torque Ensure locknuts are in good condition 9 Install mud flaps rock ejectors electrical cables and lubrication hoses BODY PADS It is not necessary to remove the dump body to replace body pads Pads should be inspected during scheduled maintenance inspections and replaced if worn excessively 1 Raise the body to a height sufficient to allow access to all pads Place blocks between the ...

Page 102: ...on of the rubber 3 A gap of approximately 1 5 mm 0 06 in is required at each rear pad This can be accom plished by using one less shim at each rear pad 4 If pad contact appears to be unequal repeat the above procedure Proper body pad to frame contact is required to assure maximum pad life FIGURE 3 4 BODY PAD INSTALLATION 1 Dump Body 2 Pad Mounting Hardware 3 Frame 4 Body Pad 5 Shim 6 Mounting Pad ...

Page 103: ...m mainte nance on the vehicle with the dump body in the raised position 1 To hold the dump body in the up position raise the body to its maximum height Refer to Fig ure 3 6 2 Remove the cable 3 from its stored position on the body and install between the rear body ear 1 and the axle housing ear 4 3 Secure the cable clevis pins with cotter pins 4 After maintenance work is completed reverse the abov...

Page 104: ...ween 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 NOTE With rock ejector arm 1 Figure 3 8 hanging vertical as shown there must be NO GAP at stop block 3 Adjust stop block as necessary to obtain NO GAP 3 If the arm 1 becomes bent it must ...

Page 105: ... 9 HOIST LIMIT SWITCH Refer to Section D Electrical System 24VDC for adjustment procedure of the hoist limit switch BODY UP SWITCH Refer to Section D Electrical System 24VDC for adjustment procedure of the body up switch ...

Page 106: ...B3 10 Dump Body B03025 NOTES ...

Page 107: ...X FUEL TANK B4 3 Removal B4 3 Installation B4 3 Repair B4 5 Cleaning B4 5 FUEL GAUGE SENDER B4 5 Removal B4 5 Installation B4 5 FUEL TANK BREATHER VALVE B4 6 Disassembly B4 6 Assembly B4 6 FUEL RECEIVERS WIGGINS QUICK FILL B4 6 LOW FUEL SWITCH B4 6 ...

Page 108: ...B4 2 Fuel Tank B04026 NOTES ...

Page 109: ...ounting caps 3 from upper mounting trun ions 10 Lift tank from brackets and move to work area 11 Inspect rubber dampeners 16 and replace if necessary Installation The weight of the empty fuel tank is approxi mately 1711 kg 3772 lbs Be certain to use lifting devices with adequate capacity 1 Thoroughly clean the frame mounting brackets and the mounting hardware holes Re tap the threads if damaged 2 ...

Page 110: ...ap Screw 5 Filler Cap 6 Fuel Return Hose 7 Breather Valve 8 Fuel Supply Hose 9 Fuel Gauge Sender 10 Drain Cock 11 Hoist Circuit Filter Assemblies 12 Steering Circuit Filter Assembly 13 Wire Harness 14 Cap Screw 15 Flat Washer 16 Rubber Dampener 17 Ground Wire 18 Terminals 19 Sender Mounting Hardware ...

Page 111: ...s 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 FUEL GAUGE SENDER Fuel gauge sender 9 Figure 4 1 is mounted on...

Page 112: ...e the solid ball is able to seat properly on the stem If not adjust the cage accordingly FUEL RECEIVERS WIGGINS QUICK FILL 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 If fuel spills from the fuel tank breather valve 7 or if the tank does not completely fill check the breather...

Page 113: ...C01029 Index C1 1 SECTION C ENGINE INDEX POWER MODULE C2 1 COOLING SYSTEM C3 1 POWER TRAIN C4 1 AIR CLEANERS C5 1 FAN CLUTCH C7 1 ...

Page 114: ...C1 2 Index C01029 NOTES ...

Page 115: ...C02027 Power Module C2 1 SECTION C2 POWER MODULE INDEX POWER MODULE C2 3 PREPARATION C2 3 Removal C2 3 Installation C2 8 ...

Page 116: ...C2 2 Power Module C02027 NOTES ...

Page 117: ...e of power module installation Plug all ports and cover all hose fittings or connections when dis connected to prevent dirt or foreign material from entering 4 It is not necessary to remove the grille or radia tor prior to the removal of the power module If radiator removal is desired or if only radiator repair is necessary refer to Cooling System in this section Removal 1 Disconnect batteries usi...

Page 118: ... Disconnect the air cleaner restriction gauge hoses Disconnect electrical wiring and hoses etc that would interfere with front center deck removal 6 Remove air inlet duct support rods on under side of center deck 7 Attach hoist to the front center deck Remove all cap screws flat washers lockwashers and nuts securing the deck Check for any remaining wir ing hoses or other items on underside of deck...

Page 119: ...curing subframe mounting bushings to the subframe support bracket 6 at rear of sub frame 16 Check engine and alternator to make sure all cables wires hoses tubing and linkages have been disconnected 17 Remove the mounting hardware at the diagonal ladder mounting pads Lift the diagonal ladder from the truck and move it to a storage area Federal regulations prohibit venting air conditioning system r...

Page 120: ...sub frame rollers Refer to Figure 2 5 Lower the rear portion of the subframe carefully until the rollers rest on the main frame guide rail NOTE Subframe rollers are supplied in the truck tool group and can be installed in the storage position after use as shown in Figure 2 5 FIGURE 2 3 AIR INTAKE DUCTS 1 Hump Hose 2 Support Rods 3 Air Intake Ducts 4 Turbocharger 5 Center Deck Structure 6 Clamp 7 T...

Page 121: ...at adequate clearance is provided for the lift ing device to be attached to the engine alterna tor cradle structure and front subframe lifting points Place stands or block under front of sub frame and lower hoist until front of subframe is supported Install safety chain to prevent sub frame from rolling FIGURE 2 4 ENGINE MODULE INSTALLATION 1 Pump Driveshaft 2 Rear Module Lift Eye 3 Cap 4 cap scre...

Page 122: ...ubber bushing 5 Figure 2 4 located at the rear of the subframe 3 Check the subframe rollers making sure they roll freely and are in the roll out position Fig ure 2 5 4 Attach a lifting device to engine alternator cra dle structure and front subframe lifting points Figure 2 6 The complete power module weighs approxi mately 16 760 kg 36 950 lbs Make sure lifting device to be used is of an adequate c...

Page 123: ...l cover 10 if grille is installed 17 Install the rear subframe mounting caps 3 and secure caps in place with lubricated cap screws 4 Tighten cap screws to 551 21 N m 407 15 ft lbs torque 18 Install radiator support struts 12 19 Install exhaust ducts 1 3 Figure 2 2 Install cap screws 2 washers and nuts to secure ducts to turbochargers Install V band clamps 5 and support clamps 4 20 Connect the cab ...

Page 124: ...the bus bar outside the battery box Also connect the three wiring harness to the bat tery box b Connect the ground cables below the battery box c Ensure the battery disconnect switches are in the OFF position Inside the battery box connect both battery negative ground cables to the battery posts d Close battery disconnect switch 34 Refill the radiator with coolant and service the engine with the a...

Page 125: ...ION C3 3 RADIATOR C3 4 Removal C3 4 Installation C3 7 Radiator Filling Procedure C3 8 REPAIRING THE RADIATOR C3 9 Internal Inspection C3 9 External Cleaning C3 9 Disassembly C3 9 Cleaning and Inspection C3 10 Assembly C3 10 Pressure Testing C3 12 COOLANT SYSTEM TROUBLESHOOTING C3 12 ...

Page 126: ...C3 2 Cooling System C03035 NOTES ...

Page 127: ...d for the engine coolant circuit In this circuit the engine water pump 10 circulates coolant through the engine block 9 heads liners internal oil coolers etc The engine coolant thermostats 5 begin to open at 82 C 180 F and are fully open at 94 C 202 F In addition a fuel cooler located on the lower right corner of the radiator assembly reduces fuel temper ature after fuel leaves the engine before i...

Page 128: ...oolant level probe 6 Remove clamps 5 securing hoses and electri cal cables to fan shroud tubes and support rods 5 Loosen clamps and remove coolant piping at upper and lower radiator tanks Refer to Figure 3 2 and 3 4 6 Grille structure 2 Figure 3 2 removal a Remove lower left grille section for access to air conditioning condenser hoses FIGURE 3 2 GRILLE INSTALLATION 1 Surge Tank 2 Grille Structure...

Page 129: ...properly remove the refrigerant from the air conditioning system NOTE The system is charged with HFC 134A refrigerant 8 After system is evacuated remove hoses from condenser and cap all openings to prevent con tamination Unclamp hoses and remove from radiator area to prevent interference when radi ator is removed FIGURE 3 4 RADIATOR AND SHROUD Rear View 1 Shroud 2 Fan Guard Str 3 Support Rod 4 Cla...

Page 130: ...x from front bumper 11 Disconnect hoses and pressure switch at receiver drier located on fan shroud 12 Remove lower right grille section and discon nect hoses from fuel cooler Cap openings to prevent contamination 13 Disconnect headlight wire harness at each light Remove cable clamps and remove harness to allow radiator removal 14 Remove hardware attaching grille structure to radiator assembly att...

Page 131: ... lights Attach connectors to lights and clamp harness at weld studs 8 Install upper and lower radiator piping Seat hoses and clamps securely 9 Position fan guard against shroud and tighten mounting hardware to 55 N m 40 ft lbs torque If halves of guard were disassembled tighten cap screws clamping halves together to 34 N m 25 ft lbs torque 10 Attach hoses to fuel cooler 11 Route A C condenser hose...

Page 132: ... system the radiator cap MUST be removed prior to adding coolant 2 Fill radiator with proper coolant mixture as specified by the engine manufacturer until coolant is visible in the sight gauge 3 Install radiator cap 4 Run engine for 5 minutes check coolant level 5 If coolant is not visible in the sight gauge repeat steps 1 through 4 Any excess coolant will be discharged through the vent hose after...

Page 133: ...are used for cleaning ensure that the cleaning solutions are not harmful to solder Otherwise damage to the radiator will result Completely rinse the cleaned tube or core in clean water after removing it from the boil out tank As an alternative to boil out tanks radiators can be cleaned externally with a high pressure washer and soap In most cases it may be best to blow out any dry dirt with a high...

Page 134: ...urther instructions or visit the L M website at www mesabi com 3 Check for signs of internal blockage in the tubes and tanks If desired you may cut open tubes for inspection If contamination is present the tube should be analyzed The radiator must be properly flushed of all contaminants and corrective action must be taken to prevent such contamination from occurring in the future Refer to Internal...

Page 135: ...an side row When installing the tubes center the top of the tube in the top seal while angling the tube only as much as necessary Twist the tube while applying upward force Push the tube into the seal until enough clearance is available to install the bottom end of the tube into the bottom seal 6 Center the bottom end of the tube in the bottom seal Push the tube downward until the formed bead on t...

Page 136: ...L M Radiator website at www mesabi com COOLANT SYSTEM TROUBLESHOOTING If abnormal coolant temperatures are experienced perform the following visual inspections and tests 1 Check the coolant level and thoroughly inspect the system for leaks a Check for proper coolant antifreeze mixture b Follow the recommendations of the engine manufacturer regarding use of cooling system additives 2 Inspect the ra...

Page 137: ...L PROCEDURE C4 3 Removal Komatsu SSDA16V160 or SDA16V160 Engine C4 3 ENGINE ALTERNATOR MATING C4 5 General Instructions C4 5 Measuring Procedure C4 5 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine C4 7 ENGINE C4 8 Removal C4 8 Service C4 9 Installation C4 9 ...

Page 138: ...C4 2 Power Train C04034 NOTES ...

Page 139: ...4037 kg 8 900 lbs Use a lifting device that can handle the load safely 1 Attach hoist with two lifting chains to the alter nator lifting eyes 7 Figure 4 2 2 Block under rear of engine a Loosen cradle adjustments setscrews 3 Figure 4 1 b Loosen engine cradle cap screws 3 Figure 4 2 FIGURE 4 1 CRADLE STRUCTURE 1 Cradle Structure 2 Jam Nut 3 Adjustment Setscrew 4 Subframe 5 Gap FIGURE 4 2 ENGINE AND ...

Page 140: ...he cap screws at all locations Be sure all the cap screw threads are completely disengaged from the alternator housing 1 6 Take up slack in hoist and remove cap screws and lockwashers 1 Figure 4 2 securing the alternator to the cradle structures 7 Keep alternator as level as possible and move away from engine 8 Note shim location and quantity Retain shims for possible use during reinstallation 9 F...

Page 141: ...er mounting surfaces 2 With magnetic base mounted on the front of the engine and the dial indicator on the front of the crankshaft measure total crankshaft end play Verify end play is within 0 13 0 38 mm 0 005 0 015 in Record Total Crankshaft End play ____________ 3 Refer to Figure 4 5 Move the engine crank shaft to the rear of its end travel a Carefully measure Dimension C at four locations 90 ap...

Page 142: ...tions 90 apart and average the measurements 1st measurement _________________________ 2nd measurement ________________________ 3rd measurement ________________________ 4th measurement _________________________ Dimension A ____________________ Average e Add 0 254 mm 0 010 in to Dimension A f Record d e as Measurement A _________________________ 5 Determining Shims Compare Measurement C Step 3 c wit...

Page 143: ...m 175 ft lbs torque 5 Install alternator to cradle structure mounting cap screws and washers 1 Figure 4 2 and tighten to 1017 N m 750 ft lbs torque 6 Tighten engine to cradle structure mounting cap screws 3 Figure 4 2 to 465 N m 345 ft lbs torque Never pry on the engine crankshaft damper 7 With magnetic base mounted on the front of the engine and the dial indicator on the front of the crankshaft m...

Page 144: ...ons for the Power Module alternator and radiator assembly The engine weighs approximately 9616 kg 21 200 lbs wet Ensure lifting devices are capa ble of handling the load safely 1 Disconnect any remaining wiring or hoses between the engine and subframe 2 Remove cap screws and lockwashers 5 Fig ure 4 7 securing front engine mount to sub frame 3 Attach spreader bar with lifting straps at front lift h...

Page 145: ...e structure but do not tighten at this time Tighten front mount cap screws to 465 N m 345 ft lbs torque 2 Install alternator on engine following instruc tions for Engine Alternator Mating 3 Tighten rear engine mounting cap screws 2 to 465 N m 345 ft lbs torque after alternator is installed 4 Adjust setscrew 3 Figure 4 1 to equalize gap 5 between cradle structure 1 and subframe 4 at left and right ...

Page 146: ...C4 10 Power Train C04034 NOTES ...

Page 147: ...5 AIR CLEANERS INDEX AIR CLEANERS C5 3 OPERATION C5 3 SERVICING THE AIR CLEANERS C5 3 Replacing The Filter Element C5 4 AIR CLEANER ASSEMBLY CLEANING C5 5 Main Filter Cleaning C5 5 Precleaner Section Cleaning C5 7 AIR INTAKE TROUBLESHOOTING C5 8 ...

Page 148: ...C5 2 Air Filtration System C05019 NOTES ...

Page 149: ...and out the clean air outlet to the engine s air intake system The function of the safety filter is to increase overall reliability and engine protection SERVICING THE AIR CLEANERS The engine must be turned off before servicing the air cleaner assemblies or opening the engine air intake system Never start the engine with the filter elements removed Serious engine damage can result Inspect and empt...

Page 150: ...r element carefully for damage holes or breaks which might affect reuse of the element If the element appears serviceable proceed with the cleaning procedure If defects are found in the element wing nut 5 must be removed from the assembly and installed on the new element 4 Check safety filter indicator 7 If the solid red area is showing replacement of the safety filter is required If the center is...

Page 151: ... CLEANING Main Filter Cleaning Only the main filter elements may be cleaned and then only if they are structurally intact Do not reuse an element that is damaged Do not clean and reuse the safety secondary filter elements Replace them with new parts After inspection determine the condition of the main filter element and choose either the washing method or compressed air method for cleaning the ele...

Page 152: ...The distance from the nozzle to the surface of the filter element must be at least 25 mm 1 in to prevent damage to the filter material 2 As shown in Figure 5 4 direct the stream of air from the nozzle against the inside of the filter element This is the clean air side of the element and air flow should be opposite of normal air flow 3 Move the air flow up and down vertically with the pleats in the...

Page 153: ...out removing the entire air cleaner from the truck 1 Remove air intake cover 3 Figure 5 1 Remove the mounting hardware that secures the precleaner section to the air cleaner assembly Remove the precleaner section The safety filter element must remain in place to protect the engine intake 2 Loosen the clamps and remove dust collector 1 from the precleaner section Wash the dust collector with a wate...

Page 154: ...uspected check the following 1 All intake lines tubes and hump hoses for breaks cracks holes etc which could allow an intake air leak 2 Check all air cleaner gaskets for positive seal ing 3 Check air cleaner elements main and safety for ruptures holes or cracks 4 Check air cleaner assembly for structural dam age cracks breaks or other defects which could allow air leakage Check all mounting hardwa...

Page 155: ...C07001 Fan Clutch C7 1 SECTION C7 FAN CLUTCH INDEX REMOVAL INSTALLATION TOOLING C7 3 DISASSEMBLY C7 6 CLEANING AND INSPECTION C7 16 ASSEMBLY C7 20 TEST PROCEDURE C7 34 ...

Page 156: ...C7 2 Fan Clutch C07001 NOTES ...

Page 157: ...C07001 Fan Clutch C7 3 FAN CLUTCH REMOVAL INSTALLATION TOOLING TOOL A FRONT SLEEVE BEARING TOOL B REAR SLEEVE BEARING ...

Page 158: ...C7 4 Fan Clutch C07001 TOOL C FRONT AND REAR SLEEVE BEARING REMOVER TOOL D WEAR SLEEVE AND RETAINER SEAL ASSEMBLY INSTALLER BEARING REMOVER ASSEMBLY PUSHER TOOL ...

Page 159: ...C07001 Fan Clutch C7 5 TOOL E BEARING INSTALLER TOOL F BEARING INSTALLER ...

Page 160: ...7 Seal Ring Hook Type 18 Bolt 19 Washer 20 Pulley 21 Pulley Adapter 22 Seal Ring Large 23 Piston 24 Seal Ring Small 25 Spring Washer 26 Shim 27 External Snap Ring 28 External Snap Ring 29 Clutch Hub 30 Facing Plate 31 Steel Clutch Plate 32 Internal Snap Ring 33 Main Bearing Front 34 O Ring Seal 35 Bearing Retainer Front 36 Oil Seal 37 Washer 38 Bolt 39 Wear Sleeve 40 Retainer Seal Assembly 41 Slee...

Page 161: ...lley 22 Seal Ring Large 23 Piston 24 Seal Ring Small 25 Spring Washer 26 Shim 27 External Snap Ring 28 External Snap Ring 29 Clutch Hub 30 Facing Plate 31 Steel Clutch Plate 32 Internal Snap Ring 33 Main Bearing 34 O Ring Seal 35 Bearing Retainer 36 Oil Seal 37 Washer 38 Bolt 39 Wear Sleeve 40 Retainer Seal Assembly 41 Sleeve Bearing Rear Short 42 Fan Mounting Hub 44 Sleeve Bearing Front Long 45 E...

Page 162: ...nstall lifting eyes and attach a hoist and chains to front bearing retainer 35 Use a small screwdriver to separate the front bearing retainer from pulley adapter 21 and set it aside on a bench 3 Remove O ring seal 34 4 Position the bearing retainer and hub assembly on the bench with clutch hub 29 up Remove external snap ring 28 FIGURE 7 2 FIGURE 7 3 FIGURE 7 4 FIGURE 7 5 ...

Page 163: ... 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 7 Remove front oil seal 36 8 Remove internal snap ring 32 FIGURE 7 6 FIGURE 7 7 FIGURE 7 8 FIGURE 7 9 ...

Page 164: ...the fan mounting hub 11 Remove front retainer seal assembly 40 Wedge a large chisel or other appropriate tool behind the retainer to force it off fan mounting hub 42 Use a chisel to make three indentations in wear sleeve 39 in order to loosen the sleeve The indentations should be approximately 120 degrees apart from one another Remove the wear sleeve NOTE Use caution when using the chisel Do not c...

Page 165: ...step If the bearings are in good condition skip the next step 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 14 Remove the stack of facing plates 30 and steel clutch plates 31 from inside the pulley 15 Remove external snap ring 27 shim 26 and spring washer 25 F...

Page 166: ... pulley to prevent it from dropping to the bench Remove bolts 9 and lockwashers 8 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 18 FIGURE 7 19 FIGURE 7 20 FIGURE 7 2...

Page 167: ...haft Rotate the pitot tube until the sealant holding it tight is broken loose Then grip the pitot tube with a pair of pliers and gently tap on the pliers to remove the pitot tubes from the hole in the shaft 21 Remove both seal rings 17 22 Remove external snap ring 16 23 Remove internal snap ring 15 FIGURE 7 22 FIGURE 7 23 FIGURE 7 24 FIGURE 7 25 ...

Page 168: ...10 from bearing retainer 11 26 Use tooling E to press rear bearing 14 out of rear bearing retainer 11 27 Use a chisel to make three indentations in wear sleeve 4 The indentations should be approximately 120 degrees apart from one another Remove the wear sleeve NOTE Use caution when using the chisel Do not cut through the sleeve Damage to the shaft can cause future leaks FIGURE 7 26 FIGURE 7 27 FIG...

Page 169: ...C07001 Fan Clutch C7 15 28 Remove rear retainer seal assembly 5 Drive the assembly off the shaft or wedge a large chisel or other appropriate tool behind the retainer to force it off FIGURE 7 30 ...

Page 170: ... seals Replace during rebuild Bolts and washers Reuse unless damaged or worn Retainer Seal assemblies Replace if damaged or worn Wear sleeves Replace during rebuild Sleeve bearings Inspect color of surface Refer to Figure 7 14 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 s...

Page 171: ...C07001 Fan Clutch C7 17 3 Check pulley and adapter dimensions 4 Check rear bearing retainer 11 dimensions 5 Check piston 23 dimensions FIGURE 7 32 FIGURE 7 33 FIGURE 7 34 ...

Page 172: ... 8 Check steel plates 31 for wear The plates must be smooth and free of grooves or heat related damage The plates are 3 07 mm 0 121 in minimum thickness when new and must be flat within 0 13 mm 0 005 in 9 Inspect facing plates 30 Minimum thickness for new facing plates is 2 77 mm 0 109 in Grooves are 0 15 mm 0 006 in deep The plates must be flat within 0 13 mm 0 005 in Check the teeth for excessiv...

Page 173: ...C07001 Fan Clutch C7 19 11 Inspect front bearing retainer 35 12 Inspect end cap 45 for any wear or raised nicks FIGURE 7 37 ...

Page 174: ...from the sealing surfaces 1 Place end cap 45 in a freezer or on dry ice to prepare for installation in the following steps 2 If removed install dowel pin 43 into fan mounting hub assembly 42 Refer to Figure 7 38 Press the pin into the hub leaving 2 3 mm 0 090 in exposed If the shaft did not originally come with pinned bearings install the dowel per instructions in Figures 7 38 and 7 39 FIGURE 7 38...

Page 175: ...aring is installed There are two sleeve bearings and each one must be installed in the proper area of the hub to ensure the lube passage is not restricted Refer to Figure 7 40 4 Turn the hub over on the bed of the press Using tooling B press rear sleeve bearing 41 into the fan mounting hub until the tool contacts the shoulder of the hub FIGURE 7 40 FIGURE 7 41 FIGURE 7 42 ...

Page 176: ...ar sleeve is color coded red 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 NOTE Some fan hubs may have a small hole on the wear sleeve mounting journal This hole is not...

Page 177: ...Press the front bearing into the bearing retainer using tooling E or equivalent Press ONLY on the outer race of the bearing until it seats at the bottom of the bore 9 Install internal snap ring 32 10 Turn the retainer over on the press bed Coat the outside diameter of front oil seal 36 and the mating surface on the bearing retainer with Loctite Primer N and 242 or equivalent Use tooling E to press...

Page 178: ...ct with the Loctite Press the bearing onto the hub using tooling D until it contacts the wear sleeve Wipe any lubricant or sealer from the seal lip The seal lip is teflon and must remain dry for proper sealing to occur Spin the bearing retainer at least 25 revolutions to ensure proper rotation of the bearing and to burnish the seal 12 Install clutch hub 29 on the fan mounting hub assembly 42 with ...

Page 179: ...wel per instructions in Figures 7 53 7 54 15 Use tooling D to press rear retainer seal assembly 5 onto shaft 6 The inner race of the retainer should be recessed 1 0 mm 0 040 in below the shoulder Check carefully to ensure that the retainer seal assembly is installed straight and not bent or damaged in any way which will cause interference between it and the bearing retainer after assembly FIGURE 7...

Page 180: ...ar sleeve diameter of the fan mounting hub with Loctite Primer N and 242 or equivalent Locate the sleeve so the notch in the sleeve will be aligned with the small lube hole in the shoulder Using tooling D press the wear sleeve onto the fan mounting hub until it is flush with the shoulder 17 Coat the outside diameter of rear bearing 14 and the mating surface of bearing retainer 11 with Loctite Prim...

Page 181: ...later step Proceed to the next step 20 Coat the outside diameter of rear oil seal 10 with Loctite Primer N and 242 or equivalent Use tooling E or an equivalent to install the oil seal in the rear bearing retainer until it is flush with the rear face Do not lubricate the seal The seal is made of teflon and must be installed dry 21 If a bearing spacer is used instead of a snap ring as explained in S...

Page 182: ...ain dry for proper sealing Spin the bearing retainer approximately 25 times to burnish the teflon seal on the wear sleeve Check for abnormal sounds or other indications of contact between the retainer seal assembly and the bearing retainer If interference is found remove the bearing retainer and eliminate the point of interference 23 Install external snap ring 16 Ensure that the snap ring is fully...

Page 183: ...ree places at the 9 12 and 3 o clock positions to prevent the tubes from rotating in operation 25 Install both hook type seal rings 17 in the grooves in the shaft Rotate the rings so the slits in the rings are 180 degrees apart from one another 26 Lubricate the seal ring grooves of piston 23 with an oil soluble lubricant such as engine assembly grease Install small seal ring 24 in the inside groov...

Page 184: ... the bolt holes align in the bearing retainer and pulley Carefully remove the bearing retainer sub assembly 30 Install spring washer 25 shim 26 and spirolock ring 27 It will be necessary to press downward to compress the spring washer while forcing the spirolock to properly seat in the groove The shim must then be centered on the spring washer to prevent it from interfering with the movement of th...

Page 185: ... Place the seal in the groove in the pulley The grease should secure the seal in the groove during installation Carefully lower the pulley Ensure that the guide bolt is aligned with a bolt hole in the bearing retainer assembly and the O ring seal is still securely in place Lower the pulley until it rests on the front bearing retainer 33 Install at least four bolts 38 with lockwashers 37 90 degrees...

Page 186: ... shaft sub 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 36 Install bolts 9 with lockwashers 8 Tighten each bolt to 49 58 N m 36 43 ft lbs 37 If removed install orifice fitting 1 in the oil in port of the bracket FIGURE 7 74 FIGURE 7 75 FIGURE 7 7...

Page 187: ...C07001 Fan Clutch C7 33 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 FIGURE 7 78 ...

Page 188: ... 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 rotatin...

Page 189: ...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 propuls...

Page 190: ...ch If the engine does not shut down use the emergency shutdown switch on the center console 4 After approximately 90 seconds verify that the steering accumulators have bled down by attempting to turn the steering wheel 5 Verify that the link voltage lights on the electrical cabinet and the DID panel in the cab are OFF If they remain on longer than 5 minutes after shutdown the propulsion system mus...

Page 191: ... 24VDC Battery Charging Alternator D2 5 Battery Box D2 5 Battery Control Box D2 6 Battery Disconnect Switches D2 6 24VDC Auxiliary Battery Receptacles D2 6 Isolator Diode D2 6 Engine Start Relay D2 6 24VDC to 12VDC Converter D2 6 24 VDC ELECTRIC CRANKING MOTOR SYSTEM WITH PRELUBE D2 7 Operation D2 7 Pressure Switch D2 8 Check Valve D2 8 Timer Solenoid D2 8 MAINTENANCE D2 8 Prelube System Operation...

Page 192: ...TROUBLESHOOTING D2 12 Preliminary Inspection D2 12 No Load Test D2 12 Interpreting Results of Tests D2 13 Disassembly D2 13 Cleaning and Inspection D2 14 Armature Servicing D2 16 Field Coil Checks D2 16 Field Coil Removal D2 16 SOLENOID CHECKS D2 17 Test D2 17 Assembly D2 18 Bearing Replacement D2 18 Motor Assembly D2 18 Pinion Clearance D2 19 MAGNETIC SWITCH D2 19 Removal D2 19 Installation D2 19...

Page 193: ...er types of water recommended by the battery manufacturer After adding water in freez ing weather operate the engine for at least 30 min utes to thoroughly mix the electrolyte DO NOT SMOKE or allow flame around a dead battery or during the recharging process The expelled gas from a dead cell is extremely explo sive Excessive consumption of water indicates leakage or overcharging Normal water usage...

Page 194: ...tand unattended If equipment is to stand unused for more than two weeks the batteries should be removed and placed in a cool dry place where they may be checked periodically and charged when necessary Remember all lead acid batteries discharge slowly when not in use This self discharge takes place even though the battery is not connected in a circuit and it is more pronounced in warm weather than ...

Page 195: ...A 24VDC to 12VDC converter located toward the bottom of the inside left wall of the auxiliary control cabinet is used to convert the 24 volt battery system voltage to 12 volts for various truck components When maintenance or repairs are performed the batteries can be quickly disconnected from the cranking motor or control circuits by using disconnect switches 7 8 located on battery control box 4 A...

Page 196: ...VDC with one pair connected to the front receptacle and the other pair connected to the rear receptacle on the truck 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 Engine Start Relay Engine...

Page 197: ...ink 9 to the prelube motor 10 driving the prelube pump but does not allow the cranking motor motors to engage the cranking motor pinion gears at this time The prelube pump supplies oil from the engine oil pan to fill the engine oil filters and oil passages prior to cranking When the pressure in the engine cam oil rifle reaches 17 2 kPa 2 5 psi the circuit to the timer solenoid is opened After a 3 ...

Page 198: ...ected to the engine cranking motor solenoids 8 for engine cranking DO NOT Attempt to jump start the truck using the terminals on the timer solenoid INTERNAL DAM AGE TO TIMER WILL RESULT MAINTENANCE Prelube system maintenance should be performed annually or at 5000 hour intervals as described below Prelube System Operation Checks Verify system operates according to the two phases of operation as li...

Page 199: ...failure b Jump starting of the vehicle with a voltage that is higher than was designed for the system can cause solenoid contacts to weld Cranking motor delays and cranks No prelubrication mode If an operator indicates the ignition is totally dead make certain the key is being held in the crank position for 3 to 4 seconds If the engine cranks after a short delay this indicates that a ground connec...

Page 200: ...e 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 switc...

Page 201: ... from excessive speed until the key switch is released When the key switch is released a return spring causes the drive pinion to disengage After the engine is running a normally closed pres sure switch senses engine oil pressure and opens the electrical circuit to prevent actuation of the motor s after the engine has started Removal 1 Disconnect battery power a Open the battery disconnect switch ...

Page 202: ...ure can be rotated 2 If the armature does not turn freely the crank ing motor should be disassembled immediately 3 If the armature can be rotated perform the No Load Test before disassembly No Load Test Refer to Figure 2 5 for the following test setup Be certain switch is open before connections or disconnections are made during the following procedures 1 Setup the motor for test as follows a Conn...

Page 203: ...tor bars or other causes which would prevent good con tact between the brushes and commutator 5 Low no load speed and low current draw indi cates a High internal resistance due to poor connec tions defective leads dirty commutator and causes listed under Number 4 6 High free speed and high current draw indicates shorted fields If shorted fields are suspected replace the field coil assembly and che...

Page 204: ...tator d If the springs 16 are distorted or discolored they should be replaced FIGURE 2 6 CRANKING MOTOR ASSEMBLY 1 C E Frame 2 Washers 3 O Rings 4 Insulator 5 Support Plate 6 Brush Plate Insulator 7 Washers 8 Plate Stud 9 Plate 10 Brush Holder 11 Lockwasher 12 Screw 13 Brush 12 required 14 Lockwasher 15 Screw 16 Brush Spring 17 Screw 18 Screw 19 Screw 20 Lockwashers 21 ate 22 Brush Holder Insu lat...

Page 205: ...D02034 24 VDC Electric Supply System D2 15 FIGURE 2 6 CRANKING MOTOR ASSEMBLY ...

Page 206: ...located Shorts between bars are sometimes produced by brush dust or copper between the bars These shorts can be elimi nated by cleaning out the slots 3 Grounds in the armature can be detected by the use of a 110 volt test lamp and test points If the lamp lights when one test point is placed on the commutator with the other point on the core or shaft the armature is grounded Grounds occur as a resu...

Page 207: ...from the solenoid switch terminal S to the solenoid motor M or MTR terminal Figure 2 9 To prevent overheating do not leave the pull in winding energized more than 15 seconds The current draw will decrease as the winding tem perature increases 4 Use the carbon pile to decrease the battery volt age to 5 volts Close the switch and read cur rent The ammeter should read 9 0 to 11 5 amps NOTE High readi...

Page 208: ...re 45 Figure 2 6 into the 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 place against the field frame c Insert screws 34 and washers 33 and tighten securely 2 Assemble lever 63 into lever housing 78 If removed 3 Place washer 79 on armature...

Page 209: ...cribed in Crank ing Motor Removal 2 Disconnect cables from the switch terminals and wires from coil terminals Figure 2 12 NOTE If the magnetic switch being removed has a diode across the coil terminals mark the leads prior to removal to ensure correct polarity during installation 3 Remove mounting cap screws and washers Remove switch from mounting bracket 4 The switch coil circuit can be tested as...

Page 210: ...minal and another on the switch mounting bracket If the meter displays any resistance reading the coil is grounded and the switch must be replaced 3 The ohmmeter should display when the probes are placed across the switch terminals NOTE The switch terminals should show continuity when 24 VDC is applied to the coil terminals however high resistance across the internal switch contacts due to arcing ...

Page 211: ...arter Failure Delay Timer D3 3 5 Minute Idle Timer D3 4 Pulse Voltage Modulator PMV D3 4 Control Power Relay D3 4 Auto Lube Timer D3 4 Diode Board DB1 D3 6 Fuse Blocks D3 7 Alarm Indicating Device AID System D3 7 Diode Matrix With Sound D3 8 Diode Matrix Without Sound D3 8 Hot Switch Inverter D3 8 Hot Switch Inverter Not Used D3 9 Temperature and Latch D3 9 RELAY BOARDS D3 10 Relay Boards RB1 RB3 ...

Page 212: ... System Components 10 06 D03036 BODY UP SWITCH D3 15 Operation D3 15 Adjustment D3 15 Service D3 15 HOIST LIMIT SWITCH D3 16 Operation D3 16 Adjustment D3 16 Service D3 16 FUSE BLOCK CHARTS D3 17 CIRCUIT BREAKER CHART D3 19 ...

Page 213: ...odule in the overhead panel Refer to Section J for additional details AUXILIARY CONTROL CABINET COMPO NENTS The following 24VDC electrical system components are located in the auxiliary control cabinet which is mounted on the left side of the main control cabinet behind the cab The auxiliary control cabinet houses various components for the 24VDC circuits engine related devices and terminal strips...

Page 214: ...own sequence will then occur However if during the 5 minute idle timing sequence the 5 minute delay switch on the instrument panel is pressed to the OFF position the center console engine shutdown switch is depressed or the ground level shutdown switch is activated the engine will shut down immediately followed by the normal shut down of all systems Test the 5 minute idle timer circuits as follows...

Page 215: ...l 3 Engine Starter Failure Delay Timer 4 5 Minute Idle Timer 5 Key Switch Power Relay 6 Pulse Voltage Modulator PVM 7 12V Power Relay 8 Control Power Relay 9 Auto Lube Timer 10 Relay Board RB1 11 Relay Board RB3 12 Relay Board RB4 13 Relay Board RB5 14 Relay Board RB6 15 Relay Board RB7 16 Relay Board RB8 17 Relay Board RB9 18 Diode Board DB1 FIGURE 3 1 AUXILIARY CONTROL CABINET LEFT WALL ...

Page 216: ...ing the locking ears while pulling the connector off the board Note the connector key used to ensure correct polarity NOTE Some digital multimeters are designed to test diodes If this type is used follow the manufacturer s instructions for proper test 2 An analog ohmmeter can be used to test the diode as follows a Place the meter on the X100 scale b With the red meter lead on the banded end of the...

Page 217: ...n Alarm Indicating Device AID System Alarm indicating device AID module 1 Figure 3 4 is connected to the electrical accessories circuits to provide the operator with a warning indication of a malfunction This system consists of up to eight printed circuit cards located in the auxiliary control cabinet The actual quantity of cards will depend on the that are options installed on the truck 1 Fuse Bl...

Page 218: ...ode matrix without sound card consists of a series of diodes capable of working with eight differ ent indicator circuits The indicator light can be a flashing light by connecting it to the 12F circuit or a steady light by connecting it to the 12M circuit In addition some of the indicator light circuits are routed through a dimmer module to allow the opera tor to vary the intensity of the lamps The...

Page 219: ...he 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...

Page 220: ... one red breaker open light 7 Each relay board has a fifth green 8 light that has a different function on each board Four green lights 9 are labeled K1 K2 K3 or K4 These lights will be on only when that particular con trol circuit has been switched ON and the relay coil is being energized The light will not turn on if the relay board does not receive the 24 volt signal to turn on a component If il...

Page 221: ...e relay 11 4 Line up the tabs and install a new relay 5 Place the crossbar in its original position and install screw 10 Tighten both screws To replace a circuit breaker NOTE Always replace a circuit breaker with one of the same amperage capacity as the one being removed 1 Activate the battery disconnect switches 2 Unplug all wiring harnesses from the relay board Remove the four relay board mounti...

Page 222: ... 3 6 TYPICAL RELAY BOARDS RB1 RB3 RB4 RB5 1 Relay Board 2 Screw 3 Screw 4 Circuit Breaker 5 Circuit Panel Card 6 Screw 7 Breaker Open Light RED 8 Bleed Down Light GREEN Relay Board 4 Only 9 K1 K2 K3 K4 Lights GREEN 10 Screw 11 Relay 12 Circuit Harness Connector ...

Page 223: ...e Display card 1 Rev Light Green This light is illuminated whenever the directional control lever is in the REVERSE position and the key switch is in the ON position 4 12 5 amp circuit breakers CB16 CB17 CB18 CB19 4 Relays Manual Backup Lights Relay K1 Stop Lights Relay K2 Retard Lights Relay K3 Backup Lights Horn Relay K4 Relay Board 4 RB4 1 Steering Pressure Bleed Down Timer Module card 1 Bleed ...

Page 224: ...e Solenoid Relay K5 Spare Relay K6 Bleeddown Relay K7 Auto Lube Power Relay K8 Relay Board 8 RB8 The following relays are installed on RB8 Full Load Signal to PSC Relay K1 70 Load Signal to PSC Relay K2 Spare or Shutter Relay K3 Load Light Power Relay K4 Spare or Shutter Relay K5 Full Load RED Light K6 Partial Load Yellow Light K7 Empty Green Light K8 Relay Board 9 RB9 The following relays are ins...

Page 225: ...ounting bolts may cause false signals or damage to the switch assem bly Adjustment Before adjusting the body up switch inspect the body pads for wear and damage Replace the body pads if required The body must be resting on the frame in the normal body down position when adjust ments are made 1 Loosen cap screws 2 Figure 3 8 and adjust proximity switch bracket 3 to achieve an air gap dimension A of...

Page 226: ...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 ...

Page 227: ...0 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 Syste...

Page 228: ... Wheel Speed Sensor 15LFWS 17 10 Cigarette Lighter 67C 18 20 R H Cab Window 67R 19 20 L H Cab Window 67P 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 Powe...

Page 229: ...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 11H...

Page 230: ...D3 20 24VDC Electrical System Components 10 06 D03036 NOTES ...

Page 231: ...oting D10 6 Undercharging D10 6 Overcharging D10 6 Corrosion D10 6 Acid Levels D10 6 Non Use or Storage D10 6 Freezing D10 7 BATTERY CHARGING ALTERNATOR D10 8 GENERAL INFORMATION D10 8 General Description D10 8 Terminal Identification and Location D10 9 Battery Positive B D10 9 Battery Negative B D10 9 DC Output D D10 9 AC Output R D10 9 Regulator Harness Plug Identification D10 9 Alternator Speci...

Page 232: ...10 18 Regulator Bypass Test Amp Rating D10 19 BENCH TESTING D10 20 Equipment D10 20 Identification Record D10 20 Advanced Troubleshooting D10 20 Bench Test 1 No Load Test D10 20 Bench Test 2 Full Load Test D10 21 Bench Test 3 Regulator Bypass Test D10 21 STATIC TESTING D10 22 Equipment D10 22 Identification Record D10 22 Regulator Tester D10 22 Check For Shorted Power Transistor D10 22 Circuit Tes...

Page 233: ...dhesive D10 35 Liquid Threadlockers D10 35 Elastoplastic Silicone Resin D10 35 ALTERNATOR EXPLODED VIEW D10 38 ALTERNATOR DISASSEMBLY D10 40 Regulator Removal D10 40 Fan Removal D10 41 Pulley Removal D10 42 Anti Drive End Housing Removal D10 42 Anti Drive End Rotor Removal D10 44 Drive End Housing Removal D10 46 Drive End Rotor Removal D10 52 Field Coil Removal D10 53 Drive End and or Anti Drive E...

Page 234: ...Rotor Installation D10 66 Rotor and Rotor Shaft Installation D10 66 Drive End Housing Installation D10 67 Anti Drive End Rotor Installation D10 71 Anti Drive End Housing Installation D10 72 Regulator Installation D10 75 THERMAL SWITCH D10 76 Removal D10 76 Installation D10 78 SUPPORT STAND D10 78 ...

Page 235: ...d BATTERY During operation the storage batteries function as an electrochemical device for converting chemical energy into the electrical energy required for operat ing the accessories when the engine is off Lead acid storage batteries contain sulfuric acid which if handled improperly may cause serious burns on the skin or other serious injuries Wear protective gloves aprons and eye protection whe...

Page 236: ...t in a voltage regulated system NOTE When washing the batteries ensure the cell caps are tight preventing any cleaning solution from entering the battery cells Acid Levels The addition of acid will be necessary if considerable electrolyte has been lost through spillage Before adding acid ensure the battery is fully charged This is accomplished by putting the battery on a battery charger and taking...

Page 237: ...d 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 ...

Page 238: ...g one stator at each end and a field coil between the stators Drive end housing 9 and anti drive end housing 6 each contain a bearing to support drive and rotor shaft 1 They are attached to each end of the shell assembly by long threaded studs Drive end housing assembly 9 has an area called control housing 2 containing all the required inter nal electrical connections for the alternator It also co...

Page 239: ... or two amp output AC Output R Relay terminal AC current output terminal for the tachometer or for relay use Located on the regulator Regulator Harness Plug Identification Alternator Specifications Volts 28VDC Amps 260 Ground Negative Regulator Steps 4 Regulator Settings 27 5 28 5 28 0 29 0 Weight 29 kg 65 lbs Performance Curve Measurements listed on the curves are for a stabi lized machine at max...

Page 240: ...the housing assembly con taining internal electrical connections of the alterna tor and mounting area for the control unit DC Direct current DC output of the alternator Diode Trio Assembly of three diodes one diode connected to each stator phase tap Used typically to operate as a signaling source once the alternator is rotating to tell the regulator to turn on self energiz ing signal or to provide...

Page 241: ...st be removed to determine true battery voltage and state of charge Voltage B A voltage value obtained when measur ing voltage at the battery positive terminal or alterna tor B terminal Voltage Battery The steady state voltage value as measured with the battery in an open circuit with no battery load This value relates to the battery state of charge Voltage Charge A voltage value obtained when the...

Page 242: ...D10 12 Battery Charging Alternator D10003 07 06 WIRING DIAGRAM FIGURE 10 5 WIRING DIAGRAM ...

Page 243: ...2 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 Heigh...

Page 244: ...nment TESTING GENERAL INFORMATION Troubleshooting Alternator On Truck Most 24 Volt charging system problems can be diag nosed with the alternator installed on the truck oper ating under normal conditions Many problems can be attributed to loose or corroded cable connectors It is essential that all battery charging cables are in satisfactory condition and all connections are clean and securely tigh...

Page 245: ...ion of the battery and the charge voltage reactions NOTE Until electrical system component temperatures stabilize the conditions listed here may be observed during cold start voltage tests a Maintenance type batteries display the fol lowing characteristics 1 Immediately after engine start the sys tem Volts are lower than regulator set point with medium amps 2 Three to five minutes into the charge ...

Page 246: ...nator B termi nal 4 Attach the meters as indicated by Figure 10 7 Measure the voltage and amperage at the alter nator not at the batteries or an intermediate point a Connect the ammeter negative lead to the end of the cable removed in Step 3 Connect the ammeter positive lead to the alternator B terminal b Connect the red lead of a voltmeter to the alternator B terminal and the black lead of the vo...

Page 247: ...the regulator set point and the charge amps remain at the lowest value for 10 minutes 4 If the charging system is not performing prop erly go to the Regulator Bypass test in the next section Table 10 3 AMP VOLTAGE READINGS Amps Volts Diagnosis HIGH LOW Charging system is good Battery is not yet fully charged Wait for charging system to bring to full charge Amps must decrease and Volts must stabili...

Page 248: ...roceed to Step 5 otherwise go to Step 3 3 If the shaft is still not magnetized remove the jumper from the alternator D terminal on the regulator and go to Step 4 4 If the shaft is not magnetized a If connected unplug the alternator to regula tor wiring harness connection b Install a jumper wire from the alternator B terminal to pin F in the wiring harness plug c Momentarily 1 second connect a jump...

Page 249: ...Amp Rating 1 Disconnect alternator to regulator wiring har ness plug 1 Figure 10 9 2 Connect a jumper wire from pin F F terminal in the alternator to regulator harness plug to the alternator B terminal 3 Start the engine and accelerate to high idle 4 Momentarily touch pin A F terminal wiring harness plug to the alternator ground terminal B Observe whether the amps increase or decrease a If the amp...

Page 250: ...normal b The alternator rated output listed on the nameplate within 10 is determined at 5000 rpm Bench Test 1 No Load Test 1 With the battery connected and no electrical load operate the alternator at 5000 rpm 2 Compare the test results to the No Load Test Table 10 5 and take the appropriate action as stated in the table Table 10 5 NO LOAD TEST Amps Volts Diagnosis HIGH LOW Test bench battery is d...

Page 251: ...stated in the table Limit the time the terminal is connected to a few seconds Doing so can protect the charging sys tem from excessive voltage increase Table 10 6 FULL LOAD TEST Amps Volts Diagnosis HIGH LOW The test bench battery is dis charged or defective Allow the battery to charge or replace the battery HIGH NORMAL The charging system is good HIGH HIGH Stop the test The regulator and or field...

Page 252: ...f a regulator tester is not available the regulator can only be tested for a shorted power transistor Check For Shorted Power Transistor 1 Set the DMM to the diode test scale and zero the meter 2 Connect one meter lead to pin A F Figure 10 11 connector socket in the regulator and con nect the other lead to pin C B connector socket in the regulator Observe the meter read ing 3 Reverse the leads and...

Page 253: ...rcuit Expected Reading 1 Ohms Pin C Alt B Terminal Regulator ground circuit 0 ohms 2 Ohms Pin A Pin F Field coil resistance 1 5 0 2 ohms 3 Ohms Pin F Alt B Terminal Insulated OL out of limits 4 Ohms Pin A Alt B Terminal Insulated OL out of limits 5 Diode Test Pin B Alt B Terminal Phase winding and diode 0 7 Volts flow 6 Diode Test Alt B Terminal Pin B Phase winding and diode OL blocking 7 Diode Te...

Page 254: ...ld coil is open b If the meter shows less than 0 5 ohm the field coil is shortened Replace the field coil Field Coil Test 2 Check For Grounded Field Coil 1 Set the digital multimeter DMM to x10K scale Ensure the DMM is zeroed 2 Connect one meter lead to pin A F Figure 10 14 in the regulator harness plug Connect the other lead to the alternator ground B terminal The DMM must show a very high resist...

Page 255: ...bench stator tester follow ing the tester s instructions Before performing tests 1 Check the stator for signs of damage such as burnt insulation or a loose coil 2 Disconnect the phase lead wire from the mount ing terminals Stator Test 1 Check For Stator To Stator Conti nuity 1 Set the DMM to the ohms scale and zero the meter 2 Connect one meter lead to phase lead P1 Fig ure 10 15 connect other met...

Page 256: ...tor is grounded to the shell Replace the stator THERMAL SWITCH TEST If the alternator is not operating properly check the thermal switch This switch is a normally closed NC switch which must have continuity between the wires from the switch Initial Test 1 Disconnect the wiring harness plug from the regulator 2 If necessary remove the cover from the drive end housing 3 Check for continuity between ...

Page 257: ...from the control box on the drive end housing 2 Locate the thermal switch inside the control box 3 Test the two wires from the thermal switch for continuity a If there is no continuity the switch is faulty b If there is continuity there may be a problem with either the alternator or the wiring har ness ...

Page 258: ...re instances residual magnetism can be lost either during an extended period of inactivity shelf time or if the alternator was exposed to a strong external magnetic field Momentarily 1 second connect a jumper wire from the jumper D terminal on the regulator to the B alternator output terminal The alternator must operate normally If not further troubleshooting is required 3 How can voltage regulato...

Page 259: ...e An incorrectly adjusted regulator voltage set point will result in either a con tinuous overcharging or undercharging condition which can affect battery performance and shorten the battery life The highest regulator voltage setting can be used only on vehicles equipped with battery isolators The battery isolators are generally used on vehicles with two or more batteries The isolator set up allow...

Page 260: ...r stator that has electric power only when the alternator is turning and producing power The terminal output is utilized on some applications for rpm or tachometer function This requires a cali bration circuit that relates the alternator shaft speed to the engine speed The output at the R terminal is AC voltage The average voltage output can be mea sured with an ordinary multi meter The R terminal...

Page 261: ...em must be of sufficient gauge for the length of the cable to be able to carry the necessary current within the circuit If the gauge is too small the resulting voltage drop will impair electrical system performance This is a critical issue for the charging system because exces sive voltage drops in the system on the positive or the negative side can prevent the batteries from recharging properly T...

Page 262: ...y before starting this procedure The alternator weighs approximately 32 kg 70 lbs To prevent personal injury it is recom mended that a sling and overhead lifting device be used when removing the alternator 1 Disconnect the battery power a If the truck is equipped with a battery equal izer open the battery disconnect switch to remove power from the system b Remove the battery cables using the follo...

Page 263: ...m the front cover of the belt guard assembly 6 Remove cover 2 7 Use a inch square drive breaker bar to release the tension on automatic belt tensioner 1 Figure 10 22 8 Remove belt 2 Replace the belt if signs of wear or damage are found FIGURE 10 19 GROUND STRAP 1 Ground Strap 2 Sub Frame FIGURE 10 20 GROUND STRAP CONNECTION 1 Ground Strap 2 Cap Screw FIGURE 10 21 BELT GUARD ASSEMBLY 1 Lock Nuts 2 ...

Page 264: ...igure 10 22 and install belt 2 5 Install cover 2 Figure 10 21 using eight lock nuts 1 6 Install ground strap 1 Figure 10 19 to the alternator Tighten ground cable cap screw 2 Figure 10 20 to 15 N m 11 ft lbs If the ground strap cable was removed from the frame reat tach it 7 Install battery cable B to the terminal on alternator 2 Figure 10 18 Tighten the nut to 32 N m 24 ft lbs 8 Connect the batte...

Page 265: ...y solvents or volatiles The standard color is tan The cured adhesive fully meets the requirements of MIL MMM A 132 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 06...

Page 266: ...rol unit cover plates item 6 Torx bit T25 rotor screws item 46 Allen socket wrench 3 mm fan guard item 69 Deep well socket 6 mm nut item 54 Socket 8 mm voltage regulator screws item 38 Socket 9 mm drive end and anti drive end housings lock flange nuts item 14 Socket 11 mm stator wire hex jam nut item 11 Socket 24 mm fan nut item 67 Socket 30 mm pulley nut item 1 Small screwdriver to release socket...

Page 267: ...D10003 07 06 Battery Charging Alternator D10 37 NOTES ...

Page 268: ...D10 38 Battery Charging Alternator D10003 07 06 ALTERNATOR EXPLODED VIEW FIGURE 10 28 ALTERNATOR ...

Page 269: ...er 30 Shell Connector Plug 31 Pin Connector Female 32 Plug Wedge Lock 33 Shell Connector Receptacle 34 Receptacle Wedge Lock 35 Pin Connector Male 36 Harness Wiring 37 Regulator 38 Screw Hex 39 Washer Stainless Steel Bellville 40 Washer Bellville 41 Lock Nut 42 Nut 43 Washer Bellville 44 Bushing Pulley 45 Shaft and Core Rotor Assembly 46 Screw Torx 47 Rotor Assembly 48 Rotor Shaft and Core Assembl...

Page 270: ...revent personal injury 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 Regulator Removal 1 Remove voltage regulator 37 a Disconnect wiring harness 36 from voltage regulator 37 b Remove and save four screws 38 and four Bellville washers 39 using an 8 mm socket 2...

Page 271: ...on for additional information Fan Removal 1 Remove fan guard 68 by removing six Allen head screws 69 using a 3 mm Allen wrench NOTE DO NOT lose the metal portion of grommet washers 70 2 Remove fan 65 by removing nut 67 using an air impact wrench and a 24 mm socket Also remove Bellville washer 66 When removing nut 67 the use of an air impact wrench is recommended 3 Remove and discard spiral ring 50...

Page 272: ... of the pulley may require a three jaw gear puller Anti Drive End Housing Removal 1 Scribe a single mark on side of shell 58 and drive end housing 20 Scribe a double mark on the side of shell 58 and anti drive end housing 64 This will ensure the proper reassembly of the end housings FIGURE 10 35 50 Spiral Ring 65 Fan FIGURE 10 36 1 Nut 2 Washer 49 Woodruff Key FIGURE 10 37 20 Drive End Housing 58 ...

Page 273: ... positioning the alternator to prevent personal injury 2 Position the alternator in the support stand with the anti drive end facing up 3 Remove and discard nine lock flange nuts 14 from anti drive end housing 64 using a 9 mm socket 4 Remove anti drive end housing 64 from shell 58 NOTE Removal may require the use of a three jaw gear puller FIGURE 10 38 FIGURE 10 39 FIGURE 10 40 14 Lock Flange Nuts...

Page 274: ... discard spiral ring 50 from carrier ring 51 Anti Drive End Rotor Removal 1 Remove one Torx screw 46 using a number T25 Torx bit Scribe a mark on the face of the rotor at the center of the screw hole This will be used to correctly position the rotor during assembly FIGURE 10 42 63 O Rings 64 Anti Drive End Housing FIGURE 10 43 48 Rotor Shaft 51 Ring Carrier 62 Bearing FIGURE 10 44 50 Spiral Ring 5...

Page 275: ...loosen rust use an air chisel with a rounded point hammer bit to vibrate the area between screw holes on the rotor face 4 Thread three screws 46 into the puller holes Tighten the screws evenly to start removing rotor 47 from rotor shaft 48 Threaded screws 46 may not be long enough to completely remove rotor 47 from the rotor shaft If necessary use a three jaw gear puller to completely remove the r...

Page 276: ...hell 58 This mark will be used during the assembly pro cess to correctly align the two parts 1 Position the support stand so the large diameter hole is facing up 2 Place the alternator in the support stand with the drive end facing up 3 Remove cover plate 7 by removing six Torx screws 6 using a number T20 Torx bit FIGURE 10 50 FIGURE 10 51 FIGURE 10 52 FIGURE 10 53 6 Screw 7 Cover Plate ...

Page 277: ... 55 and insulators 13 5 Mark the location of the six phase leads for proper reassembly Place a different identifica tion mark on both the housing and each phase lead terminal 6 Remove and discard nine lock flange nuts 14 using a 9 mm socket FIGURE 10 54 11 Hex Jam Nuts 20 Drive End Housing FIGURE 10 55 12 Flat Washers 13 Insulators FIGURE 10 56 FIGURE 10 57 14 Lock Flange Nuts 20 Drive End Housing...

Page 278: ...ive Torx screws 6 from control unit cover 21 using a T20 Torx bit Remove control unit cover 21 9 Carefully pull out and disconnect plug 30 from receptacle 33 by releasing the lock and dis connecting the gray plug assembly 10 Remove orange wedge lock 32 FIGURE 10 58 FIGURE 10 59 6 Screw 21 Control Unit Cover FIGURE 10 60 30 Plug 33 Receptacle FIGURE 10 61 30 Plug 32 Wedge Lock ...

Page 279: ...ld coil leads 13 Pull the field coil leads through the opening in the drive end housing 14 Lift drive end housing 20 along with rotor 47 and rotor shaft 48 off of shell assembly 58 This may require two people one to lift the housing and the other to guide the phase leads out of the housing FIGURE 10 62 FIGURE 10 63 20 Drive End Housing 30 Plug FIGURE 10 64 FIGURE 10 65 20 Drive End Housing 47 Roto...

Page 280: ... housing 16 Remove spiral ring 5 from pulley bushing 4 and discard 17 Place drive end housing 20 into a hydraulic press with the outer surface of the housing sup ported by the press table FIGURE 10 66 4 Pulley Bushing 20 Drive End Housing FIGURE 10 67 4 Pulley Bushing 75 Expandable Pliers FIGURE 10 68 4 Bushing 5 Spiral Ring FIGURE 10 69 20 Drive End Housing 77 Hydraulic Press ...

Page 281: ...ner ring 20 Remove flat retainer ring 10 using heavy duty internal snap ring pliers Save the ring 21 Place the drive end housing face down on a hydraulic press with the outer surface of the housing supported by the press table FIGURE 10 70 9 Front Bearing 48 Rotor Shaft FIGURE 10 71 8 Beveled Retainer Ring 9 Front Bearing FIGURE 10 72 10 Flat Retainer Ring 9 Front Bearing FIGURE 10 73 ...

Page 282: ...mark on the face of the rotor at the center of the screw hole This will be used to correctly position the rotor during assembly The rotor retaining screws have been installed with a thread lock compound Loctite DO NOT use air impact tools to remove screws 46 Use only hand tools to carefully remove these screws Using air tools can cause the screws to break resulting in damage 3 Remove remaining fiv...

Page 283: ...ning screws 53 have been installed with a thread lock compound Loctite DO NOT use air impact tools to remove screws Use only hand tools to carefully remove these screws Using air tools can cause the screws to break resulting in damage 4 Reposition the alternator in the support stand with the drive end facing up 5 Permanently mark the letters DE on the surface of field coil 60 in the location of th...

Page 284: ...il will be installed mark the letters in the same location and orientation from Steps 2 and 5 on the new replacement field coil 9 Carefully remove the field coil from the stator The clearance between the field coil and stator is minimal Use caution during the removal pro cess As the field coil is removed ensure the two field coil leads are removed without dam age NOTE In some instances removal of ...

Page 285: ...upport stand with the anti drive end facing up 4 Permanently scribe or etch a single mark aligned with the center of two stud holes across the top surface of anti drive end stator 59 and end of shell 58 Repeat at an adjacent hole A single scribe mark identifies the stator as the drive end stator The double mark identifies the stator as the anti drive end stator It is critical that these marks be p...

Page 286: ...r with the anti drive end phase leads behind them 8 Position the shell in the support stand with the faulty stator in a downward position Place sta tor installation removal tool XA3320 on top of the tabs of the stator being removed Ensure the recessed portion of the tool is fully engaged with the stator tabs Ensure the stator installation removal tool is engaged with the stator tabs of the part be...

Page 287: ...re assembly All electrical wiring connections are coated with a Dow Corning 1 2577 low VOC RTV coating or equivalent DO NOT use a coating containing acetic acid vinegar smell on any electrical com ponents Using any other coating will cause part damage 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 inc...

Page 288: ...mbly 3 Align the two scribed marks on the stator with the scribed marks on shell 58 It is critical that these scribed marks be carefully aligned If the marks are not precisely aligned the wiring and the mounting holes will not properly align 4 Insert six alignment studs through the holes in anti drive end stator 59 aligning them with the holes in drive end stator 56 5 Place the shell with the stat...

Page 289: ...e anti drive end stator is already installed in the shell and a new drive end stator is being installed 1 Precisely transfer the scribed assembly mark from faulty drive end stator 56 to the replace ment stator 2 Place the stator in the opening of the shell 3 Route three anti drive end stator phase leads through the corresponding spaces between the drive end stator windings NOTE There are two metho...

Page 290: ...ive end stator is pressed in place If the insulation sleeves are damaged or not installed properly excessive damage can be caused to the alternator when current is pro duced during operation 4 Place the stator in the opening of the shell Pre cisely align the scribed mark It is critical that this scribed mark be carefully aligned If the mark is not precisely aligned the wiring and the mounting hole...

Page 291: ...with end of shell 58 when fully installed 8 Remove the shell and stator assembly from the press Remove the installation tool Remove the six alignment studs NOTE Precisely align the alignment marks on both stators and the shell If they are not aligned remove the stator s and reinstall 9 Install nine studs 61 through stators 56 and 59 Install the studs from the anti drive end of the alternator with ...

Page 292: ...faulty field coil to the corresponding locations on the replacement field coil 1 Position shell 58 on the support stand with the drive end facing down 2 Align the letters ADE on the field coil with the non tabbed portion of the stator and route the two field coil leads through the corresponding space between the stator windings NOTE New field coils do not have terminal pins installed on the leads ...

Page 293: ...e stator tabs are vertically aligned 4 Place field coil removal installation tool XA3320 on top of the field coil 5 Engage the recessed areas of the tool with the field coil bobbin ears Rotate the tool clockwise approximately five degrees to engage the field coil with the stator tabs Ensure the letters ADE are now aligned with the non tabbed area of the stator 6 Install eight field coil screws coa...

Page 294: ... 2 N m 20 in lb DO NOT install a screw in the marked hole because there is no corresponding stator tab If installed the screw will fall into the stator cavity damaging internal parts during operation Drive End Bearing Installation 1 Install flat retainer ring 10 into the drive end housing as shown using heavy duty internal snap ring pliers Fully support the housing before pressing the bearing into...

Page 295: ...acing up 4 Lubricate the spiral ring with Komatsu grease XA3401 Wind new spiral ring 5 into the groove around pulley bushing 44 5 Compress spiral ring 5 and install pulley bush ing assembly into the inside bore of the drive end housing Position the thickest flange of the pulley bushing facing up towards the inside of the alternator FIGURE 10 112 9 Front Bearing 20 Drive End Housing FIGURE 10 113 8...

Page 296: ...Shaft Installation 1 Press rotor and rotor shaft assembly 47 48 into drive end housing 20 a Place the rotor and rotor shaft assembly into a hydraulic press with the rotor shaft fully supported b Place drive end housing 20 onto rotor shaft 48 c Press the drive end housing onto the rotor shaft Press the housing onto the shaft using a bearing driver which will press against the inner bearing race Whe...

Page 297: ...drive end housing are properly aligned 3 As the drive end housing is installed guide the two field coil leads and the six stator phase leads through the proper openings in the drive end housing NOTE If necessary install new terminal ends on the wires On the stator phase leads cut the wires to length strip the correct amount of wire insulation install insulating sleeves over the wires and solder on...

Page 298: ...the stator phase lead studs 6 Place the stator phase leads onto the stator phase lead studs and install new hex jam nuts 11 Tighten the nuts to 3 N m 30 in lb Position the insulation sleeves on the stator phase leads over the arm of each terminal ring to avoid a possible short circuit FIGURE 10 122 14 Lock Flange Nuts 61 Studs FIGURE 10 123 12 Flat Washer 13 Insulator FIGURE 10 124 11 Jam Nuts 20 ...

Page 299: ...lley bush ing assembly 4 into the outside of drive end housing 20 Position the thickest flange of the pulley bushing facing up towards the outside of the alternator 9 Guide the two field coil leads through the open ing in the drive end housing and into the control housing FIGURE 10 125 4 Pulley Bushing 5 Spiral Ring FIGURE 10 126 4 Pulley Bushing Assembly 5 Spiral Ring 20 Drive End Housing FIGURE ...

Page 300: ... the plug assembly corresponds to the white wire in the receptacle assembly Ensure the red wire corresponds with the black wire 11 Connect plug assembly 30 with receptacle assembly 33 12 Apply Dow Corning 1 2577 low VOC RTV or equivalent onto all electrical connections Also seal the opening where the field coil leads enter the control unit FIGURE 10 128 30 Plug Assembly 32 Wedge FIGURE 10 129 30 P...

Page 301: ...y thread lock compound Loctite with five Torx screws 6 using a T20 Torx bit Tighten to 3 N m 30 in lb Anti Drive End Rotor Installation 1 Reposition the alternator in the support stand with the anti drive end facing up 2 Install anti drive end rotor 47 onto shaft assembly 48 Align the previously scribed mark on the face of the rotor with the center of the screw hole FIGURE 10 131 6 Screws 7 Cover ...

Page 302: ... cen tered with the screw hole Apply thread lock compound Loctite install the screw Tighten to 7 N m 65 in lb Anti Drive End Housing Installation 1 Lubricate the spiral ring with Komatsu grease XA3401 Wind new spiral ring 50 into the groove of carrier ring 51 2 Install two new O rings 63 in anti drive end housing 64 FIGURE 10 135 46 Screw 47 Rotor FIGURE 10 136 46 Screw 47 Rotor FIGURE 10 137 50 S...

Page 303: ...y thread lock compound Loctite 222 and install nine new lock flange nuts 14 Tighten to 5 N m 45 in lb in an alternating pattern 6 Install anti drive end bearing 62 over the rotor shaft Place the shell assembly into a hydraulic press Press the bearing into the bore of anti drive end housing 64 until it is completely seated against the pulley bushing FIGURE 10 139 50 Spiral Ring 51 Carrier Ring Asse...

Page 304: ...50 into the groove around fan 65 9 Install the fan onto the rotor shaft with Bellville washer 66 and nut 67 Use an air impact wrench and a 24 mm impact socket to tighten the nut to 6 N m 50 ft lb 10 Install fan guard 68 Apply thread lock com pound Loctite Install Allen head screws 69 using a 3 mm Allen socket wrench Tighten the screws to 7 N m 65 in lb NOTE Verify the metal grommet washers are sti...

Page 305: ...back side of the regulator to the correct position NOTE The setting of this switch can depend on the type of battery being used Refer to Battery in this chapter for additional information 2 Place the regulator on the alternator Install four screws 38 with Bellville washers 39 using an 8 mm socket Tighten the screws to 8 N m 70 in lb 3 Connect wiring harness 36 to voltage regula tor 37 FIGURE 10 14...

Page 306: ...f desired disconnect field coil plug 30 from receptacle 35 This will provide additional clearance when removing the thermal switch 3 Remove the plastic tie strap securing the wires together 4 Remove all the sealant from around thermal switch 22 FIGURE 10 150 36 Wiring Harness Plug 37 Voltage Regulator FIGURE 10 151 6 Screws 21 Control Unit Cover 26 Stud Assembly FIGURE 10 152 FIGURE 10 153 22 Ther...

Page 307: ...er 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 7 Remove thermal switch 22 a Reposition the two insulation sleeves to expose the wiring connections b Remove the heat shrink insulation from both wiring connections c Unsolder each wire from the wiring terminal sleeves FIGURE 10 15...

Page 308: ...coated with a Dow Corning 1 2577 low VOC RTV coating or equivalent DO NOT use a coating containing acetic acid vinegar smell on any electrical com ponents Using any other coating will cause part damage 6 Coat the thermal switch connection with Dow Corning 1 2577 low VOC RTV coating or equivalent 7 Secure the wires together using a plastic tie strap 8 Apply Dow Corning 1 2577 low VOC RTV coating or...

Page 309: ...EMS D11 7 Fault Codes D11 7 Machine History D11 7 VHMS History D11 7 Snapshots D11 8 Manual Snapshots D11 8 Trends D11 10 Histogram Load Map Data D11 10 Haul Cycle Data D11 11 Alarm and Snapshot Triggers D11 12 Satellite Features D11 12 VHMS DIAGNOSTIC FEATURES D11 14 Fault History D11 14 VHMS LED Digits D11 14 VHMS CONTROLLER D11 14 Removal D11 15 Installation D11 15 ORBCOMM CONTROLLER D11 16 Rem...

Page 310: ...D11 2 VHMS COMPONENTS D11005 NOTES ...

Page 311: ...into usable formats and record into permanent memory 3 Communicates data to off board systems a Satellite OrbComm b Laptop Personal Computer PC Download NOTE The electric drive system does provide a limited number of faults to the interface module Refer to VHMS Troubleshooting else where in this section for a complete listing of fault codes generated by the drive system Convert and Record Data VHM...

Page 312: ...nd requests a data download All VHMS data is available for download to a laptop PC Once down loaded to a laptop PC the information is then sent to Komatsu via FTP This data is then compiled at the Komatsu computer server Based on this information the local Komatsu distributor will suggest improve ments and provide information aimed at reducing machine repair costs and downtime In order to collect ...

Page 313: ...er is connected directly to the bat tery circuit which provides a constant 24 volt signal from the truck batteries However the VHMS control ler has the ability to turn itself off and will do so auto matically within three minutes after the key switch is turned off The battery disconnect switch located at the truck battery box will remove 24 volt power from the VHMS controller and cause the VHMS co...

Page 314: ...f Do not remove 24 volt power from the VHMS con troller unless the red LED digits on the VHMS controller are off Downloading from the VHMS Controller Downloading data requires a laptop PC running Win dows 95 98 2000 ME XP operating system the VHMS Technical Analysis Toolbox software and a serial cable to connect the laptop PC to the VHMS controller Refer to the VHMS Technical Analysis Tool Box ins...

Page 315: ... fault codes will send data to WebCARE and which ones trigger a snapshot Machine History The VHMS controller maintains a history of the most recent 400 Key ON and Engine ON conditions VHMS History The VHMS controller maintains a history of the most recent 400 VHMS configuration changes The VHMS controller will record a history entry each time one of the following configuration changes occurs 1 Cha...

Page 316: ...time the VHMS controller will record the snapshot for the first earliest fault occurrence The only exception is the manual snapshot button in which case the VHMS controller will record the latest most recent snapshot Refer to Table 3 for all the items that are recorded in each snapshot Manual Snapshots A manual snapshot is taken by pressing the data store button 1 Figure 11 5 located at the rear o...

Page 317: ...er Engine Oil Temperature Cummins CENSE Controller Fuel Rate Cummins QUANTUM Controller Boost Pressure Cummins QUANTUM Controller Blow by Pressure Cummins QUANTUM Controller Vehicle Speed PLM III Sprung Weight PLM III haul cycle State PLM III Brake Pressure Interface Module Hoist Pressure 1 Interface Module Hoist Pressure 2 Interface Module Steering Pressure Interface Module Front Left Brake Oil T...

Page 318: ...ne load maps are maintained in the VHMS controller The Permanent Load Map contains load map data for the life of the engine The Temporary Load Map contains load map data since the most recent memory clear action Although the engine data is sampled every 100ms internally the histograms are only updated every two hours Table 3 Trend Data Data Item Data Source MAX AVG MIN Model Notes Engine Coolant T...

Page 319: ...g summary period but excluded from the statistics Average Carried Load Average Gross Payload Standard Deviation of Carried Load Standard Deviation of Gross Payload Number of Loads Over Rated Number of haul cycles with carried load rated payload for this truck Number of Loads Over 110 Number of haul cycles with carried load 110 of rated payload for this truck Number of Loads over 120 Number of haul...

Page 320: ...t for data is received via the satellite network Continued Table 5 Alarm and Snapshot Triggers VHMS Fault Code VHMS Fault Description Source Sent via OrbComm Snapshot Trigger Model Notes A018 RR Flat Cylinder Warning PLM III X 830E AC A019 LR Flat Cylinder Warning PLM III X 830E AC A101 Pump Filter Switches IM X 830E AC A107 Propel System Caution IM X 830E AC A108 Propel System Temp Caution IM X 8...

Page 321: ...94 OEM Temp Failed Low Engine X All C00296 OEM Pressure Out of Range Engine X X All C00297 OEM Pressure Failed High Engine X All C00298 OEM Pressure Failed Low Engine X All C00473 Remote Oil Level Signal Invalid Engine X X All C00555 High Blow by Pressure Engine X X All C00639 Intake Air Leak LBR Engine X X All C00641 High Exh Temp 1 LB Engine X All C00642 High Exh Temp 2 LB Engine X All C00643 Hi...

Page 322: ...tinuously at a rate of 10 numbers per second For a complete listing of all the error codes refer to the VHMS Troubleshooting and Checkout Procedures in this section The VHMS controller also has two red LED lights 10 and 11 Figure 11 6 Light 10 PLM III communication OFF no communication with the PLM III controller ON is communication with the PLM III controller Light 11 OrbComm OFF no communication...

Page 323: ...on 1 Install the new VHMS controller and connect the wiring harnesses to it Connect the laptop PC to the VHMS controller with the serial cable 2 Connect battery power Turn the key switch ON but do not start the engine 3 With the VHMS Setting Tool software enter the Service ID and choose the Save Load func tion 4 From the file menu select Load 5 Capture a screen shot Alt and Print Screen keys at th...

Page 324: ...tion form and send it to Komatsu as instructed on the form Failure to submit the form to Komatsu will prevent machine data from being sent to the Komatsu computer center NOTE The new controller should come with a special Orbcomm Terminal Activation form that includes space to list the failed controller serial number and new controller serial number Komatsu must have this information to maintain ac...

Page 325: ...lation 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 5 Run the flashburn program to install the operat ing system into the interface module Make sure the correct...

Page 326: ...Sensors Four pressure sensors Figure 11 10 have been added to the truck to monitor various hydraulic cir cuits The four circuits are both inlets to the hoist valve steering supply circuit front brake apply circuit The hoist pressure sensors are both located right at the inlet of the hoist valve The front brake apply pressure sensor is located in the brake circuit junc tion block in the hydraulic c...

Page 327: ...NTROLLER D12 4 INTERFACE MODULE D12 4 FLASHBURN PROGRAM D12 4 Installation D12 4 INTERFACE MODULE APPLICATION CODE D12 4 Installation D12 4 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM D12 5 Installation D12 5 Using The Program D12 5 VHMS SOFTWARE D12 5 VHMS TOOL BOX D12 5 Installation D12 5 VHMS SETTING TOOL D12 5 Installation D12 5 VHMS INITIALIZATION PROCEDURE D12 6 ...

Page 328: ...7 Machine Information Setting 2 D12 7 Date Time Setting D12 7 GCC Setting D12 8 Setting Summary D12 8 2 VHMS SNAPSHOT PROCEDURE D12 9 3 VHMS DOWNLOAD PROCEDURE D12 10 4 LOCATION OF DOWNLOAD FILES D12 10 5 VHMS FTP UPLOAD PROCEDURE D12 11 6 VHMS INITIALIZATION FORMS D12 12 WHEN REPLACING A VHMS CONTROLLER D12 13 To Set Date Time Satellite Payload Meter D12 15 Review Setting Information D12 17 ...

Page 329: ...system Komatsu Distributor Version 3 06 00 00 VHMS Setting Tool To initialize VHMS system Komatsu Distributor 1 1 0 0 Install exe Interface Module Realtime Data Moni tor Software Version 1 1 0 0 Install exe Use to watch inputs and outputs in the inter face module Komatsu Distributor EJ3055 2 exe Flashburn Software To install application code in interface module Komatsu Distributor EM2126 0 exe 830...

Page 330: ...the Flashburn program 4 Follow the on screen prompts to install the pro gram INTERFACE MODULE APPLICATION CODE Installation The application code is truck specific software that is installed into the interface module Application code is installed using the Flashburn program 1 Using a laptop PC save the application code files to a folder on a local hard drive such as C temp 830E AC File name is EM21...

Page 331: ...Installation 1 Insert the CD The VHMS Technical Analysis Tool Box software will begin installing automati cally 2 Accept the recommended defaults and finish installing VHMS Technical Analysis Tool Box 3 Double click on the new icon on the desktop VHMS Technical Analysis Tool Box 4 Initialize the software by inserting the Set Up Disk 5 Enter the User Name The User Name is user 6 Enter the Password ...

Page 332: ...o be initialized NOTE The interface module must be fully operational before initializing the VHMS controller The initialization procedure consists of the following 1 VHMS Controller Setup Procedure 2 VHMS Snapshot Procedure 3 VHMS Download Procedure 4 Location Of Download Files 5 VHMS FTP Upload Procedure 6 VHMS Initialization Forms 1 VHMS CONTROLLER SETUP PROCEDURE VHMS Setting Tool software prog...

Page 333: ...Information Settings are correct If not enter the correct settings Then click Next Machine Information Setting 2 5 Verify that the Machine Information Settings are correct If not enter the correct settings Then click Next Date Time Setting 6 Enter the correct Time Zone Date and Time Check DST Summer Time if the machine s location uses Daylight Savings Time Then click Next ...

Page 334: ...de The GCC code tells machines equipped with Orbcomm which satellite ground station to use Then click Next Setting Summary 8 Verify that all the setting information is correct and click Apply 9 Click YES 10 Click OK 11 Click OK The VHMS Setting Tool program will close ...

Page 335: ... illuminate 3 While the manual snapshot is being taken operate the machine a Operate the engine at high and low idle b Raise the dump body to the full dump posi tion c Lower the dump body to the frame then hold it in the power down position momentarily d Turn the steering wheel to full left then full right against the stops momentarily e Travel forward to maximum speed and apply the brakes hard f ...

Page 336: ...e one to ten minutes Generally if there are several snapshots in the download items the download will take longer 14 Click the OK button to complete the download 15 Verify that the Download Completed message is displayed Click on Exit 16 Select the Machine History option from the list on the left side of the screen 17 Verify that the key ON OFF and engine ON OFF records are recorded correctly 18 E...

Page 337: ...l Box on this laptop PC only In order to make this data available to others it must be sent to an online database named WebCARE Once the data has been uploaded ftp d to WebCARE it is accessible to anyone with an internet connection and an ID and password VHMS Technical Analysis Tool Box is used to per form the ftp upload Perform an ftp upload as soon as the person who performed the download can ob...

Page 338: ...Make Sending File button NOTE The compressed sending file will look similar to this file name and will always end with a K P_830E_ _A30761_1105208857 K 7 After selecting the correct file to send click the Send FTP button 8 Click the Yes button to verify that you want to upload the data to WebCARE 9 If the sending file was uploaded successfully the file will appear in the OK window If the sending f...

Page 339: ...e steps below when using the VHMS Setting Tool software to save the data and settings so they can be transferred from the old controller to the new control ler 1 Select the When VHMS Needs To Be Replaced function 2 Select the Save current setting before replace ment of VHMS controller function 3 Click the Save button 4 Click the OK button 5 Replace the VHMS controller as described elsewhere in thi...

Page 340: ...owing is the data to be loaded and then click the Next button 8 If the correct data is not showing click the Select File button and choose the correct data Then click the Next button 9 Enter the correct Time Zone Date and Time information Check DST Summer Time if the machine s location uses Daylight Savings Time Click the Apply button ...

Page 341: ... Click the OK button The Setting Tool Program will close To Set Date Time Satellite Payload Meter Date Time Satellite Payload Meter 1 Select the VHMS Setting function then click the Next button 2 Select the Set up only function then click the Next button ...

Page 342: ...f not correct set the correct Time Zone Date and Time to current time zone date and time Be sure to select DST Summer Time if it applies Click the Apply button 5 Satellite Select the correct country location from the drop down menu then click the Apply button to change the setting 6 Payload Meter Set Start Time to 0 and Inter val to 1 Then click the Apply button to save the setting ...

Page 343: ...n and then click the Next button 2 Review the settings for accuracy If something is not correct click the Back button select the appropriate category and reset the information to the correct settings If everything is correct click the Exit button 3 Click the Yes button to close the Setting Tool Program ...

Page 344: ...D12 18 VHMS SOFTWARE D12004 NOTES ...

Page 345: ... The Interface Module D13 9 VHMS CONTROLLER CHECKOUT D13 10 VHMS Controller D13 10 Necessary Equipment D13 10 Preliminary D13 11 VHMS Controller Checkout Procedure D13 12 ORBCOMM CONTROLLER D13 14 TROUBLESHOOTING D13 14 Communications Networks D13 14 Coaxial Cable D13 14 FAULT CODES D13 15 Fault History D13 15 VHMS LED Display Fault Codes D13 16 Chassis Fault Codes D13 17 Engine Fault Codes D13 20...

Page 346: ...D13 2 VHMS CHECK OUT TROUBLESHOOTING D13004 NOTES ...

Page 347: ...ewhere in this section Structure and Purpose This checkout procedure is in two parts The first part verifies that the interface module is in good working condition The second part verifies the VHMS con troller operation and also reviews the settings for accuracy The interface module should already have the appli cation code installed If not refer to the VHMS Soft ware procedures for Installing App...

Page 348: ...ns regarding the VHMS Initialization Procedure The initialization procedure and form must be completed before the truck can be put into service Necessary Equipment Checkout procedure System schematic Laptop personal computer PC VHMS Technical Analysis Toolbox software VHMS Setting Tool software Interface Module Real Time Data Monitor software Serial cable RS232 male DB9 connector on one end female...

Page 349: ...he interface module If any are found these circuits should be analyzed to determine the cause of the fault and repaired c Confirm that there are no fault codes associ ated with the communications between PLM III engine controller interface module drive system controller or the Orbcomm controller If any are found these circuits should be analyzed to determine the cause of the fault and repaired Che...

Page 350: ... change one to zero 3 Reduced Retard IM2 R short wire 76LR to ground at TB28 D momentarily and confirm state change one to zero 4 Propel System Temp Caution IM3 A short wire 34TW to ground at TB26 B momentarily and confirm state change one to zero 5 Lamp Test IM2 R actuate lamp test switch and confirm state change zero to one 6 Low Steering Precharge IM2 W short wire 33KL to ground at TB44 P momen...

Page 351: ...one to zero 9 Propel System Caution IM2 t short wire 79W to ground at TB26 D momentarily and confirm state change one to zero 10 Reduced Propel System IM3 B short wire 72LP to ground at TB25 W momentarily and confirm state change one to zero 11 Park Brake Set IM2 M disconnect park brake pressure switch in brake cabinet at CN240 momentarily and confirm state change toggles continually zero to one F...

Page 352: ...re gauge can be installed in the hydraulic circuit to compare system pressures with the pressures displayed in the Interface Module Real Time Data Monitor program Verify that the used analog inputs are in the range of the values listed below 1 Truck Speed kph IM1 gh Use GE DID to simulate vehicle speed and confirm reported speed matches vehicle speed set using GE DID 2 kph 2 Steering Pressure kPa ...

Page 353: ...onfirm that the park brake solenoid remains energized Reduce the truck speed to 0 kph Confirm that the park brake solenoid de energizes 2 Connect circuit 52B at TB35 L to 24 volts and confirm that the Battery Charger Failure lamp energizes 3 With circuit 52B at TB35 L still shorted to 24 volts confirm that the IM Warning lamp ener gizes 4 With circuit 52B at TB35 L still shorted to 24 volts confir...

Page 354: ...roller operates on 20VDC 30VDC 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 FIGURE 13 6 VHMS CONTROLLER 1 VHMS Controller 2 LED Display 3 Connector CN3B 4 Connector CN3A 5 Connector CN4B ...

Page 355: ... of ten numbers per second 4 Attach the VHMS serial cable to the machine s VHMS diagnostic port 2 Figure 13 3 and the other end to the laptop PC s serial port 5 Double click on the VHMS Technical Analysis Tool Box icon on the computer s desktop 6 Enter the appropriate User Name and Pass word and click the OK button 7 Check for any active fault codes If any are found these circuits should be analyz...

Page 356: ...oller Checkout Procedure 1 Connect the serial cable from the PC to the serial port of the VHMS controller 2 Start the serial communications software Tera Term 3 Setup the serial communications software by selecting the appropriate serial COM port and baud rate equal to 19200 4 After completing the setup wait for 5 seconds then while holding the CTRL key type VHMS Notice that nothing will display o...

Page 357: ...0 Serial No 000000 Compo Name KDE1010 SilkyID VA011740744 NOTE Use the results of step 6 and 7 to confirm that the correct software is installed in the VHMS controller 8 The VHMS controller also has two red LED lights 10 and 11 Figure 13 6 Verify the con nection status and repair any problems Light 10 PLM III communication OFF no communication with the PLM III controller Troubleshoot and repair th...

Page 358: ...ured 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 shiel...

Page 359: ...an electrical connection between the center conductor and the outer shield There are less than two megohms of resistance when measuring from the center conductor to the outer shield FAULT CODES Fault History The fault history recorded in the VHMS controller can help identify a failure within VHMS and in the com munications network to the engine interface module and PLMIII The VHMS system provides ...

Page 360: ...NTUM Alternates n8 and 09 M80A Can net System CENSE Alternates n8 and 0A M901 Source Voltage Error Alternates n9 and 01 M902 VHMS 24V Source System Error Alternates n9 and 02 M903 VHMS 12V Source System Error Alternates n9 and 03 M904 VHMS 5V Source System Error Alternates n9 and 04 M905 Abnormality in VBAT Voltage VHMS VBAT 10V Alternates n9 and 05 M990 Ethernet Power Short Alternates n9 and 90 M...

Page 361: ...al High PLMIII All A6 LR Pressure Sensor Signal Low PLMIII All A7 RR Pressure Sensor Signal High PLMIII All A8 RR Pressure Sensor Signal Low PLMIII All A9 Inclinometer Sensor Signal High PLMIII All A10 Inclinometer Sensor Signal Low PLMIII All A13 Body Up Switch Failure PLMIII All A14 Internal Checksum Failure PLMIII All A16 Internal Memory Write Failure PLMIII All A17 Internal Memory Read Failure...

Page 362: ...3 Reduced Retard Level IM GE 830E AC A124 No Propel Retard IM GE X 830E AC A125 No Propel IM GE X 830E AC A126 Hydraulic Tank Level Low IM X 830E AC A127 IM Sensor 5V Low IM X 830E AC A128 IM Sensor 5V High IM X 830E AC A139 Low Fuel IM 830E AC A152 Starter Failure IM 830E AC A153 Low Battery Voltage Engine Running IM 830E AC A154 High Battery Charge Voltage IM 830E AC A155 Low Battery Charge Volt...

Page 363: ...t Temperature Sensor Low IM 830E AC A212 Bad Truck Speed Signal IM GE X 830E AC A213 Park Brake Not Set When Expected IM GE X 830E AC A214 Park Brake Not Released When Expected IM GE X 830E AC A216 Brake Auto Apply Circuit Fail IM GE X 830E AC A230 Park Brake Request While Moving IM 830E AC A240 IM Key Switch Power Lost IM 830E AC A250 Low Battery Voltage Engine Off IM 830E AC A257 Payload CAN RPC...

Page 364: ...e All C128 RB Boost Ckt Failed High Engine All C129 RB Boost Ckt Failed Low Engine All C131 Throttle Ckt Failed High Engine All C132 Throttle Ckt Failed Low Engine All C133 PTO Circuit Shorted High Engine All C134 PTO Circuit Shorted Low Engine All C135 Oil Pressure Circuit Failed High Engine X X All C136 Pre Filter Oil Press Ckt Failed High Engine All C137 Pre Filter Oil Press Ckt Failed Low Engi...

Page 365: ... Ckt Failed Low Engine All C233 Low Coolant Pressure Engine X X All C234 Engine Overspeed Engine X X All C235 Low Coolant Level Engine X X All C237 Multi Unit Sync Error Engine All C252 Oil Level Signal Invalid Engine All C253 Oil Level Low Engine All C254 FSOV Open Circuit Engine All C259 FSOV Mech Stuck Open Engine All C261 High Fuel Temperature Engine X X All C263 Fuel Temp Ckt Failed High Engi...

Page 366: ...d Rail Press Not Achieved Engine All C473 Remote Oil Level Signal Invalid Engine X X All C487 Ether Bottle Empty Engine All C489 AXG Speed Low Error Engine All C514 Rail Actuator Mech Stuck Engine All C524 Alt Droop SW Val Fault Engine All C527 Dual Output A Shorted High or Open Engine All C528 Alt Torque SW Val Fault Engine All C529 Dual Output B Shorted High or Open Engine All C553 Rail Press OO...

Page 367: ...648 High Exh Temp 8 LB Engine X All C649 Change Lubricating Oil and Filter Engine All C651 High Exh Temp 1 RB Engine X All C652 High Exh Temp 2 RB Engine X All C653 High Exh Temp 3 RB Engine X All C654 High Exh Temp 4 RB Engine X All C655 High Exh Temp 5 RB Engine X All C656 High Exh Temp 6 RB Engine X All C657 High Exh Temp 7 RB Engine X All C658 High Exh Temp 8 RB Engine X All C661 High Power 1 ...

Page 368: ...Engine All C718 High Power 8 RB Engine All C719 Blowby Press Ckt Failed High Engine All C721 Exh Temp Ckt Failed Low 1 RB Engine All C722 Exh Temp Ckt Failed Low 2 RB Engine All C723 Exh Temp Ckt Failed Low 3 RB Engine All C724 Exh Temp Ckt Failed Low 4 RB Engine All C725 Exh Temp Ckt Failed Low 5 RB Engine All C726 Exh Temp Ckt Failed Low 6 RB Engine All C727 Exh Temp Ckt Failed Low 7 RB Engine A...

Page 369: ...r Press Ckt Failed Low Engine All C2157 Rapid Rise in LBR IMT Engine All C2158 Rapid Rise in RBF IMT Engine All C2159 Rapid Rise in RBR IMT Engine All C2241 High IMT LBM Engine All C2242 LBM IMT Ckt Failed High Engine All C2243 LBM IMT Ckt Failed Low Engine All C2244 Rapid Rise in LBM IMT Engine All C2245 High IMT RBM Engine All C2246 RBM IMT Ckt Failed High Engine All C2247 RBM IMT Ckt Failed Low...

Page 370: ...D13 26 VHMS CHECK OUT TROUBLESHOOTING D13004 FAULT TREE ANALYSIS Unable to connect to VHMS from laptop PC ...

Page 371: ...D13004 VHMS CHECK OUT TROUBLESHOOTING D13 27 Flashing Error Code N4 23 PLM III Communications Fault ...

Page 372: ...D13 28 VHMS CHECK OUT TROUBLESHOOTING D13004 Flashing Error Code N4 22 Engine Communications Fault ...

Page 373: ...D13004 VHMS CHECK OUT TROUBLESHOOTING D13 29 No Data Received By WebCARE ...

Page 374: ...D13 30 VHMS CHECK OUT TROUBLESHOOTING D13004 Coaxial Cable Troubleshooting ...

Page 375: ... Forms D14 1 SECTION D14 VHMS FORMS INDEX VHMS FORMS D14 3 VHMS INITIALIZATION CHECK LIST D14 3 VHMS DATA DOWNLOAD D14 4 VHMS INITIALIZATION FORM D14 4 VHMS INITIALIZATION CHECK LIST D14 6 VHMS INITIALIZATION FORM D14 8 ...

Page 376: ...D14 2 VHMS Forms 01 06 D14003 NOTES ...

Page 377: ...mportant to complete these forms and submit them as early as possible after new machine assembly VHMS INITIALIZATION CHECK LIST This form is used as a check list during the initialization process Fill in all information All questions should be answered with a YES If not determine the cause and repair as required Each machine model will have a different VHMS Initialization Check List Use the correc...

Page 378: ...d during the VHMS Initialization Check List procedure 1 Perform a VHMS download For more detailed information on how to perform a download refer to VHMS Download in Section D 24VDC Electrics in the appropriate shop manual 2 Start the VHMS Technical Analysis Tool Box program Use the view feature to look at the data and verify the settings are correct the SMR is correct the manual snapshot is record...

Page 379: ...hould be the time shown in the first data download Verify that it is the correct time Enter the Greenwich Mean Time GMT for the location the machine will be working Check whether the location where the machine will be working uses Daylight Savings Time DST Enter the service meter reading SMR at time of the first download Enter the GCC Code This setting tells the Orbcomm unit which satellite networ...

Page 380: ...egment rotation display to count up 4 Start VHMS Setting Tool program Select VHMS Setting then Set up All clear 5 Initial setup of VHMS controller Machine Information Setting 1 Is Product Group correct Dump truck Is Machine Model correct ex 930E Is Type correct ex 2 Is Variation Code correct ex SE Is Serial Number correct 6 Machine Information Setting 2 Is Engine Model Type correct Is Engine Seria...

Page 381: ... 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 ...

Page 382: ...ion 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 Tran...

Page 383: ...ECTION E ELECTRIC PROPULSION SYSTEM INDEX ELECTRIC PROPULSION SYSTEM COMPONENTS E2 1 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE E3 1 NOTE Propulsion system electrical schematics are located in Section R of this manual ...

Page 384: ...re started THE LINK VOLTAGE LIGHTS MUST NOT BE ILLUMINATED WHEN TEST OR REPAIRS ARE INI TIATED It requires approximately 5 minutes after the truck is shut down before the Link Volt age has dissipated AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR AND ITS CIRCUITS TO DE ENERGIZE Do not attempt to perform Auxiliary Blower Motor or Blower electrical circuit repairs until th...

Page 385: ...ontrol Interface TCI E2 6 Diagnostic Information Display DID Panel E2 7 DID Panel Event Codes E2 7 PSC SOFTWARE FUNCTIONS E2 26 Input Processing E2 26 State Machine E2 26 DC Link State E2 29 Engine Control E2 30 ALTERNATOR FIELD CONTROL E2 30 Desired Three Phase Voltage E2 30 Desired DC Link Voltage E2 30 Self Load E2 31 Propel Torque Control E2 31 Retard Torque Control E2 31 Wheel Slide Control E...

Page 386: ...k E2 34 Event Reset E2 35 SERIAL DATA COMMUNICATIONS E2 35 PSC TCI Communications Processing E2 35 PSC PTU Communications Processing E2 35 Inverter Communications Processing E2 36 OUTPUT PROCESSING E2 36 ABNORMAL CONDITIONS OVERRIDING FUNCTIONS E2 36 Fast Start E2 36 Engine Shutdown Engine Not Running E2 36 Limp Home Mode E2 37 PROPULSION SYSTEM COMPONENT ABBREVIATIONS LOCATIONS E2 38 ELECTRONIC A...

Page 387: ...verter 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 The alternator field is supplied from a tertiary winding on the alternator and is controlled by a silic...

Page 388: ...E2 4 Electrical Propulsion System Components 10 06 E02020 FIGURE 2 1 PROPULSION SYSTEM DIAGRAM ...

Page 389: ...change propulsion system status and control data event data statistical data etc and to receive required truck systems status data Communicate with the TCI to exchange propulsion Portable Test Unit PTU data propulsion real time history diagnostic and parameter data such as software code etc Drive the operator cab status and warning lamps The PSC contains the following internal removable printed ci...

Page 390: ...ure operator control inputs etc Controls the engine start sequence Provides signals to activate many of the cab mounted warning lamps and gauges Controls the parking brake solenoid Processes the front wheel speed signals for the PSC and speedometer The TCI contains the following internal removable printed circuit boards CPU Card Provides high speed communications to PSC and RS232 serial communicat...

Page 391: ...e following pages list the possible event codes which may be displayed on the DID panel when accessed Table 1 describes restrictions to operation of the propulsion and retarding systems when a fault occurs for a particular code listed in Tables 2 3 and 4 Event codes numbered 000 through 099 are applicable to the PSC and are listed in Table 2 Codes numbered 100 through 199 are applicable to Inverte...

Page 392: ...or 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 O...

Page 393: ...maintenance task 09 flash CRC Flash CRC computation did not match expected value 10 BRAM CRC CRC on BRAM does not match expected value 11 excess timeouts On power up excessive timeouts occurred 12 invalid pointers data pack corrupted On power up the status of data in BBRAM is invalid 017 DIGITAL I O CARD FAULT FB104 No power System CPU cannot communicate with digital I O card 018 ANALOG I O CARD F...

Page 394: ...ck Auxiliary speed feedback indicates no or incorrect blower 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 No power A panel connector B C or D is not properly connected 01 CNFB 02 CNI CNX...

Page 395: ...e stall condition has occurred 048 SHORTED DC LINK No power DC link short detected at startup 051 TACH LEFT REAR INV1 disable Input from M1 sensor is out of tolerance 01 zero output with truck moving Zero output from sensor with front wheels moving brake released 02 high output with truck stopped High output from sensor with all other wheel speeds at zero 052 TACH RIGHT REAR INV2 disable Input fro...

Page 396: ...sor 03 afse temp sensor AFSE temperature sensor 04 alternator temp Temperature is out of range 05 left stator temp 06 left rotor temp 07 right stator temp 08 right rotor temp 09 chopper IGBT temp 10 chopper diode temp 11 left IGBT module temp 12 left diode temp 13 right IGBT module temp 14 right diode temp 15 rectifier diode temp 070 LINK CAPACITANCE LEVEL LOW SYS Event Link capacitance level is l...

Page 397: ... Blower out of range 03 aux rpm feedback Rpm feedback does not match rpm command 04 abnormal shutdown A fault occurred during shutdown 087 HP LOW SYS Event Horsepower adjust is at negative limit for 30 seconds 088 HP LIMIT SYS Event Horsepower limit exceeded while in propulsion 089 ENGINE SPEED DOES NOT MATCH COMMAND SYS Event Engine speed feedback does not match commanded speed 02 RPM does not ma...

Page 398: ... Parameter not found 41 multiple par Parameter multiply defined 48 no cam TIC Cam ISR not running 49 no peak samp TIC Peak sample ISR not running 101 201 INVERTER CPU CARD NR INV1 INV2 off 01 Aup cmd not off Phase A up command not off 02 Adn cmd not off Phase A down command not off 03 Bup cmd not off Phase B up command not off 04 Bdn cmd not off Phase B down command not off 05 Cup cmd not off Phas...

Page 399: ...e A volts out of range 70 100 06 volt scale B flt Scale B volts out of range 70 100 07 link V scale flt Link V scale out of range 70 100 08 current scale A flt Scale A current out of range 70 100 09 current scale B flt Scale B current out of range 70 100 10 input V scale fit Input V scale out of range 70 100 11 V test VCO high High frequency on VCO Vtest channel 12 V test VCO low Low frequency on ...

Page 400: ...lt not in tolerance 02 P15V not ok 15 volt not in tolerance 03 N15V not ok 15 volt not in tolerance 06 P24V not ok 24 volt not in tolerance 07 N24V not ok 24 volt not in tolerance 106 206 DC WIRING INV1 INV2 off 01 DC pwr conn open DC power connection is open 02 link V phase V mismatch Link and phase voltage are mismatched 107 207 GDPS FAILURE SYS Event INV1 INV2 off 01 gate dr ps off No power to ...

Page 401: ...oo high while phase A down on 24 B volt lo Aup Phase B volt too low while phase A up on 25 B volt hi Bdn Phase B volt too high while phase B down on 26 B volt lo Bup Phase B volt too low while phase B up on 27 B volt hi Cdn Phase B volt too high while phase C down on 28 B volt lo Cup Phase B volt too low while phase C up on 29 C volt hi Adn Phase C volt too high while phase A down on 30 C volt lo ...

Page 402: ...nce 78 Cph pos I low Phase C positive current low unbalance 79 Aph pos I hi Phase A positive current high unbalance 80 Bph pos I hi Phase B positive current high unbalance 81 Cph pos I hi Phase C positive current high unbalance 82 no current w run No current while running 114 214 INVERTER GENERAL NR None 22 IA VCO lo Low frequency on IA channel 24 IB VCO lo Low frequency on IB channel 26 linkV VCO...

Page 403: ...Phase A current sensor failed 02 IA zero not ok Current IA not zero at startup 03 IA not ok Phase A current too high 04 I snsr ph A open Phase A current sensor open 05 I snsr ph A short Phase A current sensor short 123 223 INVERTER PHASE A VOLTS INV1 INV2 off 01 V sensor phase A Phase A voltage sensor failed 02 VA not ok Phase A voltage too high 125 225 INVERTER PHASE B B INV1 INV2 off 01 alarm B ...

Page 404: ...e 02 Bdn temp short Phase B down thermistor short 03 Bdn temp open Phase B down thermistor open 04 Bdn temp warm Phase B down thermistor warm 05 Bdn temp hot Phase B down thermistor hot 06 Bdn fb not off S Phase B down not off with enable DC volts 130 230 INVERTER PHASE B CURR INV1 INV2 off 01 I sensor ph B Phase B current sensor failed 02 IB zero not ok Current IB not zero at startup 03 IB not ok...

Page 405: ...failed 04 hold CN Phase C positive and negative IGBTs are on negative turn on 05 Cdn fb not on Phase C down feedback is not on 06 Cdn IGBT not on Phase C negative IGBT did not turn on 07 IGBT_PS_CN IGBT protective shutoff 138 238 INVERTER PHASE C NR None 02 Cdn temp short Phase C down thermistor short 03 Cdn temp open Phase C down thermistor open 04 Cdn temp warm Phase C down thermistor warm 05 Cd...

Page 406: ...thermistor short 04 chop B temp open Chop B thermistor open 05 chop B temp warm Chop B thermistor warm 06 chop B temp hot Chop B thermistor hot 07 DB2 fb not off S Chopper 2 not off with DC volts 151 251 MISCELLANEOUS INV1 INV2 off 01 tach differential Too much speed difference 153 253 INVERTER MOTOR INV1 INV2 off 01 motor open Motor connection open 02 motor short Motor connection short 154 254 IN...

Page 407: ...ng message 02 bad tick 03 bad CRC 04 FIFO overflow 05 bad start bit 06 bad stop bit 605 AUX BLOWER COMM FAULT None Lost RS422 communication with auxiliary blower controller while auxiliary blower is in failure mode and DC link is not energized 607 POSITIVE 5 VOLTS Speed limit 5V power supply out of limits 608 POSITIVE 15 VOLTS Speed limit 15V power supply out of limits 609 NEGATIVE 15 VOLTS Speed ...

Page 408: ...Event One of the connected batteries volts are incorrect with engine speed above low idle 01 control battery low Control battery voltage below minimum limit 20 02 control battery high Control battery voltage above maximum limit 32 03 crank battery low Cranking battery voltage below minimum limit 20 04 crank battery high Cranking battery voltage above maximum limit 32 629 BAROMETRIC PRESSURE SIGNAL...

Page 409: ... 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 tr...

Page 410: ...ate will support a variety of activities including Waiting for the engine to start if needed Automatic testing on initial system startup or following rest state Application of power to the DC link Externally initiated testing to clear a fault set temporary variables or for maintenance purposes NOTE The test state may be either powered or unpowered at a given point in time depending on which activi...

Page 411: ...state for the purpose of startup have been completed Transition from Test State to Ready State This transition will occur upon completion of any required testing if the TCI Rest state request is not active and there is sufficient voltage on the DC link Transition to Rest State This transition will occur automatically from the Test or Ready state if a request for Rest state is received from the TCI...

Page 412: ...d b Truck speed is below the set retard speed and acceleration is such that no retard effort is currently required to maintain this condition Transition from Propel State to Retard State This transition will occur if at least one of the following conditions exists Truck speed is such that retard is allowed and the retard pedal or lever is pressed such that a significant amount of retarding effort ...

Page 413: ...oltage is maintained 4 RP contactors open 5 Chopper turn on voltage is set above 600 volts NOTE Before the AFSE is allowed to output firing pulses the RP contactors will be commanded to open and the GF contactor will be verified to be closed The AFSE will not output firing pulses if it is disabled if GFR is dropped out or if the alternator reference signal is 0 De Powering the DC Link The PSC soft...

Page 414: ...rnator output voltage is dependent on the system state The PSC will command an alternator field reference such that the desired DC link voltage or three phase voltage is maintained Desired Three Phase Voltage During all powered states the three phase line to line voltage will not be allowed to drop below 444 volts This is the minimum voltage needed to supply the gate drive power converters During ...

Page 415: ...r stress Horsepower Available The horsepower available will be estimated from the engine speed Parasitic loads are taken into account The torque will be limited so that the engine does not overload Jerk Limit The torque command will be slew rate limited to prevent jerking motion Wheel Spin In the event that the inverters detect a wheel spin condition and reduce torque in the slipping wheel the mot...

Page 416: ...n event abnormal condition The events fall into three detection categories Power On Tests Three power on tests are executed once every time power is applied to the PSC They are as follows CPU Card Checks Upon power up the PSC will confirm the integrity of its CPU card hardware before transferring execution control to the application program residing in its FLASH memory Battery Backed RAM BBRAM Tes...

Page 417: ...e is not active Transitions to restricted states will not be allowed If the system is in a state which becomes restricted it will transition down to the highest unrestricted state The order of the states from lowest to highest is Startup Shutdown Rest Test Ready Retard Propel Transitions to the Test state or lower states in reaction to event restrictions will not be allowed until the truck is not ...

Page 418: ... data packs If a data pack is unfrozen not holding any particular fault data it is continually updated each 100 frames 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 ...

Page 419: ... commands The TCI can issue both hard and soft resets By PTU commands The PTU can issue both hard and soft resets SERIAL DATA COMMUNICATIONS The PSC system CPU card uses serial data busses to communicate with the TCI the PTU and the two inverter CPU cards PSC TCI Communications Processing This software function performs the processing necessary for the PSC to communicate with the TCI The communica...

Page 420: ...his software function processes all external outputs from the PSC Refer to the G E publication System Description for a listing of the PSC outputs ABNORMAL CONDITIONS OVERRIDING FUNCTIONS Software functions given up to this point have assumed that the truck is operating under typical circumstances The following information defines system operation under abnormal or exceptional circumstances In the...

Page 421: ...mp home mode if all of the following conditions are true The truck is not moving The TCI is requesting limp home mode The PSC is in Ready or Test state and there is no initiated testing in progress At least one inverter is functional There are no events active for which limp home mode is not possible If there are any events active for which an inverter must be turned off or cut out before limp hom...

Page 422: ...e 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 re...

Page 423: ...bly Provides voltage and electrical noise isolation for control 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 Ga...

Page 424: ...3 IGBT Phase Modules Provide negative driving voltages PWM or square wave depending on truck speed for each of the three windings of Traction Motor 1 P21A 21B 21C P22A 22B 22C 2 3 IGBT Phase Modules Provide positive driving voltages PWM or square wave depending on truck speed for each of the three windings of Traction Motor 2 P21A 21B 21C P22A 22B 22C 2 3 IGBT Phase Modules Provide negative drivin...

Page 425: ...e 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 ...

Page 426: ...E2 42 Electrical Propulsion System Components 10 06 E02020 FIGURE 2 3 CONTROL CABINET COMPONENTS HIGH VOLTAGE INVERTER AREA ...

Page 427: ...E02020 10 06 Electrical Propulsion System Components E2 43 FIGURE 2 4 CONTROL CABINET COMPONENTS LOW VOLTAGE CONTROL AREA ...

Page 428: ...E2 44 Electrical Propulsion System Components 10 06 E02020 FIGURE 2 5 CONTROL CABINET COMPONENTS CONTACTOR COMPARTMENT ...

Page 429: ...E02020 10 06 Electrical Propulsion System Components E2 45 FIGURE 2 6 CONTROL CABINET COMPONENTS REAR CABINET VIEW ...

Page 430: ...outing and clamp location of the wiring harness Proper wire routing is critical to prevent damage during operation after reinstallation 1 Disconnect the pedal wiring harness from the truck harness connector 2 Remove mounting cap screws lockwashers and nuts and remove the pedal assembly Installation 1 Install the pedal assembly using the mounting cap screws lockwashers and nuts 2 Connect the pedal ...

Page 431: ...d Control Circuit Checks Battery Power ON E3 8 TABLE II Checks with Key Switch OFF E3 9 Checks with Key Switch ON E3 9 CPU Battery Checks E3 9 MEMORY BACKUP BATTERY REPLACEMENT E3 10 TCI PROGRAMMING E3 10 PSC PROGRAMMING E3 11 INVERTER PROGRAMMING E3 11 CPU RESET E3 11 PSC CHECKOUT E3 12 PSC Digital Input Checks E3 12 PSC Digital Output Checks E3 16 TCI CHECKOUT E3 17 Modular Mining Communication ...

Page 432: ...ed Sensor Checks E3 27 Battery Boost Check E3 27 Brake Circuit Switch Checks E3 28 Hoist Steering Circuit Switch Checks E3 28 Link Energized Checks E3 28 Loadbox Test E3 30 TROUBLESHOOTING E3 34 PVM Optimum Load Curve Handshaking Troubleshooting E3 34 Phase Module and Chopper Module Troubleshooting E3 34 PHASE MODULE REPLACEMENT E3 35 Phase Module Removal E3 35 Phase Module Installation E3 35 ...

Page 433: ...qualified technician should inspect the truck and verify the propulsion system does not have dangerous voltage levels present before repairs are started If weld repairs are required the welding ground electrode should be attached as close as possible to the area to be welded NEVER weld on the rear of the Electrical Control Cabinet or the retard grid exhaust air louvers Power cables and wiring harn...

Page 434: ...perform the normal shutdown procedure Normal operation of the drive system at shutdown should allow high voltages to be dissipated NOTE In the event of a system failure performing the following procedure will ensure that no hazardous voltages are present in the drive system SHUTDOWN AFTER SYSTEM FAILURE 1 Before shutting off the engine verify the status of the drive system warning lights on the ov...

Page 435: ...paration and instruction steps are preceded by a number or a letter Procedures requiring visual checks voltage measurements etc are preceded by this symbol PTU keyboard entry steps are preceded by this symbol escape When a keyboard key must be pressed the key label is enclosed in braces PTU screen display information is shown in this type font and preceded by this symbol NOTE The following test pr...

Page 436: ...X VALUE NOTES 11B1 Measure at the 12VDC insulator in the auxiliary control cabinet 11 Measure at the 24VDC insulator in the auxiliary control cabinet 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 11A TB30 The ...

Page 437: ... VOM positive lead on the DC link bus and the VOM negative lead on the DC link bus Resistance should be approximately 1500 ohms 8 Place the VOM positive lead on the DC link bus and the VOM negative lead on the DC link bus Resistance should be approximately 6 ohms Chopper Modules CM1 CM2 9 With the VOM set on the Rx10 000 scale measure the following at each chopper module in the control cabinet GR ...

Page 438: ...r are OFF Power Supply Check PS 2 Remove the CN1 connector on the power supply Use an ohmmeter to check the harness side connector pins to ground Refer to Table II for the resistance value at each pin 3 Check for 1 4K ohms between TB3 K and TB3 L LEM 24V to 24V power supply busses 4 After resistance checks are complete reconnect CN1 connector TABLE II POWER SUPPLY HARNESS RESISTANCE CHECKS Pin Ohm...

Page 439: ...following circuits in the auxiliary control cabinet Voltage at each should be at least 25VDC 71 on TB32 71GE on TB22 7 Verify the specified voltage to ground at the following locations in the auxiliary control cabinet 15VDC at the 15PV wire on TB29 from TCI supply to operator control pedals 15VDC at the 15V wire on TB21 from TCI power to cab gauges 15VDC at the 15SPD 15RWS and 15LWS wires on TB21 ...

Page 440: ...before removal 4 Remove the old battery and install the new battery Make sure that it is positioned for proper polarity Reinstall the screws 5 Install the card in the appropriate panel slot TCI PROGRAMMING Make sure that the link voltage is drained down before servicing the propulsion system or performing tests 1 Connect the serial communication cable from the PTU to the TCI port DIAG3 on the DID ...

Page 441: ...es your truck s wheels Click Open Click Begin Download After the download is complete click Exit when you see Press exit to continue INVERTER PROGRAMMING Make sure that the link voltage is drained down and the engine is not running before performing the following procedures 1 Connect the serial communication cable from the PTU to the top ports on the ICP panel CNG for inverters 11 and 12 CNH for i...

Page 442: ... switch ON To check the PSC digital inputs Click START Programs GEOHVPTU_2 0 AC TOOLS wPTU AC v21 01 Select Normal mode enter Type password ok75e enter Under Real Time double click PSC Real Time Data Verify that the analog values are similar to the example in Figure 3 3 Also make sure that the correct truck ID is at the top of the screen and COMMLINK signal under Modes reads OK The following norma...

Page 443: ...ical Checkout Procedure E3 13 Release 21 Software Close the PSC Real Time Data screen then double click PSC Serial Data Verify that the analog and digital values are similar to the example in Figure 3 4 FIGURE 3 4 PSC SERIAL DATA SCREEN ...

Page 444: ...lts With the retarder pedal fully depressed verify that the RETARD PEDAL signal is approximately 8 5 volts With the retarder lever fully up OFF position verify that the RETARD LEVER signal is approximately 0 volts With the retarder lever fully down verify that the RETARD LEVER signal is approximately 8 75 volts The ENGINE LOAD signal should be either 50 if the PWM load signal is being used or 5 0 ...

Page 445: ...e PSC Analog Inputs screen then double click PSC Temperatures Verify that the temperature values are similar to the example in Figure 3 5 NOTE All temperatures are calculated except for the AFSE and AMBIENT TEMPERATURE values Close the PSC Temperatures screen FIGURE 3 6 PSC TEMPERATURES SCREEN ...

Page 446: ...k can be pushed inward to allow contact closure with the arc chute removed NOTE Do not check CMCTL at this time TABLE III PSC DIGITAL OUTPUT CHECKS STEP OUTPUT DESCRIPTION DEVICE CHECKOUT 1 RP1 RP1 Contactor Verify that RP1 picks up and RP1FB is highlighted 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 a...

Page 447: ... 9600 to the column Selected Baud Sequence Click OK The GE wPTU Toolbox Login Screen Connection Status window should now show Connected to AC TCI 360T DIGBT at 9600 Baud on COM1 This verifies the port communication If the Connection Status window shows Connection to target failed exit the program and restart the PTU TCI Digital Input Checks 1 Connect the serial communication cable from the PTU to ...

Page 448: ...E3 18 AC Drive System Electrical Checkout Procedure 10 06 E03018 Version 21 Software FIGURE 3 7 TCI REAL TIME DATA SCREEN ...

Page 449: ...equest Move the selector lever to the FORWARD position The parking brake will release circuit 52PBO will be 24VDC and circuit 52CS will be 0VDC 10 NEUREQ Neutral Request Move the selector lever to the NEUTRAL position The parking brake will release circuit 52PBO will be 24VDC and circuit 52CS will be 0VDC 11 PRKBRKSW Parking Brake Switch Move the selector lever to the PARK position PRKBRKSW on the...

Page 450: ...eckout Procedure 10 06 E03018 Version 21 Software Close the TCI Real Time Data screen then double click TCI Serial Data Verify that the analog and digital values are similar to the example in Figure 3 8 FIGURE 3 8 TCI SERIAL DATA SCREEN ...

Page 451: ...ed verify that the ACCEL PEDAL signal is approximately 1 5 volts With the accelerator pedal fully depressed verify that the ACCEL PEDAL signal is approximately 8 5 volts With the RSC switch up OFF position and the RSC dial fully counterclockwise verify that the RSC POT signal is approximately 10 7 volts With the RSC switch up OFF position and the RSC dial fully clockwise verify that the RSC POT si...

Page 452: ... TCI Analog Inputs screen then double click TCI Temperatures Verify that the temperature values are similar to the example in Figure 3 10 NOTE All temperatures are calculated except for the AFSE and AMBIENT TEMPERATURE values Close the TCI Temperatures screen FIGURE 3 10 TCI TEMPERATURES SCREEN ...

Page 453: ...ted on the PTU press enter Verify 0 VDC 2 LINKONLT Link Energized Light on the back of the center console will illuminate 3 SPD1 SPD2 not used not used 4 NORETARD No Retard Propel Light will illuminate A5 5 NOPROPEL No Propel Light will illuminate A6 6 PSCNOTRDY Propulsion System Not Ready Light will illuminate C6 7 RESTLT Propulsion System at Rest Light will illuminate B6 8 REDUCELT Propulsion Sy...

Page 454: ... Circuit 21A should remain 0VDC 6 Release the key switch 7 Move the directional control lever to NEUTRAL 8 Turn key switch to START position Circuit 21A should remain 0VDC 10 Release the key switch 11 Move the directional control lever to PARK FIGURE 3 11 STATUS WARNING LIGHTS Row Column Indicator Description Color A1 High Hydraulic Oil Temperature Red B1 Low Steering Pressure Red C1 Low Accumulat...

Page 455: ...the operator cab 2 Make sure that the directional control lever is in PARK and the rest switch is in the REST position 3 Turn control power switch 1 Figure 3 1 and the key switch ON Click START Programs GEOHVPTU_2 0 AC TOOLS wPTU AC v21 01 Select Normal mode enter Type password ok75e enter Under Real Time double click PSC Real Time Data Verify the values in Table VI ERASING EVENTS PSC 1 Connect th...

Page 456: ...ight is present Insert the gray plug 7 Close circuit breaker CB2 on GDPC1 in the right side compartment of the control cabinet 8 Use an analog meter to check the voltage between the pins on the P12A round connector There should be 90 100VDC 9 Open circuit breaker CB2 on GDPC1 Reconnect the round connector to P12A and close circuit breaker CB2 again 10 Carefully remove the gray plug on top of each ...

Page 457: ...cated on the back wall of the operator cab 7 Make sure that the directional control lever is in PARK and the rest switch is in the REST position 8 Turn control power switch 1 Figure 3 1 and the key switch ON Click START Programs GEOHVPTU_2 0 AC TOOLS wPTU AC v21 01 Select Normal mode enter Type password ok75e enter Under Real Time double click PSC Real Time Data Verify that ENGSPD in the Analog fi...

Page 458: ...ssure light low steering pressure light and low brake pressure buzzer should activate Hoist Steering Circuit Switch Checks 9 On the inner side of the fuel tank short circuit 39 on hoist circuit hydraulic filters bypass indicator switch to ground The hydraulic oil filter light in the overhead panel should illuminate 10 At the steering circuit hydraulic filter short circuit 39 on the filter bypass i...

Page 459: ...E03018 10 06 AC Drive System Electrical Checkout Procedure E3 29 Release 21 Software FIGURE 3 12 PSC REAL TIME DATA SCREEN FIGURE 3 13 PSC SERIAL DATA SCREEN ...

Page 460: ...lues and highlighted functions are similar to the TCI Real Time Data screen in Figure 3 15 7 Exit the TCI Real Time Data screen Leave the engine running and the PTU connected to the TCI port for the loadbox test Loadbox Test Verify that the control cabinet doors are closed and locked before performing the following tests DANGEROUS VOLTAGES ARE PRESENT INSIDE THE CONTROL CABINET WHEN THE ENGINE IS ...

Page 461: ...E03018 10 06 AC Drive System Electrical Checkout Procedure E3 31 Release 21 Software FIGURE 3 15 TCI REAL TIME DATA SCREEN FIGURE 3 16 INITIAL SELF LOAD ENGINE TEST SCREEN ...

Page 462: ...pshot then click Save To view the recorded screen under the View menu select Screen Relay the highlight the file and click Open 10 Note the ENGLOAD value on the screen If the value is 5 volts during load testing loading is satisfactory If the value is below 5 volts the electrical system needs to remove horsepower loading This is an indication of a weak engine If the value is above 5 volts the elec...

Page 463: ...E03018 10 06 AC Drive System Electrical Checkout Procedure E3 33 Release 21 Software FIGURE 3 17 TOTAL PARASITIC LOSS AT FULL POWER Komatsu SSDA16V160 27000 GHP ECS 8 Blade 78 dia 5 3 PW 798 RPM ...

Page 464: ...he rest switch OFF Connect the serial communication cable from the PTU to the PSC panel and access the PSC Manual Test screen 2 Click the appropriate GD1E or GD2E signal in the Digital Output field and turn it ON GD1E turns on all Inverter 1 phase modules and chopper module 1 GD2E turns on all Inverter 2 phase modules and chopper module 2 3 Disconnect the gray fiber optic cable on the phase module...

Page 465: ...s 7 Support the phase module and remove the two nuts and washers that secure the phase module to the control cabinet 8 Slide the phase module forward by the extended mounting arms and remove it from the control cabinet Do not pull on the gate card cover Phase Module Installation 1 Inspect the rear cooling air sealing gasket Replace it if damaged 2 Return the phase module to its original location 3...

Page 466: ...E3 36 AC Drive System Electrical Checkout Procedure 10 06 E03018 Version 21 Software NOTES ...

Page 467: ...G01020 Index G1 1 SECTION G DRIVE AXLE SPINDLE AND WHEELS INDEX TIRES AND RIMS G2 FRONT WHEEL HUB AND SPINDLE ASSEMBLY G3 REAR AXLE HOUSING ATTACHMENT G4 REAR AXLE HOUSING G5 ...

Page 468: ...G1 2 Index G01020 NOTES ...

Page 469: ...RIMS INDEX TIRES AND RIMS G2 3 FRONT TIRES AND RIMS G2 3 Removal G2 3 Installation G2 5 REAR TIRES AND RIMS G2 5 Removal G2 5 Installation G2 6 RIM AND TIRE G2 8 Tire Removal G2 8 Rim And Tire Preparation G2 8 Lubricants G2 9 Tire Installation G2 9 ...

Page 470: ...G2 2 Tires and Rims G02022 NOTES ...

Page 471: ...ucts Before storing used tires clean thoroughly and inspect for damage Repair as necessary When a truck is placed in storage it should be blocked to remove the weight from the deflated tires If stored truck cannot be blocked check air pressure and inspect tires twice a month for proper inflation pres sure FRONT TIRES AND RIMS Removal DO NOT weld or apply heat on the rim assembly with the tire moun...

Page 472: ... take up slack Remove wheel nuts 8 Figure 2 1 and wheel retainer lugs 7 securing wheel assembly to wheel hub Remove the clamp that secures the tire inflation valve to the wheel hub Care should be taken not to damage the inflation stem during tire removal 7 Move wheel assembly away from wheel hub and into clean work area Do not attempt to disassemble wheel assembly until all air pressure is bled of...

Page 473: ...checking is no longer required Check intermittently to insure torque is maintained REAR TIRES AND RIMS If the studs in the rear wheel motor require replace ment use a special tool and tighten studs to 540 ft lbs 732 N m torque Removal 1 Park truck on level ground and block front wheels Position a jack in recess of rear sus pension mount casting as shown in Figure 2 3 2 Raise rear axle housing of t...

Page 474: ...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 inner dual Attach tire handler to outer du...

Page 475: ...then loosen all the nuts and re tighten them evenly as shown in Figure 2 7 5 If run out is OK then tighten each nut as shown in Figure 2 7 to 746 N m 550 ft lbs torque 6 Secure inner and outer dual tire inflation lines to bracket on outer rim Tighten cap screws to standard torque 7 Install wheel cover Remove blocks from under truck and lower truck to the ground 8 Operate truck for one load and ret...

Page 476: ...edure until tire bead is free from rim 5 After bead is broken loose insert flat of tire tool in beading notch on lockring 6 Figure 2 8 Pry lockring up and out of groove on rim 6 Pry in on bead seat band 2 until O ring 4 is exposed Remove O ring 7 Remove bead seat band 2 from rim 3 and remove flange 5 8 Reposition wheel assembly and repeat removal procedure on opposite side of tire Remove tire from...

Page 477: ...f lubricant applied per tire should not exceed 50 grams 1 75 oz Tire Installation The preferred method for mounting tires is horizon tally and off of the truck especially for initial tire mounting on a new truck For horizontal tire mount ing a workman s stand is recommended for working inside the tire Similar methods and precautions should be used when mounting tires vertically on the truck NOTE W...

Page 478: ...oy air seal and cause air leaks at these points 6 Install outer flange 5 Figure 2 8 in position and replace bead seat band 2 Push in on bead seat band to expose O ring groove in rim 7 Lubricate new O ring 4 with soap solution and install in groove of rim 8 Install lockring 6 and tap into place with lead hammer Lockring lug must fit into slot of rim 9 Remove valve core from valve stem and inflate t...

Page 479: ...5 Disassembly G3 8 Cleaning and Inspection G3 8 Assembly G3 9 Wheel Bearing Adjustment Tire Removed G3 11 Wheel Bearing Adjustment Tire mounted G3 12 OIL SAMPLING PROCEDURE G3 13 Oil Sampling Guidelines G3 14 Procedure G3 14 OIL DRAIN AND REFILL PROCEDURE G3 14 STEERING CYLINDERS AND TIE ROD G3 15 Spherical Bearing Wear Limits G3 15 Removal G3 16 Installation G3 16 Bearing Replacement G3 16 TOE IN...

Page 480: ...G3 2 Front Wheel Hub and Spindle G03029 NOTES ...

Page 481: ...he accumu lators to bleed down 2 Disconnect brake lines leading to each caliper and main brake supply line 1 Figure 3 1 at the junction block Plug or cap all lines to prevent contamination of the hydraulic system 3 Remove any grease lines being used for a group lube or automatic lube system for the steering cylinder and tie rod Cap all lines 4 Remove cap screws and washers securing brake line junc...

Page 482: ...ructures and high forces are involved in this procedure Use caution at all times when applying force to these parts Sudden release of the spindle could cause components to move forcefully and unexpectedly Refer to Section M Options Special Tools for dimensions for fabricating the spindle pusher tool and the cap screws and washers required Multiple flatwashers may be required under the cap screws t...

Page 483: ...the specified locations carefully tap on the top surface of the spindle until the piston breaks free Note In extreme cases it may be necessary to remove additional steering arm retaining cap screws and use additional pusher cap screws to apply more force 6 With a fork lift supporting the hub and spindle assembly as shown in Figure 3 4 move to clean work area for repair Installation 1 Clean spindle...

Page 484: ...in 12NF tap 7 Install cap screws 5 and tighten to 2705 135 N m 1995 200 ft lbs 8 Install steering cylinder and tie rod in their respective mounting holes on the spindle Tighten retaining nuts to 712 71 N m 525 52 ft lbs torque Connect lubrication lines 9 Rotate the wheel hub to position the fill plug at the 12 o clock position Remove the fill plug and level plug Fill wheel hub assembly at fill hol...

Page 485: ...shers 6 Oil Level Sight Gauge 7 Shims 8 Bearing Retainer 9 Cone 10 O Ring 11 Cup 12 Disc Brake 13 Brake Support 14 Capscrew Flatwasher Nut 15 Capscrew Flatwasher 16 Seal Assembly 17 Spindle 18 Spacer 19 Cone 20 Cup 21 Capscrew Flatwasher 22 Capscrew Flatwasher 23 Brake Disc 24 Oil Drain Plug 25 Bearing Pin Outboard 26 Bearing Pin Inboard 27 Relief Valve ...

Page 486: ...10 and cone 9 If disassembly of the wheel hub is accomplished while on the truck the outboard bearing cone should be supported during wheel hub removal to prevent cone from dropping and being dam aged NOTE Half of the face seal 16 will remain in the bore of the hub Do not remove seal unless replacement is required Use extreme caution when handling face seals Seals must be replaced in a matched set...

Page 487: ...he spindle 6 Install one half of seal assembly 16 on spindle 17 using seal installation tool TY2150 Figure 3 7 and soft tipped mallet For proper installa tion use the following instructions a Handle all parts with care to avoid damaging critical areas The sealing face of seal must not be nicked or scratched b Remove all oil and protective coating from seal and from the seal seat using nonflam mabl...

Page 488: ...hub shoul der as follows 1 Inner Cup 20 Apply 133 450 N 30 000 lbs force 2 Outer Cup 10 Apply 102 300 N 23 000 lbs force 10 Install the other half of the seal assembly 16 in the hub using installation tool TY2150 and soft tipped mallet Follow procedure outlined in step 6 11 Check bearing cone 9 for free fit on the spindle 17 then remove 12 Referring to Figure 3 8 lift the hub and carefully lower i...

Page 489: ...record the depth to the end of the spindle from the face of the retainer plate 1 through each of the two holes 3 in the retainer plate adjacent to the cap screws tightened in step 2 6 Add the two dimensions measured in step 4 and divide the total by 2 to obtain an averaged depth dimension 7 Subtract the dimension stamped on the face of the retainer plate from the average depth estab lished in step...

Page 490: ...plate is removed 5 Install another chain 3 around the bottom half of the tire and tighten enough to prevent move ment during bearing adjustment procedure 6 Drain oil at wheel hub drain plug 24 Figure 3 5 Remove cover 3 7 Remove cap screws 5 retainer plate 8 and shims 7 8 Reinstall retainer plate with the thickness dimension stamp facing toward the outside cap screws and hardened washers Do not ins...

Page 491: ...ighten all cap screws alternately to 1017 102 N m 750 75 ft lbs torque in several succes sive increments while rotating the hub 23 Using a new O ring 10 Figure 3 5 install cover 3 Install cap screws and washers 2 and tighten to standard torque 24 Rotate the wheel hub to position the fill plug 4 Figure 3 5 at the 12 o clock position Remove the fill plug and level plug 6 Fill wheel hub assembly at f...

Page 492: ...arding oil sampling refer to the Komatsu Oil Wear Analysis KOWA manual If any of the following conditions appear an inspec tion or adjustment of the front wheel bearings is required The amount of metal found on the magnetic plug is high The magnetic plug will attract metal from the oil A failure is indicated by an increased amount of metal on the magnetic plug External oil leaks around the front h...

Page 493: ...ensions and maximum allowable wear specifica tions are listed in Table 1 Bearings that exceed the maximum wear limits must be replaced If premature wear of the bearings is evident check the automatic lubrication system to ensure the proper amount of lubrication is being received at the joint s in question If lubrication is done manually ensure that a sufficient amount of grease is being applied on...

Page 494: ... both ends of assembly 4 Remove pins 4 or 5 from each end of assem bly and move assembly to clean work area Bearing spacers 10 will be free when pin is removed Ensure bearing spacers do not drop out and become damaged when removing pin Installation 1 Align bearing spacers 10 and rod end 15 with pin bores on spindle and frame 2 Install pins 4 or 5 cap screws 3 and retain ers 6 or 7 and secure with ...

Page 495: ...linder 3 Cap Screw 4 Pin 5 Pin 6 Retainer 7 Retainer 8 Hardened Washer 9 Locknut 10 Bearing Spacer 11 Bearing Retainer 12 Cap Screw 13 Lockwasher 14 Bearing 15 Tie Rod End 16 Tie Rod Assembly 17 Cap Screw 18 Locknut 19 Main Frame Mount FIGURE 3 13 STEERING CYLINDER 1 Bearing 2 Cap Screw 3 Lockwasher 4 Bearing Retainer 5 Rod End ...

Page 496: ...lamp nuts 18 Figure 3 12 on tie rod and adjust as necessary a For trucks with an adjustable rod end at only one end of the tie rod adjust length by turn ing rod end in or out When dimension required is attained rotate the rod end to align the bearing bore with the bearing bore on the opposite end Reinstall pin at spindle according to the instructions in Steering Cyl inders and Tie Rod Installation...

Page 497: ...TACHMENT G4 3 PIVOT PIN G4 3 Removal G4 3 Installation G4 3 PIVOT EYE BEARING G4 4 Disassembly G4 4 Assembly G4 4 PIVOT EYE REPAIR G4 5 Removal G4 5 Installation G4 5 Disassembly G4 5 Assembly G4 5 ANTI SWAY BAR G4 6 Removal G4 6 Installation G4 6 Disassembly G4 6 Cleaning and Inspection G4 6 Assembly G4 6 ...

Page 498: ...G4 2 Rear Axle Housing Attachment G04022 NOTES ...

Page 499: ...f a jack between mounting structure and pivot eye may be necessary to push the pivot eye down away from frame structure Pivot eye may also need to be moved to one side to clear welded spacer NOTE 2 If the bore for the Pivot Pin 6 Figure 4 1 in the Mounting Structure 1 Retainer Plate side has been damaged a rework procedure to install a sleeve is available The rework drawing EG4670 is available in ...

Page 500: ...emove locknuts 6 Figure 4 2 and cap screws 5 and bearing retainers 2 2 Remove spherical bearing 4 from bearing car rier 3 3 Inspect all parts for wear or damage Replace parts showing excessive wear or damage Spherical Bearing Outer Race O D 222 25 222 22 mm 8 75 00 8 7488 in Bearing Bore I D 152 37 152 40 mm 5 9990 6 0000 in If bearing carrier 3 is damaged or worn refer to Pivot Eye Repair Assembl...

Page 501: ...Disassembly 1 Remove spherical bearing 4 Figure 4 2 as described in Pivot Eye Bearing Disassembly 2 If bearing carrier 3 is damaged or worn setup an appropriate tool to press bearing carrier out of the pivot eye structure bore Bearing Carrier new I D 222 209 0 013 mm 8 7484 0 0005 in O D 247 701 0 013 mm 9 7520 0 0005 in 3 Inspect pivot eye structure bore for excessive wear or damage Pivot Eye Bor...

Page 502: ...ion the other spacer 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 dard torque 3 Repeat above procedure to install remaining pin spacers and retainer cap screw and lock nut Start the pin ...

Page 503: ...ear Axle Housing G5 1 SECTION G REAR AXLE HOUSING INDEX REAR AXLE HOUSING G5 3 REAR AXLE HOUSING G5 3 Removal G5 3 Installation G5 3 WHEEL MOTOR G5 4 Removal G5 4 Cleaning and Inspection G5 4 Installation G5 4 ...

Page 504: ...G5 2 Rear Axle Housing G05025 NOTES ...

Page 505: ...ons 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 3 Install anti sway bar 4 Install rear suspensions as covered in Section H Suspensions 5 Install whe...

Page 506: ...g and Inspection 1 Thoroughly clean the cap screw holes and mounting faces of the rear housing and the wheel motor 2 Check mounting faces of wheel motor and rear housing for nicks scratches or other damage Installation Maximum Cap Screw Usage High tightening force is required to attach wheel motors Repeated tightening operations will cause cap screw material to fatigue and break DO NOT reuse mount...

Page 507: ...d then final tighten alternating cap screws 180 apart to 2007 N m 1480 ft lbs torque 4 Connect all cables and lines to their appropriate location on the wheel motor 5 Insure wheel motor breathers are properly installed No sharp bends or kinks in hoses are allowed in any line between the wheel motors and the breathers Install wheel cover 6 Fill wheel motor gear with oil specified in Sec tion P Lubr...

Page 508: ...G5 6 Rear Axle Housing G05025 NOTES ...

Page 509: ...H01019 Index H1 1 SECTION H SUSPENSIONS INDEX FRONT SUSPENSION H2 REAR SUSPENSION H3 OILING AND CHARGING PROCEDURES H4 ...

Page 510: ...H1 2 Index H01019 NOTES ...

Page 511: ... H2 3 Removal H2 3 Installation H2 5 TURN OF THE NUT Tightening Procedure H2 6 MINOR REPAIR ONLY Lower Bearing Structure Seals H2 8 Bearing Structure Removal H2 8 Bearing Structure Installation H2 8 MAJOR SUSPENSION REBUILD H2 9 Disassembly H2 9 Assembly H2 10 PRESSURE TEST H2 11 ...

Page 512: ...H2 2 Front Suspensions H02026 NOTES ...

Page 513: ...rances and are precisely fitted All parts must be completely clean during assembly 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 s...

Page 514: ...er rod seals bearing O ring and backup ring replacement is required it will not be necessary to remove suspension from truck Refer to Minor Repair Only Lower Bearing Structure Seals for bearing structure removal and installation 6 If major suspension rebuild is required continue removal procedure 1 Valve Guard 2 Valve Cap 3 SwivelNut SmallHex 4 Valve Body Large Hex FIGURE 2 2 CHARGING VALVE INSTAL...

Page 515: ...RMS medium tool cut Surface flatness must be within 0 254 mm 0 010 in 3 Clean and dry all cap screws nuts and washers as stated in Step 1 above NOTE The use of dry threads in this application is not recommended Due to the high tightening forces required to load these cap screws dry threads may cause damage to tools 4 Lubricate cap screw threads cap screw head seats washer face and nut seats with a...

Page 516: ... 9 Service the suspension For instructions refer to HYDRAIR II Oiling and Charging Procedure 10 Install suspension boot and secure with clamp TURN OF THE NUT Tightening Procedure NOTE The Turn of the Nut tightening procedure was developed for high strength 1 1 2 UNC cap screws grade 8 or better in this joint application only Do not use this tightening method for other joint types or cap screws of ...

Page 517: ...ber has NOT turned during the tightening procedure as marked in Step 6 b NOTE Do not exceed 4 RPM tightening speed Do not hammer or jerk wrench during the tighten ing procedure 7 Loosen the top two corner cap screws 1 and the bottom outer four cap screws 8 the 4 bot tom cap screws with nuts 8 Tighten the top two corner 165 mm 6 5 in cap screws to 95 N m 70 ft lbs torque then use the turn of the nu...

Page 518: ... buffer seal 24 be certain radius is posi tioned toward the seal as shown in Figure 2 8 2 Install new O rings 20 and backup rings 21 in their appropriate grooves in the lower bearing structure 16 NOTE Backup rings must be positioned toward the flange of bearing structure as shown in Figure 2 9 3 Install temporary guide bolts to ensure bolt hole alignment as bearing retainer is seated Lift lower be...

Page 519: ...pin 10 nut 11 piston stop 12 and key 13 Separate cap and bearing Remove O rings 14 and backup rings 15 Remove bearing 6 3 Rotate the suspension 180 NOTE Steel balls 9 will fall free when the housing is rotated 4 Attach lifting device to the piston 8 and care fully lift out of housing FIGURE 2 8 SUSPENSION ASSEMBLY 1 Housing 2 Plate 3 Cap Screw 4 Hardened Washer 5 Cap Screw 6 Washer 7 O Ring 8 Back...

Page 520: ...must be positioned toward bearing retainer bolt flange as shown in Figure 2 9 3 Install lower bearing assembly 16 into lubri cated suspension housing Install cap screws and hardened lockwashers 18 19 through retainer flange and into tapped holes in hous ing Tighten to 420 N m 310 ft lbs torque 4 Install new backup rings and O rings 14 15 Figure 2 7 in end cap grooves Backup rings must be positione...

Page 521: ...nder the large hex valve body Tighten large hex of charging valve to 27 4 N m 16 5 ft lbs torque 13 Install remaining plugs and or pressure sensor 14 Pressure test according to instructions on the following page PRESSURE TEST After rebuild is complete suspension assembly should be tested for leakage When pressure testing suspension must not be allowed to extend Assembly must be mounted in a contai...

Page 522: ...H2 12 Front Suspensions H02026 NOTES ...

Page 523: ...H03024 Rear Suspensions H3 1 SECTION H REAR SUSPENSIONS INDEX REAR SUSPENSIONS H3 3 Removal H3 3 Installation H3 6 Disassembly H3 8 Cleaning and Inspection H3 8 Assembly H3 8 PRESSURE TEST H3 9 ...

Page 524: ...H3 2 Rear Suspensions H03024 NOTES ...

Page 525: ...er to use the removal tools listed above If the pins do not contain the necessary holes new pins may be purchased or a rework of the pins is neces sary Refer to Figure 3 5 for pin rework details 1 Remove cap screws washers and metal shield 2 Figure 3 1 from the suspension 2 Remove charging valve cap 1 Figure 3 2 loosen small hex 4 on charging valve and turn counterclockwise three full turns to uns...

Page 526: ...tool 1 Figure 3 4 to each lower pin using the cap screws listed in Table 1 Tighten the cap screws to 240 24 Nm 177 17 ft lbs torque The rear HYDRAIR II suspension weighs approx imately 1088 kg 2 400 pounds Be certain the capacity of the lifting device used is sufficient for lifting this load 10 Position a fork lift or other suitable lifting device under the suspension to be removed and secure it t...

Page 527: ...he pin from the lower mounting 16 Install the tool on the upper pins and repeat the pin removal process If the pin does not contain the necessary puller holes an alternative removal method is needed 17 Remove the cylinder from the truck Clean the exterior of the suspension thoroughly and move to a clean work area for disassembly 18 If it is necessary to remove the remaining rear suspension cylinde...

Page 528: ...e hole in the pin 6 Install cap screw 2 Figure 3 3 and locknut 3 Tighten to 420 N m 310 ft lbs torque 7 Lower the suspension housing until the lower mount bearing aligns with the bore in the rear axle housing and repeat the above procedure to install the bottom pin The parts in the top and bottom joint are identical 8 Install the nitrogen charging kit and add nitro gen to raise frame off stands or...

Page 529: ...H03024 Rear Suspensions H3 7 FIGURE 3 6 REAR SUSPENSION ASSEMBLY ...

Page 530: ... O ring 20 and backup ring 19 from housing bearing 9 If the spherical bearings 6 Figure 3 3 require replacement remove the retainer rings 5 Press bearing out of bore Cleaning and Inspection 1 Clean all parts thoroughly in fresh cleaning sol vent Use a solvent that does not leave a film after evaporation such as Trichlorethylene Acetone or Lacquer Thinner When using cleaning agents follow the solve...

Page 531: ...t damage to machined and chrome surfaces 8 Install the bleeder screw 6 Figure 3 6 and vent plug 7 Install vent plug 14 and tighten both vent plugs to 87 N m 64 ft lbs torque 9 Install vent plug 11 and pressure sensor or plug 13 Install protective cover 10 Install shield 8 11 Using new gasket install charging valve Tighten large hex of charging valve to 22 4 N m 16 5 ft lbs torque PRESSURE TEST Aft...

Page 532: ...H3 10 Rear Suspensions H03024 NOTES ...

Page 533: ...AIR CHARGING KIT H4 4 Installation of Charging Kit H4 4 Removal of Charging Kit H4 4 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS H4 5 FRONT SUSPENSION H4 5 Front Suspension Oiling H4 5 Front Suspension Nitrogen Charging H4 7 REAR SUSPENSION H4 8 Rear Suspension Oiling H4 8 Rear Suspension Nitrogen Charging H4 9 OIL AND NITROGEN SPECIFICATIONS CHART H4 11 ...

Page 534: ...H4 2 Oiling and Charging Procedures H04025 NOTES ...

Page 535: ...w all safety instructions cautions and warnings provided in the following proce dures to prevent any accidents during Oiling and Charging Proper charging of HYDRAIR II suspensions requires that three basic conditions be established in the following order 1 Oil level must be correct 2 Suspension piston rod extension for nitrogen charging must be correct 3 Nitrogen charge pressure must be correct Fo...

Page 536: ...lve 4 suspensions may be charged separately or together Removal of Charging Kit 1 Close both outlet valves 3 2 Turn T handles 1 counterclockwise to release charging valve cores 3 Remove charging valve adapters 2 from charging valves 4 Tighten swivel nut small hex on charging valve If a new charging valve is being used tighten swivel nut to 14 2 N m 10 5 ft lbs torque then loosen and retighten swiv...

Page 537: ...e suspension Refer to Figure 4 2 for front suspension support block placement and Figure 4 4 for rear support block placement FRONT SUSPENSION 1 Park the unloaded truck on a hard level sur face Place the directional control lever in PARK Place chock in front and behind two sets of wheels to prevent roll away 2 Thoroughly clean area around the charging valve on the suspensions Remove the protec tiv...

Page 538: ...ension 3 Depress the charging valve core to release nitrogen pressure from the suspension When all nitrogen has been vented to the atmosphere the suspension should have collapsed slowly and be seated solidly on the support blocks 4 Remove top fill plug next to the charging valve Figure 4 2 5 Fill the suspension with clean HYDRAIR oil with 6 friction modifier until the cylinder is full to the top o...

Page 539: ...AIR Charging Kit and a bottle of pure dry nitrogen Refer to Installation of Charg ing Kit 4 Charge the suspensions with nitrogen gas to 50 8 mm 2 in greater than the charging height listed in Figure 4 2 Close inlet valve 4 Figure 4 1 5 Remove the oiling blocks from the suspensions and install the nitrogen charging blocks Secure the blocks to prevent accidental dislodging NOTE Use caution to preven...

Page 540: ...cord the extension dimen sions Maximum downward travel is indicated by the dirt ring at the base of the piston Operator com ments on steering response and suspension rebound should also be noted REAR SUSPENSION 1 Park the unloaded truck on a hard level sur face Apply the parking brake and chock the wheels 2 Thoroughly clean the area around the charging valve on the suspensions Remove the protec ti...

Page 541: ... Drip pans should be used and all spillage cleaned from the outside of the suspension Install the bleeder and vent plugs Continue to fill the oil until it reaches the fill port Allow the suspension to stand for at least 15 minutes to clear any trapped nitrogen and or air bubbles from the oil Add oil if necessary and install the fill plug Rear Suspension Nitrogen Charging Lifting equipment overhead...

Page 542: ... side exceeds 10 mm 0 39 in check the front suspensions for equal extension Adjust the front as necessary NOTE A low left front suspension will cause the right rear suspension to be high A low right front suspension will cause the left rear suspension to be high 8 Close outlet valves 3 and remove charging kit components Refer to Removal of Charging Kit 9 If the charging valve is being reused tight...

Page 543: ...ance Synthetic Motor Oil 5W 30 AK4065 Suspension Oil premixed with 6 Friction Modifier 5 Gallon container AK4066 55 Gallon container NOTE VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension VJ3911 and VJ5925 oils are supplied in 5 gallon 19 Liter cans FRICTION MODIFIER FRICTIONMODIFIERMixingInstructions 94 Suspension oil 6 Friction Modifier Part Number Suspension Oil Am...

Page 544: ...H4 12 Oiling and Charging Procedures H04025 NOTES ...

Page 545: ... Index J1 1 SECTION J BRAKE CIRCUIT INDEX BRAKE CIRCUIT J2 1 BRAKE CIRCUIT COMPONENT SERVICE J3 1 BRAKE CIRCUIT CHECKOUT PROCEDURE J4 1 WHEEL SPEED FRONT DISC BRAKES J5 1 ARMATURE SPEED REAR DISC BRAKES J6 1 ...

Page 546: ...J1 2 Index J01038 NOTES ...

Page 547: ...CUIT INDEX BRAKE CIRCUIT J2 3 OPERATION J2 3 SERVICE BRAKE CIRCUIT OPERATION J2 3 SECONDARY BRAKING AND AUTOMATIC APPLY J2 5 PARKING BRAKE CIRCUIT J2 5 Normal Operation key switch on engine running J2 5 BRAKE LOCK CIRCUIT J2 6 WARNING CIRCUIT J2 6 ...

Page 548: ...J2 2 Brake Circuit J02037 NOTES ...

Page 549: ... the operator s cab The remainder of the system including the brake manifold circuit accumulators and electrical compo nents are located in a weatherproof cabinet behind the cab This cabinet is accessible for diagnostic and service work The brake manifold contains dual circuit isolation check valves accumulator bleed down valves and valves for brake lock park brake and automatic apply functions Al...

Page 550: ...ction Block 11 BF BR Test Port Front Rear Brake 12 Stop Light Switch 13 Brake Lock Shuttle Valve 14 Brake Lock Pressure Reducing Valve 15 Brake Lock Solenoid 16 Park Brake Solenoid 17 Bleed Down Valve Front Brake Accumulator 18 Accumulator Test Port 19 Automatic Apply Valve 20 Bleed Down Valve Rear Brake Accumulator 21 Brake Manifold 22 LowBrakeAccumulator Pres sure Switch 23 Park Brake Pressure S...

Page 551: ...never the park brake solenoid is de energized a spring in the solenoid valve will shift the spool to the position to allow the park brake to be applied Normal Operation key switch on engine run ning Directional Control Lever in Park Position The parking brake solenoid 16 is de energized The oil pressure in the parking brake lines return to tank and the springs in the parking brake will apply the b...

Page 552: ...Pa 2300 psi the low steering pressure light low brake pressure light and buzzer will turn on Pressure Sensor low accumulator pressure 22 Located on the brake manifold When the accumulator with the lower hydraulic pressure falls below 15860 kPa 2300 psi the low brake pressure light and buzzer will turn on Brake Lock Degradation Switch 9 Figure 2 1 Located on the junction block 10 in the brake cabin...

Page 553: ...s 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 B1 Parts 17 20 Rear Brake 17 Spool Return Spring 18 Regulator Spool 19 Regulator Sleeve 20 Reaction Plunger 21 Retainer Plug 22 Base Plate 1 1 A Adjustment Collar Contact Area B PX Port C Automatic Apply Piston Area D Tank Port E Orfice F Brake Ap...

Page 554: ...J2 8 Brake Circuit J02037 FIGURE 3 3 BRAKE VALVE PARTIAL CUT AWAY 1 Actuator Base 2 Brake Valve 3 Orfice Set Screw ...

Page 555: ... 9 Boot and Cap J3 9 Valve Body Seal Installation J3 10 Regulator Sleeve O Ring Installation J3 10 Actuator Plunger O ring Installation J3 11 Assembly of Valve J3 11 VALVE BENCH TEST AND ADJUSTMENT J3 13 Test Set Up Procedure J3 14 Brake Valve Output Pressure Adjustment J3 14 Final Test and Adjustment J3 15 Installation Of Brake Pedal Actuator Assembly to Brake Valve J3 17 BRAKE ASSEMBLIES WITH IN...

Page 556: ...rocedure J3 19 Removal J3 19 Installation J3 19 Disassembly J3 19 Cleaning and Inspection J3 21 Assembly J3 21 Charging Procedure J3 23 BRAKE MANIFOLD J3 24 Removal J3 24 Removal J3 24 Installation J3 25 Disassembly J3 25 Cleaning and Inspection J3 25 Assembly J3 25 Cleaning and Inspection J3 25 Assembly J3 25 ...

Page 557: ...f the Brake Valve is to be removed from the vehicle for repair or adjustment additional equipment will be required as outlined in disassembly assembly NOTE Minor repairs and service adjustment may not require the removal of the brake valve Before disconnecting pressure lines replacing components in the hydraulic circuits or install ing test gauges always bleed down hydraulic steering and brake acc...

Page 558: ...3 Figure 3 1 to bleed down both brake accumulators 3 Remove access panel in front of operator s cab 4 Tag and remove all hydraulic lines from brake valve Plug lines and ports to prevent possible contamination Remove all valve fittings 5 If equipped remove retard pedal that is located on brake pedal FIGURE 3 2 SINGLE PEDAL BRAKE VALVE ASSEMBLY 1 Brake Valve 2 Retainer Clip 3 Pivot Shaft 4 Bushings ...

Page 559: ...efer to brake accumulator precharge procedures this section 3 If equipped install electronic retard pedal to brake pedal Figure 3 3 4 With the engine shut down and key switch OFF open both brake accumulator bleed down valves Precharge both accumulators NOTE For best performance charge the accumulators in the temperature conditions the vehicle is expected to operate in During the precharge allow te...

Page 560: ...lip 3 Pivot Shaft 4 Bushings 5 Shims 6 Retainer Clip 7 Nylon Bearing 8 Pivot Shaft 9 Place 0 010 in Shim Here 10 Jam Nut 11 Cap Screw 12 Pedal Structure 13 Pad 14 Nut 15 Cap Screw 16 ElectronicRetardPedal Assembly 17 Brake Pedal Actuator 18 Spring Pivot Lower 19 Spring 20 Spring Pivot Top 21 Set Screw 22 Jam Nut ...

Page 561: ...ring 22 and face seal 23 9 Loosen plunger locknuts 2 Loosen the socket head cap screw from the adjustment collars 1 10 Unscrew and remove the adjustment collars 11 Remove the two socket head cap screws 5 Figure 3 4 that retain the actuator base 6 to the valve body 12 Remove the actuator base from the valve body 13 Remove controller from vice 14 Remove the four cap screws 29 Figure 3 5 and washers ...

Page 562: ...prings 7 Spring Seats 8 Regulator Spool 9 Back up Ring 10 O Ring 11 Back up Ring 12 O Ring 13 O Ring 14 Regulator Sleeve 15 Spool Return Spring 16 Reaction Plunger B1 17 Reaction Plunger B2 18 Wiper Seal 19 Back up Ring 20 Poly Pak Seal 21 Valve Body 22 O Ring 23 Face Seals 24 Set Screw Orifice Plug 25 O Ring 26 Retaining Plug 27 Base Plate 28 Washer 29 Cap Screw 30 Plate 31 Cap Screw ...

Page 563: ...atched set 4 Inspect each spring carefully for cracks or breaks Any spring with a crack or break must be replaced Also if the valve was not reaching proper regulated pressure replace all regulator springs 5 Inspect the threaded inserts 7 Figure 3 4 in the actuator base If any of the threads are damaged the inserts must be replaced 6 Lubricate all parts with a thin coat of clean type C 4 hydraulic ...

Page 564: ...1 4 for the second bore Regulator Sleeve O Ring Installation 1 Install O ring 2 Figure 3 7 onto the smallest groove on the top of the regulator sleeve 3 Install O ring 5 onto the middle groove on the regulator sleeve Install O ring 6 onto the larg est groove on the bottom on the regulator sleeve 2 Install a split nylon back up ring 4 onto each side of O ring 5 located in the middle of the regulato...

Page 565: ...letely seated and bottomed 3 Repeat Steps 1 through 4 for the B2 actuation plunger 4 Install the plunger return spring 4 Figure 3 5 regulator springs 5 6 and spring seat 7 into the appropriate circuit If spring seat does not seat correctly on top of the control spring lightly shake the valve to correctly position the spring seat 5 Lightly lubricate the regulator spool 8 6 Install the regulator spo...

Page 566: ...are facing the counter bore or toward the top of the valve 16 Install the base plate 27 on top of the retainer plug Tighten the four allen screws 29 evenly alternating diagonally to evenly seat the regula tor sleeve assembly Tighten to 15 8 16 9 N m 140 150 in lbs torque 17 Using a new O ring 22 Figure 3 5 and seal 28 install plate 30 on valve body 18 Install the actuator base 6 Figure 3 4 on top ...

Page 567: ...1 1 16 in 12 SAE Ohmmeter NOTE It is possible to check the pressures with the brake valve installed and connected to the vehicle Remove the brake pedal assembly and actuator cap and boot assembly to adjust individual brake circuit pressures FIGURE 3 9 TEST BENCH SET UP 1 Motor 2 Pump 3 System Pressure Gauge 4 Needle Valve 5 Needle Valve 6 Brake Valve 7 Front Brake Pressure Gauge 8 Shut Off Valves ...

Page 568: ...34 kPa 5 psi 9 Test the valve with ISO grade hydraulic oil at 49 3 C 120 10 F Brake Valve Output Pressure Adjustment 1 Install the pedal pivot shaft pin in the actuator base by itself without installing the pedal assembly 2 By taking a screw driver or pry bar and placing it under the pivot pin and on top of the threaded plunger assembly each circuit can be actuated individually Refer to Figure 3 9...

Page 569: ...t stand following steps 2 through 9 under Test Setup Procedure 13 With test stand pump adjusted for 22 064 kPa 3 200 psi or with engine running and brake system supply pressure at or above 20 685 kPa 3 000 psi depress the pedal as quickly as possible The pressure on the output circuits must reach the minimum pressure listed below at port B1 and port B2 within 1 0 seconds Measurement of time begins...

Page 570: ...t interfere with pedal travel 22 If pressure is not within specifications re adjust If pressure is within specifications apply a few drops of Locktite to the jam nut 23 Check internal leakage at port T Leakage 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 24 T port leakage must be less than 250 cc minute with valve...

Page 571: ...ng retainer clip 2 5 Assemble spring assembly 8 and install com plete assembly to brake pedal actuator as shown Be sure to install spring assembly correctly with larger ball socket end pointing to the pedal struc ture and smaller end toward the valve assembly NOTE If pedal is adjusted properly the spring assembly will not interfere with pedal travel The spring and spring pivots are different for p...

Page 572: ...pedal 2 Install retard pedal 16 to brake pedal actuator 17 with pivot shaft 8 Install two retainer clips 6 3 With jam nut 10 loose adjust cap screw 11 until roller on retard pedal just contacts the brake pedal actuator Tighten jam nut 10 4 Connect wiring harness to retard pedal FIGURE 3 11 BRAKE VALVE WITH RETARD PEDAL 1 Brake Valve 2 Retainer Clip 3 Pivot Shaft 4 Bushings 5 Shims 6 Retainer Clip ...

Page 573: ...ey switch ON engine shut down and applying service brake pedal The service brake light should not come on 3 Close bleeddown valves by rotating clockwise Removal 1 Shut down engine and exhaust all hydraulic pressure from the system by opening accumu lator manual drain valves 2 Remove the valve guard and Dyna seal from top of accumulators 3 Depress valve core to release gas precharge pressure from a...

Page 574: ... O ring washer and anti extrusion ring from plug Fold anti extrusion ring to enable removal Refer to Figure 3 15 8 Remove plug and poppet assembly from shell Refer to Figure 3 16 9 With wrench on valve stem flats remove the nut from the valve stem 10 Insert hand into shell fluid opening Depress bag and eliminate as much gas pressure as possible 11 Grasp heel of the bladder and withdraw from shell ...

Page 575: ...nd inspected place accumulator shell in vise or on table 2 Thoroughly coat the inside of the accumulator shell with a liberal amount of clean hydraulic oil to lubricate and cushion the bladder Make sure the entire internal of the shell is lubricated 3 With bladder assembly on bench expel all air to completely collapse bladder and fold bladder longitudinally into a compact roll To maintain rolled c...

Page 576: ... anti extru sion ring Refer to Figure 3 21 15 Install O ring over plug and poppet assembly and push until seated DO NOT TWIST O RING 16 Install spacer with smaller diameter of the shoulder toward shell 17 Install locknut on plug and poppet assembly and tighten securely This will squeeze O ring into place Refer to Figure 3 22 18 Install pipe plug into plug and poppet assembly 19 Install accumulator...

Page 577: ... small copper washer in the swivel connector may be necessary 3 Precharge bladder slowly to about 69 kPa 10 psi before completely tightening the valve stem nut With wrench on valve stem flats tighten valve stem nut 4 Proceed to inflate accumulator to 9653 345 kPa 1400 50 psi pressure by slowly opening the pressure regulator valve on nitrogen cylin der closing it occasionally to allow needle on pre...

Page 578: ...ves NV1 13 Figure 3 24 and NV2 11 counterclockwise 4 Confirm brake accumulators are bled down by applying the Brake Lock switch key switch ON engine shut down and applying service brake pedal The service brake light should not come on 5 Close the bleeddown valves by rotating clock wise 6 Remove the valve guard and Dyna seal from top of accumulators 7 Depress valve core to release gas precharge pre...

Page 579: ... 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 Cleaning and Inspection 1 After disassembly clean all parts with an approved cleaning solution 2 Blow all parts dry with air and keep free from foreign matter 3 Replace all O rings an...

Page 580: ...J3 26 Brake Circuit Component Service J03034 NOTES ...

Page 581: ...RAKE CIRCUIT CHECK OUT PROCEDURE J4 3 EQUIPMENT REQUIRED J4 5 INITIAL SYSTEM SET UP J4 6 PARKING BRAKE J4 6 BRAKE SYSTEM CHECK OUT J4 7 BRAKE LOCK J4 7 FAILURE MODES CHECK OUT J4 8 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING J4 9 KOMATSU CHECK OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET J4 12 ...

Page 582: ...J4 2 Brake Circuit Check Out Procedure J04036 NOTES ...

Page 583: ...hooting brake circuit For Steering Circuit Test Procedure refer to Section L Hydraulic System FIGURE 3 1 HYDRAULIC BRAKE CABINET 1 Rear Brake Accumulator 2 Charging Valve 3 Front Brake Accumulator 4 Park Brake Pressure Reducer Valve 5 Hoist Pilot Valve 6 Hoist Pilot Manifold 7 Hoist Up Limit Solenoid 8 Pilot Operated Check Valve 9 Brake Lock Low Pressure Switch 10 Junction Block 11 BF BR Test Port...

Page 584: ...caping under pressure can have sufficient force to enter a person s body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this type of injury is not received immediately The steering accumulator can be bled down with engine shut down turning key switch OFF and wait ing 90 seconds Confirm the steering pressure is released b...

Page 585: ...for bleeding brakes f Volt ohm meter with leads and two 61 mm 24 inch leads with alligator clips BRAKE CIRCUIT ABBREVIATIONS AA Automatic Apply Pressure AF2 Accumulator Front Brake AF1 Supply Pressure to Dual Controller for Front Brakes AR2 Accumulator Rear Brake AR1 Supply Pressure to Dual Controller for Rear Brakes BF Brake Pressure Front 11 Figure 4 1 BL Brake Lock Apply Pressure BR Brake Press...

Page 586: ...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 PARKIN...

Page 587: ...of 20 sec onds Record on data sheet 15 Release pedal and within two seconds assure that each circuit s pressure is zero Record on data sheet 16 To check pedal free play refer to the procedure Additional Testing and Adjustment With brake pedal installed in this Section J of the service manual NOTE Free play is defined by the gap between the setscrew in the pedal structure and the actuator cap There...

Page 588: ... recharge hydraulic system Allow engine to run until low brake accumulator pressure stabilizes at or above 22 064 kPa 3 200 psi 28 Turn engine off Allow the steering accumulator to bleed completely down Turn key switch ON Slowly open the rear brake accumulator bleed down valve and observe LAP1 pressure Record LAP1 pressure at set points for low brake warning lamp and auto apply brake pres sures Al...

Page 589: ...n in the brake valve subassembly Brake valve is out of balance Actuator piston defective Brake valve is defective Remove obstruction Adjust balance according to instructions Replace piston Rebuild or replace Brake Valve assembly TROUBLE The Brakes are Not Going to Full Pressure Internal malfunction of modulating section of Brake Valve Supply pressure is low Improper collar adjustment inside brake ...

Page 590: ...is defective Check wiring Replace the switch TROUBLE Low Pressure Warning Comes On and Pressure is Low Steering circuit is malfunctioning The pump is worn Check steering circuit pressures Rebuild or replace pump TROUBLE A Squeal is Heard When Controller is Operated Rapid operation of controller Brake Valve assembly is damaged Hydraulic oil is too hot Normal Replace the brake valve assembly Check e...

Page 591: ...ternal leakage in brake valve assembly Pump is worn Check all steering and brake system components Check accumulator precharge Correct plumbing Replace brake valve assembly Rebuild or replace pump TROUBLE The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM Leak in charge system Accumulators precharge too high or too low Brake Valve plumbed incorrectly Internal leakage in b...

Page 592: ...____________ 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 STEP 9 _______________ Left outboard lining disc gap _______________ Left inboard lining disc gap _______________ Right outboard lining disc gap _______________ Right inboard lining disc gap Brake System STEP 12 ___...

Page 593: ...0 psi is OK STEP 25 _______________ LAP1 pressure when low brake pressure warning occurs 15 859 517 kPa 2300 75 psi STEP 26 _______________ LAP1 pressure when auto apply occurs 14 479 kPa 2 100 100 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 occu...

Page 594: ...J4 14 Brake Circuit Check Out Procedure J04036 NOTES ...

Page 595: ...RAKES J5 3 BRAKE CALIPER J5 3 Caliper Removal J5 3 Installation J5 4 Disassembly J5 5 Assembly J5 5 Cleaning and Inspection J5 6 BRAKE LINING J5 7 Replacement J5 7 FRONT SERVICE BRAKE CONDITIONING BURNISHING PROCEDURE J5 9 GENERAL J5 9 Safety Precautions J5 9 Front Brake Conditioning J5 9 BRAKE BLEEDING PROCEDURES J5 10 ...

Page 596: ...J5 2 Rockwell Wheel Speed Front Disc Brakes 10 06 J05024 NOTES ...

Page 597: ...sembly Subassemblies should be blown dry with compressed air after cleaning Dust shields should be wiped dry with a clean cloth The use of vapor degreasing or steam cleaning is not recommended for the brake assemblies or the component parts Moisture will cause parts to rust Be certain that all wheels are securely blocked to prevent truck from moving Do not loosen or disconnect any hydraulic brake ...

Page 598: ...original location 2 Install the inboard half of caliper assembly 2 Figure 5 2 to the top leg of the brake caliper support and secure caliper assembly with four cap screws 6 Tighten cap screws to standard torque 3 Repeat Step 2 at the other two brake caliper support legs 4 Install the upper outboard half of brake caliper assembly 2 to the top leg of the brake caliper adapter 4 and secure with six c...

Page 599: ...ling pistons 11 Figure 5 3 into the housings 1 lubricate all cylinder walls threads seals piston seal surfaces etc with clean C 4 hydraulic oil 1 Install new piston seals 12 and backup rings 13 in housings 2 With housing lying on mounting face gently push each piston past piston seal until seated in bottom of cavities 3 Install new or reusable dust shields 10 NOTE Do not allow lubricant to contact...

Page 600: ...avities and surfaces of piston for evidence of dirty fluid particularly if dust shields were ruptured 5 Inspect piston cavities for evidence of varnish formation caused by excessive and prolonged heating of brake oil Piston should be handled with care The usual cause of nicked piston surfaces is mishandling during the cleaning procedure Steel tools should never be used in piston cavi ties and seal...

Page 601: ...ny minor thread roughness 10 Brake housings and pistons should be thor oughly cleaned After cleaning passages cavi ties and external surfaces should be blown dry with clean dry compressed air Piston should also be cleaned and blown dry NOTE Cleaned and dried parts should not be left exposed for any appreciable time without a protective coating of lubricant for short term storage coating all intern...

Page 602: ...x new and used linings in a brake assembly 9 Slide linings 9 into caliper It may be neces sary to again pry pistons into housing 1 10 Install end plates 7 8 apply Loctite 271 to threads of end plate cap screws 6 Install cap screws and tighten to 54 6 N m 403 ft lbs torque Check that linings 9 slide freely between end plates 11 After completing lining replacement reinstall front wheels Refer to Whe...

Page 603: ...EAR brakes while burnishing front wheel brakes as follows a Relieve stored pressure in hydraulic system according to the previous WARNING instructions b Disconnect BR hydraulic tube 1 Figure 5 5 at both ends inside brake control cabinet Install a 8 0 75 x 16 UNF 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...

Page 604: ... engine at idle make partial brake applica tion of service brake pedal a Maintaining partial application open bleeder valve until a clean stream of oil is discharged from caliper b Close bleeder valve 5 Repeat above steps until all air is bled from all calipers 6 Check hydraulic tank oil level as bleeding takes place Maintain correct oil level as needed Before returning truck to production all new...

Page 605: ...ssembly J6 8 PISTON SUBASSEMBLY J6 11 Disassembly J6 11 PREPARATION FOR ASSEMBLY J6 12 Clean Parts J6 12 For Rough Metal Parts J6 13 Dry and Inspect Parts J6 13 Corrosion Protection J6 13 INSPECTION J6 13 Caliper Parts J6 13 Shoes Linings and End Plates J6 14 Inspect linings J6 14 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT IN CLEARANCE BIC J6 14 Piston Assembly Adjuster Grip Force J6 15 Adjuste...

Page 606: ...ECTIONS J6 28 Shoes Linings and End Plates J6 28 Inspect the following areas for fluid leaks J6 28 Dust Boots J6 28 Brake Disc J6 28 BRAKE LINING J6 29 Replacement J6 29 BRAKE DISC J6 29 Inspection J6 29 SERVICE BRAKE CONDITIONING BURNISHING PROCEDURE J6 30 GENERAL J6 30 SAFETY PRECAUTIONS J6 30 Rear Brake Conditioning J6 31 BRAKE BLEEDING PROCEDURE J6 32 ...

Page 607: ...6 1 from upper service brake caliper Remove crossover tubes on lower brake assembly 4 Remove two center caliper mount cap screws 6 Figure 6 2 from outboard caliper and install two 7 8 9 NC X 14 in studs 5 Slowly remove the four remaining caliper mount cap screws The brake lining is under spring pressure and it will extend out as the cap screws are loosened Do not let the brake lining pull away fro...

Page 608: ...nd remove from wheel motor 14 Support inner disc 12 and remove cap screws and flat washers 11 Remove inboard disc 12 Remove shims 7 and bushing 8 between disc and adapter 15 Use small diameter wire and wrap it around the brake lining and inner caliper half 14 16 Remove inner half of caliper 14 A brake bleeder may have to be removed temporarily to obtain clearance around adapter 15 Cover or plug ho...

Page 609: ...0 in shim at brake mounting surface Measure dimension A again measuring from outer surface of shim to inside face of brake disc c When dimension A is less than 126 21 mm 4 97 in then subtract dimension A from 126 49 mm 4 98 in d Make a measured shim pack equal to the result obtained in Step 4c If not equal then within 0 127 mm 0 005 in of the result This will be brake disc shim pack 7 5 Remove dis...

Page 610: ...ained in Step 14c If not equal then within 0 127 mm 0 005 in of the result This will be brake disc shim pack 7 15 Remove cap screws 11 and outer disc 12 Remove outer disc adapter 10 16 With brake linings secured to caliper with wire install inner brake caliper half 5 over the two studs Ensure brake bleeder plug 3 Figure 6 3 is installed in the location shown 17 Install outer disc adapter 10 Figure...

Page 611: ... the service brakes The service brake piston adjusters will adjust automatically when pressure is applied to the service brake 5 Parking brake adjustment occurs automatically when the parking brake is released and the ser vice brake is applied 6 Move directional control lever to PARK 7 Turn key switch to the OFF position 1 Bleeder Plug 2 Bleeder Plug 3 Bleeder Plug 4 Bleeder Plug 5 Bleeder Plug 6 ...

Page 612: ... the parking piston cap 1 5 Use a long 3 16 in Allen wrench through the hole in the center of the parking piston cap to loosen the shoulder bolt that attaches the park ing piston adjusting bolt to the lining assembly 6 Separate the two lining end plates from the cali per housing half by removing the six cap screws 1 Figure 6 5 three from each end plate 7 Remove the brake lining 8 Use a suitable sp...

Page 613: ...Figure 6 9 from the collar inside the parking pistons of each caliper housing 13 Use a pick or suitable tool to remove the parking piston boots from each caliper housing 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 1 Spring Washers 2 Cap FIGURE 6 7 SPRINGS AN...

Page 614: ... Position the caliper housing so that the ends of the adjuster pin and nut are up Use a 5 32 inch Allen wrench to hold the pin and remove the nut and washer from the caliper housing 19 Use a suitable dowel or drift to push the pistons 1 Figure 6 13 out of each caliper housing 20 Use a suitable tool to remove the two service piston dust seals 1 Figure 6 14 from the cali per housing Discard the dust...

Page 615: ...s procedure for each caliper half PISTON SUBASSEMBLY Disassembly NOTE Disassembly of the piston subassembly during brake overhaul is not mandatory Clean the piston subassembly thoroughly If the piston surface is acceptable for reuse and the piston subassembly passes the functional tests for adjusting grip force spring force and built in clearance BIC return the piston subassembly to service 1 Remo...

Page 616: ...an be flammable poisonous and cause burns Examples of solvent cleaners are carbon tetrachloride and emulsion type and petroleum base cleaners Read the manufac turer s instructions before using a solvent cleaner then carefully follow the instructions Also follow the procedures below Wear safe eye protection Wear clothing that protects your skin Work in a well ventilated area Do not use gasoline or ...

Page 617: ...aliper Parts 1 inspect the pistons housing bores and O ring grooves for scratches or corrosion Remove small scratches or corrosion with a fine emery cloth Replace the components if they are worn beyond wear limits or if there are large scratches or large amounts of corrosion 2 Measure the outer diameter of the service pis ton Replace the piston if the outer diameter is less than 76 07 mm 2 995 in ...

Page 618: ...ge can occur 4 Cracks on the Linings Replace linings that have larger or deeper cracks than the small tight cracks on the surface of the lining which are normal when the caliper is used under high temperature conditions These cracks are referred to as heat check cracks PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT IN CLEARANCE BIC 1 Place the piston subassembly onto a spring tester table Install a...

Page 619: ...and lower the arbor several times to verify both BIC and spring return force The BIC should be between 1 40 1 65 mm 0 055 0 065 in If not in this range readjust the BIC Recheck for the correct BIC Step 3 through Step 5 above Piston Assembly Adjuster Grip Force 1 Inspect the piston assembly adjuster grip force This is the force required to cause the adjuster pin to slip in the pair of adjuster grip...

Page 620: ...cial calibrated spring pod Slowly lower the arbor to push in the extended adjuster pin as shown in View A Figure 6 20 The adjuster pin should slip into the adjuster and move downward at readings between 173 362 kg 380 800 lbs 1 6 35 mm in 2 7 9 mm 0 31 in 3 8 6 mm 0 34 in 4 Three dowels 0 375 in dia x 1 5 in long 5 9 7 mm 0 38 in 6 12 7 mm 0 50 in 7 15 7 mm 0 62 in 8 25 4 mm 1 0 in 9 31 8 mm 1 25 ...

Page 621: ...surements of the adjuster subassemblies installed onto the adjuster pin it is necessary to have either a force calibrated hydraulic shop press or a calibrated spring pod Fig ure 6 18 available for use with a standard arbor press Obtain force measurements as illustrated in Figure 6 21 1 Place the spring pod on the arbor press table Use both special sleeves Figures 6 26 as shown in Views A and B of ...

Page 622: ...pin diameter be clamped in a vise or gripped with pliers In normal use the surface of the pin will show only a very slow rate of wear and both pins and adjusters will normally outlast many brake lining changes and brake overhauls 5 If required install the adjuster on the adjuster pin as follows as shown in Figure 6 22 a Place the adjuster and pilot pin subassembly onto the end of the adjuster pin ...

Page 623: ...shown in View A Figure 6 23 4 Raise the arbor Place the return spring over the spring guide and lower the arbor slowly until the dial indicator again reads ZERO Read the spring force on the tester scale as shown in View B Figure 6 23 This value is the spring return force exerted under maximum deflection installed in the piston subas sembly Because of the manufacturing tolerances this can be as low...

Page 624: ...es and brake overhauls NOTE Any rework of the adjuster pin must be avoided unless absolutely necessary If required install the adjuster onto the adjuster pin using the following procedure 1 Place the adjuster and pilot pin subassembly onto the end of the adjuster pin 2 Press the adjuster 4 Figure 6 24 off the expendable pilot pin onto the adjuster pin 3 Press the second adjuster onto the adjuster ...

Page 625: ...compress the return spring to minimum height and hold 8 Screw the threaded ring against the spring retainer using a spanner wrench to ensure that the threaded ring is bottomed Holding the spring compressed back off the threaded ring one full turn plus the additional amount needed to install the lock ring into the first available lock ring position NOTE This procedure provides the required built in...

Page 626: ...dust seals are fully seated 6 Install a washer and new O ring onto the exposed part of each adjuster pin 7 Lightly apply silicone grease to the four service piston assemblies and adjuster pin O rings Inspect the outside diameter of each service pis ton for nicks scratches surface roughness or other defects Replace service pistons having any of these defects 8 Install the four service pistons 1 Fig...

Page 627: ...27 mm 5 in parking piston backup ring 2 Figure 6 29 into the outer groove of each parking piston NOTE Position the O rings into the parking piston grooves next to the backup rings so that the O rings are toward the smaller diameter of the parking piston and the backup ring will be farthest from the disc 15 Lightly lubricate two new larger diameter 127 mm 5 in parking piston O rings 3 using sili co...

Page 628: ...per housing install the parking piston adjusting collar into the inner bore of each piston The collar should conform to the shape of the inner bore of the parking piston 20 Install snap ring 2 Figure 6 31 into the snap ring groove of each parking piston inner bore to retain the adjusting collars 21 Make a short bend in the end of a length of safety wire Hook the bent end of the wire into one of th...

Page 629: ...Figure 6 33 and end plate cap screws into each caliper half Tighten the cap screws to 515 624 N m 380 460 ft lb 26 Install a new lining assembly 1 into the caliper half Position the threaded hole into each lining assembly backing plate to align with the hole in the parking piston adjusting bolt 27 Secure the lining assembly to the caliper hous ing using safety wire so that it cannot move Secure th...

Page 630: ... surfaces outer parking piston surfaces and to the threads of the parking piston cap NOTE The concave side of the first spring washer must face the parking piston cup down Install the second cup up third cup down and fourth cup up NOTE Center each of the spring washers in the piston to make installation of the parking piston cap easier 31 Install four spring washers 1 2 Figure 6 35 onto the surfac...

Page 631: ...into the center hole of each parking piston cap Tighten each pipe plug until it is flush with the surface of the cap NOTE Retain the crossover tubes for assembly after the brake is installed onto the vehicle 34 Install the fittings bleeder screws and plugs into the housing subassemblies according to 12 o clock or six o clock installation requirements 35 Cover any open ports to prevent contaminatio...

Page 632: ...e lining which are normal when the caliper is used under high temperature conditions These cracks are referred to as heat check cracks Inspect the following areas for fluid leaks Pistons If fluid leaks at a piston disassemble the caliper Inspect the piston bore O rings and backup rings Service as necessary Elbow Fitting If fluid leaks at the elbow fitting tighten the fitting If the leak continues ...

Page 633: ...ds and wipe dry after cleaning 4 Squeeze the service pistons back into the bores by using a special tool or a large C clamp over the piston and the back side of the caliper Use caution not to damage dust shields 5 Refer to Caliper Assembly Steps 19 35 to install new brake linings 6 Refer to Caliper Installation to install caliper on truck BRAKE DISC Inspection Inspect brake discs for wear 1 Place ...

Page 634: ... brakes until the recommended brake disc sur face temperature is reached then allow brakes to cool Cool brakes if necessary by driving machine Rear brakes will normally cool faster than fronts Repeat cycle 3 4 more times 2 To expedite the burnishing cycles of heating and cooling operate the brakes on only one axle at a time so that the other system will be cooling operate front brakes with rear br...

Page 635: ... 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 until the disc temperatures reach...

Page 636: ...atch excess oil 4 With engine at idle make partial brake applica tion of service brake pedal a Maintaining partial application open bleeder valve until a clean stream of oil is discharged from caliper Use bleeder valves shown in Figure 6 39 b Close bleeder valve 5 Repeat above Steps until all air is bled from all calipers 6 Check hydraulic reservoir level as bleeding takes place maintain correct l...

Page 637: ...CTION L HYDRAULIC SYSTEM INDEX HYDRAULIC SYSTEM L2 HYDRAULIC COMPONENT REPAIR L3 STEERING CIRCUIT L4 STEERING CIRCUIT COMPONENT REPAIR L5 HOIST CIRCUIT L7 HOIST CIRCUIT COMPONENT REPAIR L8 HYDRAULIC CHECKOUT PROCEDURES L10 ...

Page 638: ...L1 2 Index L01041 NOTES ...

Page 639: ...L02043 Hydraulic System L2 1 SECTION L HYDRAULIC SYSTEM INDEX HYDRAULIC SYSTEM L2 3 HYDRAULIC SYSTEM OPERATION L2 3 COMPONENT DESCRIPTION L2 4 ...

Page 640: ...L2 2 Hydraulic System L02043 NOTES ...

Page 641: ...rake circuits share a com mon hydraulic tank 1 Figure 2 1 The tank is located on the left frame rail forward of the rear wheels The service capacity of the tank is 901 l 238 gal Type C 4 hydraulic oil is recommended for use in the hydraulic system NOTE It is recommended that any hydraulic oil to be used for filling or adding to the hydraulic system is routed through a 3 micron filter device prior ...

Page 642: ...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 HIGH PRESSURE HYDRAULIC FILTERS The truck is equipped with high pressure hydraulic oil f...

Page 643: ...e installed on the Overcenter Valve Manifold located above the steering brake pump These fittings are used to attach hoses to an operational truck in the event that the hoist pump hoist valve or other hoist system component malfunctions This will allow maintenance personnel to raise the truck body to dump the load before moving the disabled truck The steering circuit and hoist circuit relief valve...

Page 644: ...FROM BELOW TRUCK 1 Hydraulic Tank 2 Hoist Cylinders 3 Steering Brake Pump 4 Steering Circuit Filter 5 Hoist Circuit Pump 6 Bleeddown Manifold 7 Flow Amplifier 8 Steering Cylinders 9 Steering Accumulators 10 Steering Quick Disconnects 11 Brake Quick Disconnects For Jumper Hose ...

Page 645: ...4 Disassembly L3 6 Inspection Of Parts L3 9 Assembly L3 10 HYDRAULIC TANK L3 16 Filling Instructions L3 16 Removal L3 16 Installation L3 17 HYDRAULIC TANK STRAINERS L3 17 Removal L3 17 Inspect and Clean L3 17 Installation L3 18 HYDRAULIC TANK BREATHERS L3 18 HOIST CIRCUIT FILTERS L3 19 FILTER ELEMENT REPLACEMENT L3 20 Removal L3 20 Installation L3 20 INDICATOR SWITCH L3 20 ...

Page 646: ...L3 2 Hydraulic Component Repair L03039 NOTES ...

Page 647: ...in valve 12 Figure 3 1 located on the bottom of the tank NOTE If oil in the hydraulic tank has not been contaminated the shut off valves can be closed and both pump inlet lines can be drained eliminating the need to completely drain the tank Refer to Figure 3 1 3 Remove the rear axle blower hose support strap FIGURE 3 1 HOIST PUMP PIPING BOTTOM VIEW 1 Hydraulic Tank 2 Hoist Pump Shut Off Valves 3 ...

Page 648: ...bracket Remove the six cap screws holding the support bracket to the T bracket and remove support bracket 11 Make sure the lifting and support devices are in place on both pumps Loosen but do not remove the rear support bracket cap screws holding the steering pump Lower the pumps allowing hoist pump to come down further than steering pump 12 Remove the four cap screws 10 Figure 3 2 Slide hoist pum...

Page 649: ...efer to Hydraulic Tank this section for filling instructions 9 Open the three suction line shut off valves Loosen cap screws at the pump on suction hoses 12 16 to bleed trapped air Then loosen cap screws at the pump on pressure hoses to bleed any trapped air Tighten all cap screws securely NOTE If trapped air is not bled from steering pump possible pump damage and no output may result 10 Reconnect...

Page 650: ...e cap screws 5 securing the bear ing plate to the transition plate and remove O ring 7 Remove dowels if damaged or if replacement of the transition plate is necessary 6 Remove connector plate 9 Figure 3 3 Remove O ring 8 and steel rings 10 and 14 Remove dowels 6 if damaged or if con nector plate replacement is necessary NOTE If the connector plate is stuck tap lightly with a plastic hammer to loos...

Page 651: ...move dowels 16 if damaged or if replace ment of the bearing plate 10 is necessary 13 Unthread the thru studs 12 and remove Remove flange 5 if stuck tap flange lightly with a plastic hammer to loosen Remove O ring 8 Remove dowels 6 if damaged or if replacement of the flange 5 or gear plate 7 is necessary 14 Remove steel rings backup ring O ring and retainer Remove drive gear 1 and idler 3 from gear...

Page 652: ... out of the flange bore Refer to Fig ure 3 6 Use care not to mar scratch or dam age the seal bore surface or bearings 17 After the seals and snap ring have been removed clean the bore thoroughly If neces sary the bore may be smoothed with number 400 emery paper only FIGURE 3 5 SEAL REMOVAL PREPARATION 1 Flange 2 Bearings 3 Wooden Blocks FIGURE 3 6 SHAFT SEAL REMOVAL 1 Flange 2 Punch 3 Bearings ...

Page 653: ...scard and replace with new 3 Examine the gears If excessive wear is visible on the journals sides or face of the gears or at the point where the drive gear rotates in the lip seal discard and replace with new 4 If any of the internal parts show excessive wear replace with new Replace all O rings and seals with new 5 Inspect the bearings if they are worn beyond the gray teflon into the bronze mater...

Page 654: ...e seals with hydraulic oil Position the inboard shaft seal 3 Figure 3 9 with the metal face toward the outboard end of the flange 6 Position the press ring over the seal Make sure that the seal stays centered and true with the bore and start applying pressure with the vise Continue pressing the seal until it just clears the snap ring groove in the bore 7 Install snap ring 2 Figure 3 9 Make sure th...

Page 655: ...n plate 9 on the suction side of the gear plate The isolation plate has a relief area milled on one side turn that side up or toward the pressure plate 12 With the bronze side up and the milled slot fac ing toward the discharge side slide pressure plate 2 Figure 3 11 down into the gear bores until it rests on the backup ring and O ring Do not force the plate down the gear bores If it hangs up on t...

Page 656: ...es gear pump timing 14 With the extension end of the drive gear facing toward the shaft seals install the drive gear Do not drop the gear in the bore as damage to the bronze face of the pressure plate could result Use care when pushing the drive gear exten sion thru the shaft seals Install the idler gear 15 Install the opposite pressure plate with the bronze side down and the milled slot facing to...

Page 657: ...and connector plate O ring 7 Install dowel 14 if removed Lubricate the I D of the bearings 17 and install connector plate 6 Install snap ring 8 and coupling 9 FIGURE 3 13 HOIST PUMP REASSEMBLY 1 Drive Gear and Shaft 2 Idler Gear 3 Gear Plate 4 Relief 5 O Ring 6 Connector Plate 7 O Ring 8 Snap Ring 9 Coupling 10 Thru Studs 11 Steel Ring 12 Backup Ring 13 O Ring Retainer 14 Dowel 15 Isolation Plate ...

Page 658: ... Make sure relief in gear plate is toward bearing plate 7 21 Install rear drive gear 1 and idler gear 13 The rear drive gear must be timed with the front drive gear This is accomplished by lining up a tooth on the rear drive gear with the valley of two teeth on the front drive gear as shown in Figure 3 12 FIGURE 3 14 HOIST PUMP REASSEMBLY 1 Drive Gear Rear 2 Dowel 3 O Ring 4 O Ring 5 Coupling 6 Co...

Page 659: ...hten nuts to 325 to 339 N m 240 to 250 ft lbs torque 28 Using an 18 inch 45 cm adjustable wrench check pump drive shaft rotation The drive shaft will be tight but should turn freely with a maxi mum of 7 to 14 N m 5 to 10 ft lbs torque after the initial surge Refer to Figure 3 15 29 If the shaft will not turn properly disassemble the pump and examine the parts for burrs or for eign material causing...

Page 660: ...d be visible in the lower sight glass If not stop the engine and add oil per Filling Instructions Minor adjustments to oil level can be made by using the drain cocks 5 next to filler neck If a hydraulic system component fails an oil anal ysis should be made before replacing any com ponent If foreign particles are evident system must be flushed Refer to Hydraulic System Flushing instructions Remova...

Page 661: ...f trapped air is not bled from steering pump possible pump damage and no output may result HYDRAULIC TANK STRAINERS Removal Prior to opening the hydraulic tank allow at least 90 seconds for the accumulator to bleed down after engine shutdown with the key switch OFF 1 Stop the engine and turn the key switch OFF and wait at least 90 seconds NOTE If the oil is to be reused clean containers must be us...

Page 662: ...ped air inside steering pump Refer to Pump Pressure Setting Section L for air bleed ing procedure NOTE If trapped air is not bled from steering pump possible pump damage and no output may result HYDRAULIC TANK BREATHERS There are two breather filters 3 Figure 3 16 located on top of the hydraulic tank to allow air in and out of the tank The filters should be replaced at the interval specified on th...

Page 663: ...ch operating temperature before using the warning lamp as an indicator to change the element Refer to Section P Lubrication and Service for rec ommended normal filter element replacement inter val Earlier replacement may be required if the restriction indicator lamp turns on Premature filter restriction may indicate a system component failure and signal a service requirement before extensive secon...

Page 664: ...e care to avoid contact with hot oil if truck has been operating Avoid spillage and contami nation 3 Loosen setscrew 8 Remove bowl 10 4 Remove filter element 9 5 Remove and discard backup ring 7 and O ring 6 6 Clean bowl in solvent and dry thoroughly Installation 1 Install new element 9 Install new O ring 6 and backup ring 7 2 Install bowl on filter head and tighten Lock in place with setscrew 8 3...

Page 665: ...IT L4 4 FLOW AMPLIFIER L4 4 No Steer L4 6 Steering Left L4 8 Steering Right L4 10 No Steer External Shock Load L4 12 BLEED DOWN MANIFOLD L4 14 ACCUMULATORS L4 15 Low Precharge Warning Switch L4 15 HIGH PRESSURE FILTER L4 15 STEERING BRAKE PUMP L4 15 Operation L4 16 PRINCIPLE OF OPERATION L4 18 Full Pump Volume L4 18 Half Pump Volume L4 18 Neutral Position L4 19 ...

Page 666: ...L4 2 Steering Circuit L04048 NOTES ...

Page 667: ... circuit pressure The top side of the piston is pre charged to 9 653 kPa 1400 psi with pure dry nitrogen when the piston is at the bottom The accumulator oil is supplied constantly to the flow amplifier via the bleed down manifold The accumu lators also act as a reservoir for pressurized hydrau lic oil to be used during an emergency situation should the hydraulic steering oil supply malfunction fo...

Page 668: ...he operator s cab The steering control unit is connected directly to the steering col umn The valve incorporates a rotary meter which ensures the oil volume supplied to the steering cylin ders is proportional to the rotation of the steering wheel Operation of the steering control unit is both manual and hydraulic in effect providing the operator with power steering The valve will be spring returne...

Page 669: ...L04048 Steering Circuit L4 5 FIGURE 4 2 FLOW AMPLIFIER ...

Page 670: ...so out port P through a hose to port P on the steering control unit In the control unit it goes to a closed area in the con trol valve As pressure builds up in these two areas oil passes through orifices in the end of the priority valve and builds pressure on the end of the valve and port PP When pressure reaches approximately 3 447 kPa 500 psi the spool moves compressing its spring and closes off...

Page 671: ...L04048 Steering Circuit L4 7 FIGURE 4 3 FLOW AMPLIFIER No Steer ...

Page 672: ... oil access to a series of holes K that are in the same plane as hole G The passage of oil through holes K past the valve body is metered by holes K being opened the same propor tion as is hole G The number of holes K 9 in sleeve E determine the amount of additional oil that is added to the steering control unit oil passing through hole G This com bined oil going to the center area Q of the direct...

Page 673: ...L04048 Steering Circuit L4 9 FIGURE 4 4 FLOW AMPLIFIER Steering Left ...

Page 674: ...e flow amplifier assembly at port R and shifts the directional valve the opposite direction The oils flow through the amplifier valve exactly the same The combined oil from the amplifier valve passes through the center area Q of the directional valve to port CR where it goes to the opposite ends of the steering cylinders to turn the wheels right The returning oil comes back through port CL to go t...

Page 675: ...L04048 Steering Circuit L4 11 FIGURE 4 5 FLOW AMPLIFIER Steering Right ...

Page 676: ...d to port CR The shock and suc tion relief valve inside the flow amplifier assembly at port CR will open at its adjusted setting 19 995 kPa 2900 psi and allow oil to escape from the pressur ized ends of the cylinders preventing a higher pres sure As the cylinders are allowed to move the other ends will have less than atmospheric pressure on port CL This low pressure permits oil that is escaping th...

Page 677: ...L04048 Steering Circuit L4 13 FIGURE 4 6 FLOW AMPLIFIER No Steer External Shock Load ...

Page 678: ...re not individually rebuildable and are factory preset Refer to Steering Circuit Check Out Procedure for relief valve setting Each time the key switch is turned OFF it energizes the bleed down solenoids When the bleed down solenoids are energized all hydraulic steering pres sure including the accumulator is bled back to the hydraulic tank Brake pressure however will not bleed down due to internal ...

Page 679: ... the key switch is turned ON and before the engine is started If nitrogen pressure is too low the warning lamp turns ON a latching circuit prevents the warn ing lamp from turning off when the engine is started and steering system pressure compresses the nitro gen remaining in the accumulator Do not operate the truck with less than 7 584 kPa 1100 psi nitrogen precharge in the accumula tors because ...

Page 680: ...cing the piston shoes against the swashblock The semi cylindrical shaped swashblock limits the piston stroke and can be swivelled in arc shaped saddle bearings 21 The cradle is swivelled by the control piston 14 1 Plug 2 O Ring 3 Spring 4 Back Up Ring 5 O Ring 6 Back Up Ring 7 O Ring 8 Piston Ring 9 O Ring 10 Back Up Ring 11 Spring 12 Control Piston Stop Pin 13 Spring 14 Piston 15 Pin 16 Control P...

Page 681: ...L04048 Steering Circuit L4 17 FIGURE 4 9 CUT AWAY VIEW OF STEERING PUMP ...

Page 682: ...its outermost stoke is reached At that point the piston bore passes from the left crescent port to the right crescent port While rotating across the right side crescent each piston moves downward on the angled swashblock face Thus each piston is forced inward Each piston displaces fluid through the right side crescent to port B until it s innermost stroke is reached At that point the piston bore a...

Page 683: ...herefore no inward or outward motion of the pump pistons exists as pis ton shoes rotate around the swashblock face The lack of inward and outward motion results in no fluid being displaced from the piston bores to the cres cents in the valve plate and subsequently no deliv ery from pump ports 1 Control Piston 2 Housing 3 Piston 4 Swashblock FIGURE 4 12 PUMP IN NEUTRAL POSITION FIGURE 4 13 STEERING...

Page 684: ...L4 20 Steering Circuit L04048 NOTES ...

Page 685: ...G L5 8 STEERING ACCUMULATOR CHARGING PROCEDURE L5 9 Temperature During Precharge L5 12 ACCUMULATOR STORAGE PROCEDURES L5 12 Instructions For Storing Bladder Accumulators L5 12 Installation L5 13 Bladder Storage Procedures L5 13 FLOW AMPLIFIER L5 14 Removal L5 14 Installation L5 14 Disassembly L5 16 Reassembly L5 17 STEERING CONTROL UNIT L5 18 Removal L5 18 Spline Inspection L5 18 Installation L5 1...

Page 686: ... 28 Removal L5 28 Installation L5 29 Disassembly L5 30 Control Piston Group L5 30 Valve Plate Group L5 31 Rotating Group L5 31 Swashblock Group L5 32 Driveshaft Group L5 32 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 Sw...

Page 687: ...d 10 5 Clean exterior of manifold before removing any components Installation 1 Install bleed down manifold Secure in place with cap screws Tighten cap screws to stan dard torque 2 Unplug lines and attach Tighten connections securely 3 Attach electrical leads to the bleed down sole noid and steering pressure switch If check valves or relief valves were removed replace using new O ring seals 4 Star...

Page 688: ...4 Figure 5 2 turns Turning the complete charging valve assembly may result in the valve assembly being forced out of the accumulator by the nitrogen pressure inside Wear protective face mask when discharging nitrogen gas 3 Loosen small hex nut 4 Figure 5 2 three com plete turns Remove valve cap 1 Install charg ing manifold assembly and bleed off all nitrogen pressure 4 Disconnect electrical leads ...

Page 689: ... do not overtighten as this may distort the accu mulator wall 3 If the pressure switch 9 Figure 5 3 or valve assembly 8 were removed install at this time Connect electrical leads to the pressure switch Using a new O ring uncap and connect the hydraulic line to the accumulator 4 Precharge the accumulator with pure dry nitro gen as outlined in the Steering Accumulator Charging Procedure NOTE Permane...

Page 690: ...th a cleansing agent check the inside and outside of shell Special attention should be given to the area where the gas valve and hydraulic assembly pass through the shell Any nicks or damages in this area could destroy the accumulator bladder or damage new seals If this area is pitted con sult your Komatsu Service Manager Repair of the housing by welding machining or plating to salvage a worn area...

Page 691: ...til it seats solidly into position on the shell fluid port opening 12 Connect nitrogen charging kit to charging valve Refer to Steering Accumulator Charging Pro cedure to charge accumulator With hydraulic port assembly firmly in place slowly pressurize the bladder using dry nitrogen with sufficient pressure first 172 kPa 25 psi then approxi mately 345 kPa 50 psi to hold port assembly in place so b...

Page 692: ...es sary for a portion of the test 1 Refer to Steering Accumulator Charging Proce dure to precharge accumulator first to 172 kPa 25 psi and then to 9653 kPa 1400 psi 2 After accumulator is charged with nitrogen to 9653 kPa 1400 psi tighten swivel nut 4 Fig ure 5 6 to close internal poppet at 11 5 17 cm kg 10 15 in lbs torque 3 Submerge accumulator assembly under water and observe for 20 minutes No ...

Page 693: ...a tor under pressure 2 Be certain oil pressure has been relieved then remove bleed plug 12 Figure 5 5 from each accumulator being charged NOTE If a new or rebuilt accumulator or any bladder accumulator with all nitrogen discharged is being precharged while installed on the truck and connected to the hydraulic system the oil side of the accumulator must be vented to allow proper bladder expansion T...

Page 694: ...p 13 If the precharge is less than 172 kPa 25 psi then set the regulator 6 Figure 5 7 for 172 kPa 25 psi at gauge 5 Completely open valve 1 or 8 which ever one is connected to the accumulator then slightly open valve 2 and slowly fill the accumulator based on the fill time rate specified in Table 1 12 After 172 kPa 25 psi precharge pressure is obtained in gauge 9 close valve 2 13 If accumulator is...

Page 695: ...el connec tor to remove charging hose assembly Check for nitrogen leaks using a common leak reac tant NOTE If a new charging valve was installed the valve stem must be seated as follows a Tighten small hex swivel nut 4 Figure 5 6 to 14 2 N m 10 5 ft lbs torque b Loosen small hex swivel nut c Retighten small hex swivel nut to 14 2 N m 10 5 ft lbs torque d Again loosen small hex swivel nut e Finally...

Page 696: ... the accumulators to operating pressure while installed on the truck DO NOT handle the accumulator with a nitrogen pre charge greater than 827 kPa 120 psi Instructions For Storing Bladder Accumulators 1 If accumulator was just rebuilt make sure there is approximately 5 of accumulator capacity of oil inside the accumulator before adding nitrogen precharge pressure Refer to Table 1 for oil lubricati...

Page 697: ...cumulator and reach the other end 5 Lay the accumulator flat on the work bench or floor and slowly rotate accumulator two com plete revolutions This will thoroughly coat the accumulator walls with a film of oil necessary for bladder lubrication during precharging 6 Stand the accumulator upright and secure Install the pressure gauges and charge the accumulator first to 172 kPa 25 psi then to 690 kP...

Page 698: ...ove into posi tion 2 Install mounting cap screws and tighten to stan dard torque 3 Identify hydraulic line location unplug lines and connect at proper location tighten fittings securely Use new O rings on the flange fittings FIGURE 5 8 FLOW AMPLIFIER VALVE 1 Cap Screw 2 Lockwasher 3 Cap Screws 4 Lockwasher 5 Cover 6 O Ring 7 O Ring 8 O Ring 9 Not Used 10 O Ring 11 O Ring 12 Shock Suction Valve Com...

Page 699: ...L05035 Steering Component Repair L5 15 FIGURE 5 8 FLOW AMPLIFIER VALVE ...

Page 700: ...p 34 and springs 32 33 Remove O rings 40 49 5 Remove spring control 31 and main spool 29 Remove priority valve spool 43 Remove spring control 25 springs 23 24 and spring stop 22 6 Remove amplifier valve spool assembly 51 Set amplifier valve spool assembly aside for fur ther disassembly if required 7 Remove shock and suction valve 28 Set shock and suction valve aside for further disas sembly if req...

Page 701: ...seal 5 and plug 20 Tighten plug to 2 5 N m 22 in lbs torque 5 Install counterpressure valve assembly 15 Install plug 17 using new O ring 16 6 Install both shock and suction valves 12 28 as complete units Install spring stop 22 springs 23 24 and spring control 25 Install orifice screws 26 35 if removed from main spool 29 Install main spool 29 7 Install amplifier spool assembly 51 Install pri ority ...

Page 702: ...ines are opened 3 Tag all hydraulic lines for proper identification during installation Disconnect hydraulic lines 3 4 5 6 7 Figure 5 11 at steering control unit 2 ports and plug Move lines clear of valve 4 Remove the four mounting cap screws flat washers and lockwashers securing the steering control unit to the mounting bracket Remove the steering control unit 5 Place the steering control unit in...

Page 703: ...ng the steering control unit hydrau lic steering lines should be checked for correct hook up before starting the engine 4 Tighten all cap screws to standard torque Unplug and attach hydraulic lines to their proper ports Refer to Figure 5 11 for port locations 5 Start engine and check for proper steering func tion and any leaks 6 Replace access cover and secure in place with cap screws and lockwash...

Page 704: ...housing bore 10 Remove O ring 5 kin ring 6 and bearing assembly 7 11 Remove ring 8 and pin 9 and carefully push inner spool out of outer sleeve 12 Press the neutral position springs 10 out of their slot in the inner spool 13 Remove the dust seal 2 Figure 5 14 using a screwdriver Take care not to scratch or dam age the dust seal bore Cleaning and Inspection 1 Clean all parts carefully with fresh cl...

Page 705: ... install the neutral position springs place a screwdriver in the spool slot as shown in Figure 5 16 2 Place one flat neutral position spring on each side of the screwdriver blade Do not remove screwdriver 3 Push two curved neutral position springs in between one side of the screwdriver blade and a flat spring Repeat for the opposite side Remove the screwdriver 4 Slide the inner spool in the sleeve...

Page 706: ...to position 8 Position the O ring and kin ring on the spool 9 Position the steering unit with the housing hori zontal Slowly guide the lubricated spool and sleeve with fitted parts into the bore using light turning movements Refer to Figure 5 18 NOTE Cross pin must remain horizontal when spool and sleeve are pushed into bore to prevent pin from dropping out of spool FIGURE 5 17 BEARING INSTALLATIO...

Page 707: ...ng Spools 3 Ball 4 Threaded Bushing 5 O Ring 6 Kin Ring 7 Bearing Assembly 8 Ring 9 Pin 10 Neutral Position Springs 11 Cardan Shaft 12 Spacer 13 Tube 14 O Ring 15 Distribution Plate 16 Gear Wheel Set 17 O Ring 18 O Ring 19 End Cover 20 Washers 21 Rolled Pin 22 Cap Screws with Pin 23 Cap Screws ...

Page 708: ...an shaft It may be necessary to rotate the gear slightly to find the matching splines on the cardan shaft Splines are machined to insure proper align ment of cardan shaft and inner gear wheel 15 Grease the O rings 17 18 on both sides of the outer gear wheel with Vaseline and install 16 Align outer gear wheel bolt holes with tapped holes in housing and match marks 17 Align cover 19 using match mark...

Page 709: ...slowly advancing rod over rod seal and rod wiper 4 Install new piston seal 4 and bearing 3 on piston 5 Make sure the piston seal is tight on piston NOTE Installation of the piston seal may require the following procedure a Heat the piston seal assembly in boiling water for 3 to 4 minutes b Remove piston seal assembly from the water and assemble on the piston Do not take longer than 5 seconds to co...

Page 710: ...al filter element replacement inter val Earlier replacement may be required if the restriction indicator lamp turns on Premature filter restriction may indicate a system component failure and signal a service requirement before extensive secondary damage can occur NOTE An early indication of the filter warning light at first installation may be due to restriction in the filter as it cleans the sys...

Page 711: ...tallation 1 Install new element 7 Install new O ring 6 on bowl 2 Install bowl on filter head and tighten 3 Install drain plug 10 and O ring 9 Tighten bleed plug 4 Indicator Switch The indicator switch 1 Figure 5 22 is factory preset to actuate at 241 kPad 35 psid When activated the switch will illuminate the amber Hydraulic Oil Filter warning lamp located on the overhead display in the operator s ...

Page 712: ...nk by use of the drain located on the bottom side of the tank NOTE 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 3 micron filtering system available for refill 3 Disconnect the suction and discharge lines at the steering pump 5 Figure 5 23 Disconnect and cap pump case drain line from fitting at top of pump housin...

Page 713: ...ugh opening until steering pump housing is full This may require 2 3 l 2 3 qts of oil 8 Uncap the case drain line connect to steering pump fitting and tighten case drain line 9 Replace hydraulic filter elements Refer to Hydraulic Filters earlier in this section NOTE Use only Komatsu filter elements or elements that meet the Komatsu hydraulic filtration specification of Beta 12 200 10 Open shut off...

Page 714: ...aces of dust sand or other abrasive particles which could damage the unit are in the air Do not work near welding sand blasting grinding benches and the like Place all parts on a CLEAN surface To clean parts which have been disassembled it is impor tant CLEAN solvents are used All tools and gauges should be clean prior to working with these units and new CLEAN and threadless rags used to handle an...

Page 715: ...in 8 contacts the sleeve Use a large mallet to drive piston and sleeve assembly outward from the valve plate 14 When all sleeve seals 5 6 7 are clear of the valve plate re extend control piston 11 While tipping the assembly enough to clear the hole pull the assembly from the valve plate 15 Remove pin 18 from control piston by pressing or tapping it out through the hole on opposite side Control sto...

Page 716: ...of the pump housing Saddle bearings 24 can then be easily removed and saddle O ring 21 may also be removed at this time INSPECTION Always wear safety goggles when using solvents or compressed air Failure to wear safety goggles could result in serious personal injury 1 Clean all parts thoroughly 2 Replace all seals and O rings with new parts 3 Check all locating pins for damage and all springs for ...

Page 717: ...1 Shaft 2 Bearing 3 Snap Ring 4 Retainer Ring 5 Lifting Eyes 6 Name Plate 7 Screw Drive 8 Name Plate 9 Plug 10 O Ring 11 Plate 12 Adjusting Screw 13 O Ring 14 Gland 15 O Ring 16 Jam Nut 17 Pin 18 O Ring 19 Pin 20 Housing 21 Seal Retainer 22 O Ring 23 Plug 24 Seal 25 Plug ...

Page 718: ...eeve 5 Back up Ring 6 O Ring 7 O Ring 8 Pin 9 Back up Ring 10 Cylinder Barrel 11 Control Piston 12 Ball 13 Piston Shoe Assembly 14 Retainer Ring 15 Washer 16 Pin 17 Link 18 Pin 19 Dowel Pin 20 Saddle 21 O Ring 22 Roll Pin 23 Roll Pin 24 Saddle Bearing 25 Swash Block 26 Cylinder Bearing 27 Retainer 28 Spring ...

Page 719: ...d cra dle All shoes must be equal within 0 003 mm 0 0001in If one or more piston shoe assemblies 13 needs to be replaced all piston shoes assemblies must be replaced c Inspect cylinder bearing 26 and matching cylinder barrel bearing mating surface for galling pitting or roughness Replace if nec essary FIGURE 5 26 PUMP REAR HOUSING 1 Plug 2 O Ring 3 Cap Screw 4 O Ring 5 Plug 6 O Ring 7 Plug 8 Valve...

Page 720: ...emove 4 way valve 8 and relief valve 14 from compensator block Remove all plugs and orifices 10 30 Clean block in solvent inspect all passages and orifices for obstruc tions 20 Remove unloader valve from block 29 Remove plugs and clean block passages If unloader is inoperative replace entire module Stroke Adjuster Assembly 21 Measure and record dimension A on stroke adjuster assembly as shown in F...

Page 721: ...pinned make certain swashblock strokes SMOOTHLY in the saddle by pulling firmly on the free end of control link 17 Figure 5 25 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 in...

Page 722: ...ing or damage 22 Push cylinder barrel forward until the cylinder spline reaches the driveshaft spline Rotate the cylinder slightly to engage shaft splines 23 Continue to slide cylinder barrel forward until it encounters the cylinder bearing 26 Figure 5 25 Lifting the driveshaft slightly helps cylinder barrel 10 and cylinder bearing engagement Continue pushing cylinder forward until the pis ton sho...

Page 723: ... remove cap screw from pin NOTE Valve plate is a slight press fit into pump housing Make sure pilot diameter on valve plate 17 Figure 5 26 is aligned with mating diameter on the pump housing prior to assembly 41 Insert four cap screws 20 Figure 5 26 and alternately tighten until valve plate is drawn up to the pump housing Tighten cap screws evenly to 330 N m 244 ft lbs torque 42 Install O ring 22 ...

Page 724: ...L5 40 Steering Component Repair L05035 NOTES ...

Page 725: ...lters L7 4 Hoist Valve L7 5 Hoist Pilot Valve L7 6 Hoist up Limit Solenoid L7 6 Pilot Operated Check Valve L7 6 Counterbalance Valve Manifold L7 7 HOIST SYSTEM OPERATION MODES L7 8 Float Position Of Pilot Valve And Body On Frame Figure 7 6 L7 8 Power Up Operation Figure 7 7 L7 10 Hold Operation Figure 7 8 L7 12 Power Down Operation Figure 7 9 L7 14 Float Operation Figure 7 10 L7 16 ...

Page 726: ...L7 2 Hoist Circuit L07034 NOTES ...

Page 727: ...the operator through a flexible cable to the hoist pilot valve 6 in the hydraulic component cabinet located behind the operator s cab Also in the hydraulic cabinet is the hoist up limit solenoid 4 The hoist up limit solenoid prevents the hoist cylinders from extending to maxi mum physical limit A counterbalance valve in the overcenter manifold 12 prevents abrupt cylinder extension due to material ...

Page 728: ...e 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 High Pressure Filters Hoist pump output flows to two remote mounted high pressure filters located on the lower inboard side of the fuel tank The filter elements are rated at 7 micron The filter assembly is equipped with a bypass valve which per...

Page 729: ...e core and the outlet and provides a con trolled back pressure in the low pressure core when oil is returning to tank The load check allows free flow from the inlet to the high pressure core and prevents flow from the high pressure core to the inlet The anti void check valve allows free flow from the low pressure core to the high pressure core and pre vents flow from the high pressure core to the ...

Page 730: ... way load check valve which allows free flow from the center passage to bridge core and prevents reverse flow The hoist pilot valve is also equipped with a power down relief valve 8 The power down relief valve is located between the power down control port and return galley The power down relief valve limits power down pressure at 10342 kPa 1500 psi Hoist up Limit Solenoid The Hoist up Limit Solen...

Page 731: ... the counterbalance valve There are 2 pilot pressures that can open it cylinder head raise pressure rod return pressure If there is no raise pressure it will take 20684 kPa 3000 psi of rod end return pressure to open it If there is theoreti cally 4592 kPa 666 psi or more of raise pressure it is wide open for the return oil In between these 2 maximums the ratio of raise return pressure is 1 4 5 to ...

Page 732: ...n to the tank through Hoist Valve Port 10 Oil also flows out Hoist Valve Port 12 to Port 12 on the Pilot Valve through the Hoist Pilot Valve spool and out Pilot Valve Port 10 to the tank This oil flow is limited by orifices in the inlet sections of the Hoist Valve and therefore has no pressure buildup FIGURE 7 6 HOIST CIRCUIT FLOAT POSITION 1 Hoist Relief Valve 17237 kPa 2500 psi 2 Flow Control Va...

Page 733: ...L07034 Hoist Circuit L7 9 FIGURE 7 6 FLOAT POSITION ...

Page 734: ...n pressure passes through the check poppet in the bottom of Spool 7 to build pressure under the spool which moves the spool upward compressing the top spring This movement allows the returning cylinder oil to flow into the Low Pressure Passage 20 to the Low Pressure Relief Valve 3 Approximately 517 kPa 75 psi causes this valve to open allowing the oil to flow out Port 10 to the tank The counterbal...

Page 735: ...L07034 Hoist Circuit L7 11 FIGURE 7 7 POWER UP ...

Page 736: ... trap the oil in the cylin ders and hold the body in its current position FIGURE 7 8 HOIST CIRCUIT HOLD POSITION 1 Hoist Relief Valve 17237 kPa 2500 psi 2 Flow Control Valve 3 Low Pressure Relief Valve 517 kPa 75 psi 4 Counterbalance Valve 5 Rod End Work Port 6 Hoist Cylinders 7 Rod End Spool 8 Head End Spool 9 Head End Work Port 10 Return Port 11 Supply Port 12 Pilot Supply Port 13 Power Up Pilot...

Page 737: ...L07034 Hoist Circuit L7 13 FIGURE 7 8 HOLD POSITION ...

Page 738: ...ve spool As oil attempts to return from the head end of the hoist cylinders it initially encounters the closed Head End Spool 8 Pressure increases on the bottom end of the spool causing it to move upward This allows the returning oil to go into the Low Pressure Passage 20 build up 517 kPa 75 psi to open the Low Pressure Relief 3 and exit the Hoist Valve through Port 10 to the tank As the body desc...

Page 739: ...L07034 Hoist Circuit L7 15 FIGURE 7 9 POWER DOWN ...

Page 740: ...re under the Rod End Spool 7 to move the spool upward This connects the Low Pressure Passage to the Rod End of the hoist cylinders The 517 kPa 75 psi in the Low Pressure Passage causes oil to flow to the rod end of the cylin ders to keep them full of oil as they retract When the body reaches the frame and there is no more oil flow from the cylinders the Main Spools center them selves and close the...

Page 741: ...L07034 Hoist Circuit L7 17 FIGURE 7 10 FLOAT POSITION ...

Page 742: ...L7 18 Hoist Circuit L07034 NOTES ...

Page 743: ...sassembly L8 5 Cleaning and Inspection L8 6 Assembly L8 6 SPOOL SECTION L8 6 Disassembly L8 6 Cleaning and Inspection L8 9 Assembly L8 9 HOIST PILOT VALVE L8 10 Removal L8 10 Installation L8 10 Disassembly L8 11 Cleaning and Inspection L8 12 Assembly L8 13 BODY UP LIMIT SOLENOID L8 14 PILOT OPERATED CHECK VALVE L8 14 HOIST CYLINDERS L8 14 Removal L8 14 Installation L8 15 Disassembly L8 16 Cleaning...

Page 744: ...SSEMBLY OF QUILL AND CYLINDER L8 19 Quill Installation L8 19 Installation of Check Balls and Plugs in Quill L8 20 Assembly of Cylinder L8 21 COUNTERBALANCE MANIFOLD L8 23 DISABLED TRUCK DUMPING PROCEDURE L8 24 Hookup L8 24 Dumping Procedure L8 24 ...

Page 745: ...roximately 145 KgS 320 lbs Use a suitable lifting device that can handle the load safely 5 Attach a suitable lifting device that can handle the load safely to the hoist valve and remove hoist valve from truck 6 Move the hoist valve to a clean work area for disassembly Installation 1 Attach a suitable lifting device to the hoist valve Move the hoist valve into position with the sepa rator plate 8 F...

Page 746: ...the machined sealing surfaces for scratches or nicks If scratches or nicks are found remove by lapping on a smooth flat steel surface with fine lapping compound 3 Lubricate the new O rings lightly with multipur pose grease Replace O rings between sec tions Stack the sections together making sure O rings between the sections are properly posi tioned 4 Install the four tie rods with the dished washe...

Page 747: ...n relief valve 4 is factory preset at 17237 kPa 2500 psi Replace as a complete assembly only If adjustment is neces sary refer to Checking Hoist System Pressure Relief Valve later in this section NOTE If restrictor poppet removal in cover 1 is required refer to step 4 and Figure 8 6 4 Remove sleeve 9 backup ring 8 O ring 7 backup ring 6 Remove backup ring 5 O ring 4 backup ring 3 and restrictor po...

Page 748: ...pec tive bores Install springs 12 4 Install O rings 10 and cover 13 Install cap screws 14 Tighten cap screws to 81 N m 60 ft lbs torque 5 Install low pressure relief 7 in sleeve 6 and install assembly in housing 9 Install main relief valve 4 Install springs 3 5 Install cover 2 Install cap screws 1 Tighten cap screws to 81 N m 60 ft lbs torque Connect external tube tighten nuts to 34 N m 25 ft lbs ...

Page 749: ... 5 Remove spool assembly 2 Figure 8 9 Note the color of the lower spring blue to insure proper location during reassembly Also note the V groove 1 on end of spool FIGURE 8 7 POPPET BALL 1 Poppet 2 Steel Ball 3 O Ring 1 Restrictor Poppet 2 O ring 3 Backup Ring 4 Seal Ring 5 O Ring Note Items 2 3 not used on all valves FIGURE 8 8 RESTRICTOR POPPET REMOVAL 1 V Groove 2 Spool Assembly 3 Spool FIGURE 8...

Page 750: ...3 Spring 4 Plug 5 Poppet Red 6 Spool End 7 Spool 8 Spring Blue 9 Spool End 10 Poppet White 11 Spring Seat 12 O Ring 13 O Ring 14 Plug 15 Spool Housing 16 Cover 17 Plug 18 O Ring 19 O Ring 20 Spring Seat 21 Spring Blue 22 Spool End 23 Spool 24 Spool End 25 Poppet Green 26 Plug 27 Spring 28 Spring Seat ...

Page 751: ...threads of spool end 6 Install spool end 6 and tighten to 34 N m 25 ft lbs torque Install poppet 5 Apply Dri loc 204 to the threads of plug 4 Install plug 4 and tighten to 20 N m 15 ft lbs torque NOTE Poppets 5 10 and 25 may be color coded and must be installed in their original location 3 Repeat step 2 for the opposite end of spool 7 Make sure spring 8 is blue in color 4 Lubricate spool assembly ...

Page 752: ...ic lines 2 13 14 and 15 over valve ports and assemble fittings Tighten hydraulic line connections securely 3 Place hoist control lever in spring centered position Adjust pilot valve spool until centerline of cable attachment hole extends 1 16 in 29 5 mm from the face of the valve body 4 Align control cable eye with pilot valve spool hole and insert pin 9 Secure pin in place with cotter key 5 5 Thr...

Page 753: ...efully slide the spool 14 out of the spool housing 17 Remove seal retainer 25 wiper 26 and O ring 27 from spool 14 5 Insert a rod in the cross holes of the detent pin 3 and unscrew from spool 14 Slight pres sure should be exerted against the detent pin as it disengages and spring tension is released 6 Remove spring seats 19 spring 4 and spacer 5 1 Snap Ring 2 Ball 4 3 Detent Pin 4 Spring 5 Spacer ...

Page 754: ...d Inspection 1 Clean all parts including housings in solvent and blow dry with compressed air 2 Inspect seal counter bores they must be free of nicks or grooves 3 Examine springs for breaks or distortion 4 Inspect spool 14 Figure 8 12 The spool must be free of longitudinal score marks nicks or grooves 5 Test spool 14 in spool housing for fit Spool must fit freely without binding through a com plet...

Page 755: ...96 in lbs torque Install spring 20 Carefully install spool into spool housing 8 Apply grease to the cross holes of the detent pin 3 to hold balls 21 and 2 9 Slide detent sleeve 22 into cap 24 and place over a punch Using this punch depress ball 21 and insert balls 2 in detent pin cross holes 10 While holding down on ball 21 slide detent sleeve 22 and cap 24 as an assembly over the detent pin 3 Con...

Page 756: ...e engine and key switch has been OFF for at least 90 seconds to allow accumulator to bleed down Be sure Park Brake is applied 2 Disconnect the lubrication lines to the upper and lower bearings of the hoist cylinder 3 Remove cap screw and lockwashers from clamps securing the hydraulic hoses to the hoist cylinder Cap and plug lines and ports to pre vent excessive spillage and contamination Secure cy...

Page 757: ... with the air bleed vent plug toward the front of the truck Install spacer 6 Figure 8 17 Align bearing eye with pivot point and push cylinder into place 2 Install retaining plate 3 locking plate 2 and cap screws Tighten cap screws to 298 N m 220 ft lbs torque Bend locking plate tabs over cap screw flats 3 Align the top hoist cylinder bearing eye with the bore of the upper mounting bracket Refer to...

Page 758: ...r assembly out of cylin der housing If equipped remove cushion ring 24 NOTE As internal parts are exposed protect machined surfaces from scratches or nicks 8 Rotate the cylinder housing 180 Remove the retainer installed in step 5 9 Fabricate a round disc 318 mm 12 5 in in diameter 10 mm 0 38 in thick with a 14 mm 0 56 in hole in the center Align the disc over the second 2 and first 3 stage cylinde...

Page 759: ...L08038 Hoist Circuit Component Repair L8 17 FIGURE 8 18 HOIST CYLINDER ...

Page 760: ...usly been tack welded a Check the quill for tightness by using special tool SS1143 Figure 8 19 and applying a tightening torque of 1356 N m 1000 ft lbs b If the quill moves remove quill clean threads in cover assembly and quill and reinstall using the procedure in Quill Installa tion 5 When a cylinder assembly is dismantled the cap screws 7 Figure 8 18 should be checked carefully for distress and ...

Page 761: ...ds 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 ti...

Page 762: ...at area is not deformed measure the plug thickness as shown in Figure 8 20 Older Plug is 0 25 0 02 in thick Newer plug is 0 38 0 02 in thick 1 Use the newer plugs and make certain threads in quill tube and on plugs are clean and dry free of oil and solvent 2 Use Loctite LOCQUIC Primer T TL8753 or equivalent and spray mating threads of both plugs 3 Figure 8 20 and quill assembly 2 Allow primer to d...

Page 763: ...nd first stage cylinder in place when the housing is rotated Rotate housing 180 to position the lower mounting eye at the top 7 Install bearings 19 and buffer seal 18 rod seal 20 and rod wiper 21 in the second stage cylinder 2 8 Attach a lifting device to the rod eye 1 and align it over the housing 4 If equipped install cushion ring 24 on rod Lubricate the rod with hydraulic oil and lower the rod ...

Page 764: ...2 and cap screws 1 Tighten cap screws to 780 N m 575 ft lbs torque NOTE 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 16 Install O ring 12 Figure 8 18 and backup ring 23 on cover 10 Align and lower cover onto housing 4 Install cap screws 11 and lock washers Tighten cap screws...

Page 765: ...ercenter while dumping Figures 8 23 through 8 25 show the proper place ment of the O rings and backup rings on the needle valve counterbalance valve and the cavity plug For information on how the counterbalance valve functions see Hoist Circuit Operation this section For adjusting of the counterbalance valve refer to the Hydraulic Checkout Procedure in this Section FIGURE 8 23 NEEDLE VALVE 1 O Rin...

Page 766: ...ruck 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 NOTE The power down circuit will use a smaller diameter hose tube than the power up circuit 2 Connect another hose from the power down quick disconnect 4 to the power up circuit of the disabled truck NOTE If both ...

Page 767: ...ng the number of turns slowly screw the relief valve adjustment screw clockwise until it bottoms 5 Repeat step 4 to dump the disabled truck Lowering the Body 6 Place the hoist lever of the good truck in FLOAT to lower the body If necessary momentarily place the hoist control in POWER UP until the body is able to descend in FLOAT Do not accelerate the engine 7 After body is lowered shut down the tr...

Page 768: ...L8 26 Hoist Circuit Component Repair L08038 NOTES ...

Page 769: ...TESTS L10 7 Steering Control Unit Flow Amplifier L10 7 Bleeddown Manifold L10 7 ACCUMULATOR BLEED DOWN PROCEDURE L10 9 LOW STEERING PRESSURE SWITCH L10 9 CHECKING HOIST SYSTEM PRESSURES L10 16 Hoist System Relief Pressure Adjustment L10 16 Power Down Relief Pressure Adjustment L10 17 HOIST COUNTERBALANCE VALVE L10 18 Preparation L10 18 Counterbalance Valve Pressure Check Only L10 18 Counterbalance...

Page 770: ...L10 2 Hydraulic Check out Procedure L10028 NOTES ...

Page 771: ... NOTE All accumulators must be fully precharged with nitrogen before starting engine Permanent damage to bladder accumulators will result if engine is started without proper precharge 2 Check nitrogen precharge in all accumulators Refer to Steering Accumulator Charging Proce dure this section and Brake Accumulator Charging Procedure Section J Brake Circuit for detailed charging instructions 3 Inst...

Page 772: ...064 345 kPa 3200 50 psi If necessary to adjust pump pressure a Install calibrated pressure gage capable of 35 000 kPa 5000 psi at base of either steer ing accumulator in the SAE 4 or 6 port or on a tee placed in the port marked ACC on the unloader valve block on the pump b Bottom out the unloader valve adjustment screw 11 Figure 10 1 c Back out the pressure compensator adjust ment screw 8 d Fully ...

Page 773: ...critical until it impairs performance 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 SHOCK SUCTION VALVES Shock Suction Valve Settings Relieve pressure before disconnec...

Page 774: ... the other valve If shock suction valve pressure is not correct replace valves NOTE The shock suction valves are only serviced as complete units and cannot be adjusted while installed in the flow amplifier valve 5 After checking shock suction valves lower the steering relief pressure to 17 237 kPa 2500 psi Steering relief pressure can be adjusted by steering full left or right and adjusting steeri...

Page 775: ...engine and run at low idle DO NOT TURN STEERING WHEEL WHEN RETURN HOSES ARE DISCONNECTED d Measure leakage from steering control unit tank line Leakage not to exceed 164 ml 10 in 3 per minute If leakage is excessive replace steering control unit e Measure leakage from the flow amplifier return hose from the HT port Maximum allowable leakage is 820 m l50 in 3 per minute If leakage is excessive repl...

Page 776: ... will come out the return port that was used to check manifold leakage 7 Before removing plugs on bleeddown manifold or connecting lines that have been discon nected be sure to draw a vacuum on the hydraulic tank to prevent spillage Reconnect all hoses to their proper location 8 Turn the key switch to the OFF position to allow steering accumulators to bleed down Remove test equipment FIGURE 10 4 B...

Page 777: ... a fitting that screws into the hydraulic tank filler tube in place of the filler cap 3 By opening the needle valves both accumula tors can be bled down and the oil discharged back into the hydraulic tank LOW STEERING PRESSURE SWITCH 1 Shut down engine and turn key switch OFF Wait 90 seconds for steering accumulator to bleed down Turn steering wheel to be sure no pressure remains 2 Connect a calib...

Page 778: ...ect oil supply problem and or oil leak age Repair or replace defective components Replace neutral position springs Adjust Repair or replace defective components Repair steering control valve Slip A Slow move ment of steering wheel fails to cause any movement of the steered wheels Leakage of cylinder piston seals Worn steering control valve Replace seals Replace steering control valve Spongy or sof...

Page 779: ...on in the lines or circuit by removing obstruction or pinched lines etc Clean the steering control unit If another component has malfunctioned generating contaminating materials flush the entire hydraulic system Steering control valve locks up Large particles in spool section Insufficient hydraulic power Severe wear and or broken cardan shaft pin Clean the steering control unit Check hydraulic oil...

Page 780: ...e compensator Repair or replace pistons or pump housings Turn volume stop screw counterclockwise Tighten jam nut Repair or replace defective parts Repair or replace defective parts Clear restriction Make sure suction line shut off valve is open Clean suction strainer Check for proper hydraulic tank oil level and make sure suction line shut off valve is open Unresponsive or slug gish control Contro...

Page 781: ...lar or unsteady operation Fluid level is reservoir is low or supercharge is insufficient Air entering hydraulic system Worn piston pump Faulty output circuit components Check for proper hydraulic tank oil level Inspect inlet hose and connections Repair or replace broken worn parts Repair or replace relief valve or pressure compensator valve Excessive heating Operating pump above rated pres sure Lo...

Page 782: ...ice screw Free Wheeling no end stop Leaky shock valve or suction valve position 6 Setting pressure of shock valve too low position 6 Disassemble clean and check shock and suction valves Adjust the shock valve pressure setting Inability to Steer No Pressure Build up Leaky relief valve in the priority valve position 1 Defective steering control unit Clean and perhaps replace the relief valve Replace...

Page 783: ...L10028 Hydraulic Check out Procedure L10 15 FIGURE 10 5 FLOW AMPLIFIER VALVE ...

Page 784: ... in the hydraulic cabinet behind the operators cab Be sure there is adequate safe overhead clear ance before raising body to full up position 4 With engine at low idle place hoist lever in power up position and hold until body is in the full raised position Pressure at both hoist pumps should be 17 237 690 kPa 2500 100 psi NOTE Each hoist pump section supplies oil to a separate inlet section on th...

Page 785: ...Pa 1500 75 psi 3 If power down relief pressure is not within spec ifications remove cap and adjust relief valve 2 Figure 10 7 on hoist pilot valve 1 To increase power down relief pressure turn adjusting screw in clockwise To decrease power down relief pressure turn adjusting screw out counter clockwise NOTE The power down relief valve is located on the pilot control valve in the hydraulic componen...

Page 786: ...unterbalance valve Counterbalance Valve Pressure Check Only 1 Start the engine At low idle raise the body and as it extends to the third stage read the pres sure on the gauge connected to the TR port All counterbalance valve pressures are read adjusted while hoist cylinders are in third stage a If pressure is 20 684 kPa 3000 psi or above stop hoisting immediately Pressure is adjusted too high and ...

Page 787: ...stem of counter balance valve 4 Figure 10 9 on manifold Turn adjustment stem fully clockwise to start adjustment procedure so counterbalance valve pressure is as low as possible Note Turning adjustment stem in clockwise decreases the pressure Turning the stem out counterclockwise increases the pressure Complete valve adjustment range is 3 turns 2 Start the engine and operate at high idle Raise the...

Page 788: ...he following areas Scored pressure plates Scored shafts Scored gear bore Abrasive wear caused by metal parti cles Metal coarse contaminants visible to the eye Entire hydraulic system may require com plete cleaning See Flushing Procedure in the following pages Check other hydraulic system components for possible source of contaminants External damage to pump Incorrect installation Remove and repair...

Page 789: ...her system components for possi ble source of metallic object Pressure plate black O rings and seals brittle Gear and journals black Excessive heat Check hoist system relief valve settings Verify correct hydraulic oil level Verify correct oil viscosity Broken shaft Broken housing or flange Excessive pressure Check relief valve pressure Verify relief valve is functioning properly TROUBLESHOOTING CH...

Page 790: ...rottle and main tain for four minutes This will circulate oil with all valves in the neutral position 9 Shut down engine and turn key switch OFF Allow at least 90 seconds for the accumulator to bleed down This will return all contaminants to the hydraulic tank 10 To be able to fully extend the hoist cylinders in the following procedure disconnect hoist limit solenoid in brake cabinet behind cab 11...

Page 791: ...eed down before opening circuits to take measurements to make repairs or to install or remove gauges 2 If the hydraulic system had been contaminated clean the affected components and the hydrau lic tank 3 Perform the hydraulic system flushing proce dure 4 Perform the hydraulic system checkout proce dure to insure all components are operating cor rectly 5 Connect the particle counter to the test fi...

Page 792: ...L10 24 Hydraulic Check out Procedure L10028 NOTES ...

Page 793: ...N M OPTIONS AND SPECIAL TOOLS INDEX ANSUL FIRE CONTROL SYSTEM M02005 M2 1 ENGINE COOLANT HEATER M07011 M7 1 SPECIAL TOOL GROUP M08021 M8 1 RADIATOR SHUTTERS M19 1 PAYLOAD METER III M20008 M20 1 RESERVE ENGINE OIL SYSTEM M31 1 ...

Page 794: ...M1 2 Index M01055 NOTES ...

Page 795: ...le M2 5 Actuator M2 6 Linear Detection Wire M2 6 Power Wire M2 6 Test Kit M2 6 Squib M2 6 Securing the Detection Wire M2 7 Preliminary Test Before Final Hook Up M2 7 Installation Procedure for Squib M2 9 Placing the Electric Detection Actuation System Into Service M2 9 INSPECTION AND MAINTENANCE SCHEDULES M2 10 Daily M2 10 Normal Maintenance Based On Actual Operating Hours M2 10 IN CASE OF FIRE M2...

Page 796: ...M2 2 Fire Control Systems M02005 NOTES ...

Page 797: ...r struc ture near the bumper NOTE Operating either actuator will activate fire control system Inspection and Maintenance It is imperative that the fire control system is inspected at least every six months To ensure that it will operate effectively 1 Check the system for general appearance mechanical damage and corrosion 2 Inspect each chemical tank fill cap gasket for damage and replace if necess...

Page 798: ... bursting disc with flat side toward extinguisher 5 Fill tank with dry chemical to not more than three inches 76 mm from the bottom of the fill opening 6 Inspect fill opening threads and gasket If nec essary clean threads 7 Install the fill cap and tighten the cap hand tight 8 Remove the cartridge guard from the dry chem ical tank and remove the cartridge 9 Insure that the cartridge puncture pin i...

Page 799: ...ate the expel lant cartridge Components of the checkfire electric detection and actuation system are shown in Figure 2 5 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 ...

Page 800: ...rcuit to fire the squib Power Wire Figure 2 8 Consists of a battery connector and conductor lead wires to connect the actuation system to the truck electrical system battery circuit The battery con nector is equipped with a 5 ampere in line fuse replaceable Test Kit Figure 2 9 Provides for checking of electrical continuity and con sists of an indicator light assembly and an End of Line linear dete...

Page 801: ...often if desired or to keep the wire out of the way Secure the wire to mounting surfaces decks struts hydraulic hoses in the area or any secure non moving part of the protected equip ment Always keep the previously mentioned guidelines in mind when installing the wire Preliminary Test Before Final Hook Up All necessary linear detection and power wire instal lation is now completed Before arming th...

Page 802: ... test module refer to the Troubleshooting sec tion c Proceed to the end of the last length of detection wire and remove the jumper assembly Figure 2 15 Finally put original plugged blank connector onto detection wire The test module light should immediately go out If light does not go out refer to Trouble shooting d Remove the test kit from the system by first disconnecting the squib connector fro...

Page 803: ...tside of actuator body Install squib connector onto threaded stud of squib Figure 2 20 Hand tighten as firmly as possible Placing the Electric Detection Actuation System Into Service To place the electric detection and actuation system into service proceed as follows 1 Check all fasteners for tightness Insure jam nut on actuator body is securely tightened 2 Before installing actuator cartridge pus...

Page 804: ...r wire as follows a Check for wear due to abrasion at wall pen etrations around corners etc b Check for damage from direct impact or other abuse c Check mounting locations for tightness d Insure mounting hardware has not come loose or been broken either of which would allow the wire to sag 4 Weigh the actuation cartridge on the electric detection and actuation system Replace car tridge if the weig...

Page 805: ... lead wire seal 14 Install actuation cartridge back into lower actua tor body and tighten firmly by hand IN CASE OF FIRE Procedure to follow during and after a fire In the event of a fire the following steps should be taken 1 Turn the machine off 2 Manually activate fire suppression system if possible 3 Move away from the machine taking a hand portable extinguisher along if you can 4 Stand by with...

Page 806: ...als with mounting the bracket and power wire Replace the entire length s of detection wire involved in the fire area Before the system is put back into service it is impor tant that the inside chamber of the actuator be cleaned thoroughly Failure to do so may cause excessive carbon build up on the internal O ring and piston chamber This build up will also stop the puncture pin from returning to it...

Page 807: ...nnector assembly Wire broken Dead battery Battery connection loose SUGGESTED CORRECTIVE ACTION Install jumper assembly Reconnect Loosen green lens install new bulb Look for possible short in external power wiring and change fuse Install new length Charge battery or install new one Clean and tighten TROUBLE Test Module Light Will Not Go Out POSSIBLE CAUSES Jumper assembly left in place on end of de...

Page 808: ...M2 14 Fire Control Systems M02005 NOTES ...

Page 809: ... Coolant Heater M7 1 SECTION M ENGINE COOLANT HEATER INDEX ENGINE COOLANT HEATER M7 3 GENERAL M7 3 Maintenance M7 3 HEATING ELEMENT M7 3 Removal M7 3 Installation M7 4 THERMOSTAT M7 4 Removal M7 4 Installation M7 4 ...

Page 810: ...M7 2 Engine Coolant Heater M07012 NOTES ...

Page 811: ...f 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 a Remove the two Phillips head screws and slide end cover out of the way b Connect a voltmeter at the two electrical ter minals and check for operating voltage 220 to 230 ...

Page 812: ...el 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 perature sensing unit Installation 1 Install a new temperature sensing unit and secure in place wit...

Page 813: ...e Gauge Suspensions 8 Dry Nitrogen Gas NOTE Arrangement of parts may vary from illustration shown depending on Charging Kit P N ROLL OUT ASSEMBLY EYE BOLT Part Number Description Use EB1759 Nitrogen Charging Kit Suspension Accumulator Nitrogen Charg ing Part Number Description Use EJ2627 Roller Assy Power Module Remove Install Part Number Description Use TG1106 Eye Bolt 0 75 10 UNC Misc lifting re...

Page 814: ...3535 Offset Box End Wrench 1 5 in Miscellaneous Cab Mounting Part Number Description Use TZ2734 3 4 in Torque Adapter Miscellaneous Part Number Description Use TZ2733 Tubular Handle Use with PB8326 TZ2734 Part Number Description Use TY2150 Seal Installation Tool Installation of Front Wheel Bearing Face Seals ...

Page 815: ...ment Tool Rear Suspension and Anti sway Bar TY4576 Sleeve Alignment Tool Steering Linkage and Tie Rod Assembly Refer to Section G Part Number Description Use PB6039 Hydraulic Coupling Miscellaneous Part Number Description Use EF9160 Harness Payload Meter Download Refer to Section M Part Number Description Use TZ5146 Tube Miscellaneous ...

Page 816: ...llaneous PB6825 Impact Socket 1 5 8 Miscellaneous TZ2100 Socket 1 7 8 Miscellaneous TZ2727 Socket 2 1 4 Miscellaneous TZ2728 Socket 2 3 4 Miscellaneous TR0532 Square Drive Extension 8 Miscellaneous TR0533 Square Drive Extension 17 Miscellaneous TV1186 Extension 3 1 2 Miscellaneous TR0546 Sliding T Handle Miscellaneous TZ2730 Adapter 1 x 1 1 2 Miscellaneous TZ2731 Adapter 3 4 x 1 Miscellaneous EF67...

Page 817: ...val and Installation VJ6567 Radiator Tube Installation Tool Radiator Tube Installation XA2307 Breaker Tool Radiator Tube Removal BF4810 Bearing Tool 24V Alternator BF4818 Front Bearing Removal Tool 24V Alternator BF4820 Bobbin Removal Tool 24V Alternator BF4821 Bearing Insertion Tool 24V Alternator BF4822 Stator Service Tool 24V Alternator Part Number Description Use J 24092 Puller Legs A C Servic...

Page 818: ...using the spindle tool to properly remove the spindles from the machine PART NUMBER DESCRIPTION USE Make locally using dimensions shown below Puller Tool To separate front wheel spindle from suspension piston KC7095 Pusher Cap Screws 1 25 x 8 in Use on 830E AC WA0366 Hardened Flatwashers 1 25 in ...

Page 819: ...ECTION M RADIATOR SHUTTERS INDEX RADIATOR SHUTTERS 3 OPERATION M19 3 Hydraulic Circuit M19 3 Electrical Circuit M19 4 MAINTENANCE AND REPAIR M19 4 TROUBLESHOOTING M19 5 Hydraulic Troubleshooting M19 8 Electrical Troubleshooting M19 10 ...

Page 820: ...M19 2 Radiator Shutters M19003 NOTES ...

Page 821: ...3 This valve reduces the steering circuit pressure 24 132 kPa 3500 psi to 10 342 kPa 1500 psi The pressure is further reduced to 517 kPa 75 psi by the pressure reducing valve 4 which supplies the shutter solenoid valve 5 to pressurize the head end of the shutter actu ator cylinder 11 closing the shutters during engine warm up When the shutters are signalled to open the solenoid valve will be de en...

Page 822: ...ter actuator cylinder to close the shutters If the cab air conditioner is switched on relay K3 will energize opening the 24VDC circuit 712ST supply ing the shutter control solenoid preventing the shutters from closing Refer to the electrical schematic at the back of the shop manual for additional wiring information MAINTENANCE AND REPAIR The solenoid valve 5 Figure 19 1 and pressure reducing valve...

Page 823: ...ons securely before applying pressure Hydraulic fluid escaping under pressure can have sufficient force to enter a person s body by pene trating the skin and cause serious injury and possi bly death if proper medical treatment by a physician familiar with this type of injury is not received immediately FIGURE 19 3 HYDRAULIC TROUBLESHOOTING 1 Oil Supply 2 Pressure Reducing Valve 3 Pressure Reducing...

Page 824: ... gauge with a 0 3500 kPa 0 500 psi range to tee fitting Pressure should be 517 kPa 75 psi In Spec GO TO STEP 7 Out of Spec GO TO STEP 5 5 Check hydraulic pressure between pressure reducing valve 2 and pressure reducing valve 3 Install hose with tee fitting between pressure reducing valve 2 and pressure reducing valve 3 Con nect pressure gauge with a 0 35000 kPa 0 5000 psi range to tee fitting Pres...

Page 825: ... 65T1 on relay board 8 In Spec GO TO STEP 17 Out of Spec GO TO STEP 16 16 K5 Relay is defective 16 Replace K5 relay GO TO STEP 15 17 Check shutter disable switch 17 Check for 24VDC in circuit 65T1 inside shutter disable switch box In Spec GO TO STEP 19 Out of Spec GO TO STEP 18 18 Check for open circuit in cir cuit 65T1 18 Locate and repair open con nection in circuit 65T1 GO TO STEP 17 19 Check s...

Page 826: ... should be 517 kPa 75 psi pressure in hose 9 and NO pres sure in hose 8 NO 4 Install hose with tee fitting between pressure reducing valve 3 and valve 4 Connect pressure gauge with a 0 3500 kPa 0 500 psi range to tee fit ting Pressure should be 517 kPa 75 psi YES 3Connect 24 VDC power source to solenoid valve There should be 517 kPa 75 psi pressure in hose 8 and NO pres sure in hose 9 NO 5 Install...

Page 827: ...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 Cause Remedy Pressure reducing valve 2 is defec tive Replace pressure reducing valve 2 Hydraulic Supply to shutters is incorrect Perform trouble shooting proce dures in appropri ate shop manual to correct truck hydraulic system NO YES ...

Page 828: ...ot close Cause Remedy Hydraulic problem Open cir cuit between 65T1 65T2 Relay 5 defective Relay 3 defective Open cir cuit in 712R from key switch Repair hydraulic system Repair open cir cuit Replace relay 5 Replace relay 3 Repair cir cuit 712R Use a V O M to check for 24 VDC in circuit 65T2 at shut ter solenoid valve Check for 24 VDC in circuit 65T1 at relay 5 Check for 24 VDC in circuit 712ST at ...

Page 829: ...itch M20 7 Payload Meter M20 7 Communications Ports M20 7 Key Switch Input M20 8 Payload Meter Power M20 8 Load Lights M20 8 Wiring and Termination M20 9 TCI Outputs M20 9 OPERATOR S DISPLAY AND SWITCH M20 10 Reading the Speedometer M20 10 Reading the Load Display M20 10 Using the Operator ID M20 10 Using the Load and Ton Counter M20 10 Total Ton Counter M20 10 Total Load Counter M20 11 Clearing t...

Page 830: ...g Weight Data M20 17 Maximum Speed Data M20 17 Alarm Records M20 17 Fault Code Data M20 18 PC SOFTWARE OVERVIEW M20 19 PC Overview M20 19 System Configuration M20 19 Installing the PLMIII Software M20 19 DOWNLOADING DATA M20 20 PLM III SYSTEM CONFIGURATION M20 21 Starting Communications M20 21 Displayed Payload Units M20 21 Time Units M20 21 Connection Menu M20 21 Connecting to the Payload Meter M...

Page 831: ...ng Data M20 31 Deleting Haul Cycle Records M20 31 Viewing Alarms M20 32 Deleting Alarm Records M20 32 TROUBLESHOOTING SECTION M20 33 TROUBLESHOOTING M20 33 Viewing Active Alarms M20 33 Real Time Data Display M20 33 Testing the Payload Lights M20 33 Creating Log Files of Inputs M20 34 Daily Inspections M20 34 Periodic Maintenance M20 34 Abnormal Displays at Power Up M20 35 No Payload Display When K...

Page 832: ...t Rear Pressure Low M20 45 Troubleshoot Wiring to Right Rear Suspension M20 45 Alarm 9 Inclinometer High M20 46 Alarm 10 Inclinometer Low M20 46 Troubleshoot Inclinometer Wiring M20 46 Alarm 13 Body Up Input Failure M20 47 Alarm 16 Memory Write Failure M20 48 Alarm 17 Memory Read Failure M20 48 Alarm 18 M20 49 Alarm 19 M20 49 Alarm 22 M20 49 Operator Switch Doesn t Work M20 50 Alarm 26 User Switch...

Page 833: ...for each front and average per rear tires The payload meter stores lifetime data that cannot be erased This data includes Top 5 maximum payloads and time stamps Top 5 positive and negative frame torque and time stamps Top 5 maximum speeds and time stamps Data Gathering Windows 95 98 NT software is available to down load store and view payload and fault information The PC software will download an ...

Page 834: ...tage between 1 and 4 volts Zero degrees of incline is represented by 2 6vdc on the signal line The voltage signal will be decreased by 0 103vdc for every degree of nose up incline Operator Display The speedometer display gauge is used as a speed ometer and payload display The top display is used for speed and can display metric km h or English mph units Grounding terminal 4 on the back of the spee...

Page 835: ... from the switch located on the dash panel The brake lock switch connects the circuit to ground Open circuit indicates brake lock off Ground indicates brake lock on Payload Meter The payload meter is housed in a black aluminum housing There is a small window on the face of the unit Status and active alarm codes can be viewed through the window During normal operation a two digit display flashes 0 ...

Page 836: ...ontrols the relay The load lights are also protected by a 15 amp circuit breaker in the junction box Load Lights PLMIII uses load lights to indicate to the shovel oper ator the approximate weight of the material in the truck The load lights are illuminated only when the brake lock is applied The lights are controlled by the payload meter through a series of relays in the junc tion box The payload ...

Page 837: ...s wire is typically termi nated with a 10 ring terminal Most connections for the PLMIII system are made in the payload meter junction box 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 i...

Page 838: ... Operator ID The current operator ID number is recorded with each haul cycle The number can be between 0 and 9999 To set the Operator ID 1 Press the SELECT switch until Id is dis played 2 Hold the SET button until 0000 is displayed The first digit should be flashing 3 Press the SET button again to change the digit 4 Press the SELECT button once to adjust the second digit 5 Use the SET button again...

Page 839: ...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 The inclinometer displays whole degrees of incline Positive incline is truck nose up The gauge will quickly display the type of information shown every 10 seconds For example if the left front pre...

Page 840: ...r 10 seconds without the brake lock applied the meter will switch to loading and record the continuous_loading flag in the haul cycle The payload meter switches from loading to maneu vering as soon as the truck begins moving The maneuvering zone is 160m and is designed to allow the operator to reposition the truck under the shovel More payload can be added anytime within the maneuvering zone Once ...

Page 841: ...ng scale weights to PLMIII weights SOURCES FOR PAYLOAD ERROR Payload Error The number one source of error in payload calcula tion is improperly serviced suspensions The payload meter calculates payload by measuring differences in the sprung weight of the truck when it is empty and when it is loaded The sprung weight is the weight of the truck supported by the suspensions The only method for determ...

Page 842: ...of the tire The rolling radius may change at difference speeds by growing larger at higher speeds The actual rolling radius of the tire will also change between a loaded and empty truck The payload meter does not compensate for these changes NOTE Earlier 730E 830E models are subject to incorrect speed data due to electrical interference The incorrect speeds are generated while the truck is stopped...

Page 843: ...hen the meter transitions from empty to loading state Dump start time seconds Number of seconds from the start of the haul cycle to the time when the meter switches from loaded to dumping state Loaded haul distance m Distance traveled while loaded Empty haul distance m Distance traveled while empty Loaded max speed km h Maximum speed recorded while the truck is loaded Loaded max speed time seconds...

Page 844: ...ccurate as a typical final load calcula tion Typically this is recorded when loading begins before an accurate tare is calculated or the load is dumped before the load can be accurately mea sured F Final Zone to Dumping Transition This message is generated when the payload meter senses a body up while it is calculating the final pay load indicating that the operator has dumped the load It may also...

Page 845: ...or example if the left front and right rear pressure rises as the right front and left rear pressure drops the truck frame experiences a twisting motion along the longitudinal centerline In this case the payload meter will record a positive frame torque The 5 highest values in the positive and negative direction are stored in permanent memory within the payload meter Sprung Weight Data The payload...

Page 846: ...d 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 Alar...

Page 847: ... and uses the laptop computer to make the necessary settings The setup procedure can be broken down into several steps Connecting the laptop to the PLMIII system Starting communications Setting the time date Setting the truck type Setting the truck ID Setting the speedometer display gauge units Installing the PLMIII Software The CD ROM containing the Payload Data Manage ment PDM Software will auto...

Page 848: ...rted delete the entire query results from the database If neces sary the data can easily be imported back into the main database for analysis at a future date Remov ing this older data will improve performance The PC software downloads the data from the pay load meter into a single Paradox database The data from all the trucks is added to the same database Downloading the payload meter can take se...

Page 849: ...ns dis tances and speeds are displayed in Kilometers Long Tons Payload is displayed in long tons dis tances and speeds are displayed in Miles 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 connection screen displays basic system infor mation to the user Frame S N should agree with ...

Page 850: ... latest configuration information stored on the payload meter When changes are made to the configuration the Save Changes button must be pressed to save the changes into the payload meter To confirm the changes exit to the main menu and re connect to the payload meter Setting the Date and Time The time shown on the form is the time transmitted from the payload when the connection was first establi...

Page 851: ... the payload meter Setting the Truck Number Most mining operations assign a number to each piece of equipment for quick identification This num ber or name can be entered in the Truck Number field It is very important to enter a unique truck num ber for each truck using the PLMIII system This number is one of the key fields used within the haul cycle database The field will hold 20 alpha numeric c...

Page 852: ...ed use the PLMIII software to connect to the payload meter 2 From the Truck Configuration screen select Clean Truck Tare 3 Be sure to follow the screen instructions Inclinometer Calibration The inclinometer calibration procedure is designed to compensate for variations in the mounting attitude of the inclinometer The inclinometer input is critical to the payload calculation This procedure should b...

Page 853: ...n the AND condition If the user selects a truck and date range the query will sort the data for that truck number AND the date range Sorting on Truck Unit Number The truck unit number is the truck unit number entered into the payload meter when it was config ured at installation The query can be set to look for all trucks or one particular truck number When the program begins it searches through t...

Page 854: ...0 format To view the haul cycle reports from the first shift for truck 374 from January 5 2000 to January 8 2000 1 Select truck 374 from the Truck Unit pull down menu 2 Change the From date to January 5 2000 3 Change the To date to January 8 2000 4 Change the From time to 06 00 5 Change the To time to 18 00 6 Press the Query Database and Display to view the results This query will display haul cyc...

Page 855: ...rated 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 during the month of July 2000 from 8 00 AM to 5 00 PM It is important to carefully select the query data and press the Query Database Display button before printing a report 0 00 6 00 18 00 24 00 12 00 Jan 5 2000 Jan 9 2000 Jan 8 2000 Jan ...

Page 856: ...nd are not included in the summary statistics for reports or display Summary one page report A summary of the queried data can be printed onto 1 page The cycle data is summarized onto one sheet Displayed is the speeds cycle times load statistics frame and tire data Detailed multi page report The detail report starts with the summary report and follows with pages of data for each haul cycle The det...

Page 857: ... number of bars and the distance between them The program limits the number of bars to 20 This allows graphs to fit on the screen and print onto 1 page 5 Press the Create Graph button The graph will be displayed based on the query set tings from the Payload Summary screen The graph can be customized and printed Exporting Data The data from the database can be exported for use with other software a...

Page 858: ...hour Right Front Tire kilometer hour Average Rear Tire kilometer hour Frame serial number Reserved 1 5 7 10 These values are internal calculations used in the continued development of PLMIII and should be ignored Reserved 6 This value is the payload estimate at the shovel just before the truck begins to move The second series of data below the haul cycle data is the alarms The alarm columns left t...

Page 859: ...ll ask for a zip file to import locate the file and press Open The program will only import zip files created by another computer running the PDM Software Deleting Haul Cycle Records To delete haul cycle records from the main database press the Delete button at the bottom of the Pay load Summary screen The program will display a summary of the records from the displayed query To delete a record se...

Page 860: ...ram will display a summary of the alarms from the query To delete an alarm select one at a time and press the Delete button It is recommended that the query data be exported to a zip file for archival purposes before deletion Multi ple records may be selected by holding down the Shift key Pressing the Delete All button will select all the alarms from the current query and delete them NOTE There is...

Page 861: ...ive alarms at the time of connection The screen does not automatically refresh If a con dition changes to cause an alarm the user must exit and re enter the Connect to Payload Meter screen Real Time Data Display The PC software can be used to view the live input readings from the payload meter The numbers dis played are 1 second averages 1 Connect to the payload meter and start the PC software 2 F...

Page 862: ...the Start Log button to start taking data and recording into the file Once a file is started it cannot be stopped and started again 7 Press the Stop Log button to stop recording data Attempting to start the log file again will overwrite the previous file and erase the previ ous data To gather more data close the real time data window start it again and create a new log file Daily Inspections An im...

Page 863: ...d an error while reading the current truck configuration record from memory Er 02 Bad Calibration Record error indicates that the meter encountered an error while passing messages between the microprocessors on the circuit board Er 03 Interprocessor Communications error indicates that the meter encountered an error while passing mes sages between the microprocessors on the circuit board To resolve...

Page 864: ...n PLMIII junction box Check all connectors and terminal connectors in the power circuits to the payload meter If two digit display on payload meter displays 00 then 88 on power up continue to No Display on Operator Display This two digit display normally alternates 0 on each display In the case of active alarms this display will show the code for each active alarm The alarm codes are in the operat...

Page 865: ...ad Meter III M20 37 No Display on Speedometer No Display on Operator Display If the speedometer works but the operator displays remain blank confirm payload connections at No Payload Display When Key Switch is Turned ON ...

Page 866: ... Personal Digital Assistants PDA synchronization software is not using the serial port Often PDA software like Palm Pilot s HotSync software will take control of the serial port and not let other applications use the serial connection Close the synchronization software and retry the Payload Data Manager software Confirm Operator Switch use If this switch works properly it confirms that the communi...

Page 867: ...itch 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 ...

Page 868: ...lay Doesn t Clear When The Load Is Dumped 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 ...

Page 869: ...state The payload meter must be in the empty or tare zone states to begin calibration This can be checked by using the real time monitor mode of the Payload Data Manager software The payload meter can be reset to acknowledge the beginning of a new haul cycle by raising the body when the truck is empty This may be necessary after servicing the suspensions ...

Page 870: ...urrent being read by the payload meter is higher than 22ma or lower than 2ma The pressure sensor is designed to output 4 20ma over a pressure range of 4000 psi Confirm 18v sensor supply at TB46 L in payload junction box Confirm proper connection of signal circuit 39FD from left suspension connection box TB42 B to payload junction box TB46 F to payload meter connector R264 pin 39 ...

Page 871: ...current being read by the payload meter is higher than 22ma or lower than 2ma The pressure sensor is designed to output 4 20ma over a pressure range of 4000 psi Confirm 18v sensor supply at TB46 L in payload junction box Confirm proper connection of signal circuit 39FC from right suspension connection box TB41 B to payload junction box TB46 G to payload meter connector R264 pin 20 ...

Page 872: ...rent being read by the payload meter is higher than 22ma or lower than 2ma The pressure sensor is designed to output 4 20ma over a pressure range of 4000 psi Confirm 18v sensor supply at TB46 L in payload junction box Confirm proper connection of signal circuit 39FC from right suspension connection box TB41 B to payload junction box TB46 G to payload meter connector R264 pin 20 ...

Page 873: ...urrent being read by the payload meter is higher than 22ma or lower than 2ma The pressure sensor is designed to output 4 20ma over a pressure range of 4000 psi Confirm 18v sensor supply at TB46 L in payload junction box Confirm proper connection of signal circuit 39FC from right suspension connection box TB41 B to payload junction box TB46 G to payload meter connector R264 pin 20 ...

Page 874: ... 10 Inclinometer Low Troubleshoot Inclinometer Wiring These alarms indicate that the voltage to the payload meter from the inclinometer is out of range The voltage on signal 39FE should be greater than 0 5v and less than 5 0v as measured in the junction box between TB46 ...

Page 875: ...mped 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 ...

Page 876: ...ad meter be removed for 1 minute First turn the key switch OFF Wait 30 seconds then turn the battery disconnect OFF Wait 1 minute before restoring power In cases where re powering the payload meter does not restore normal operation it may necessary to reprogram the payload meter All current data in memory will be lost This will effectively restart the payload meter See Troubleshooting Abnormal Dis...

Page 877: ...g the suspensions 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 ...

Page 878: ...rm 26 User Switch Fault SELECT Alarm 27 User Switch Fault SET Confirm power to the payload meter speedometer and display gauge Confirm that a laptop is not connected to the PLMIII system Turn key switch OFF Wait 1 minute and turn key switch ON Confirm problem still exists ...

Page 879: ...M20008 02 05 Payload Meter III M20 51 Connector Map This diagram shows the general location of connectors terminal boards and miscellaneous connections ...

Page 880: ...M20 52 Payload Meter III 02 05 M20008 Connectors ...

Page 881: ...B45 X This voltage should be 24vdc from the batter ies 6 Turn the key switch ON The speedometer dis play gauge on the dashboard will scroll the truck type across the lower display The payload meter defaults to 930E 7 In the PLMIII junction box check the sensor supply voltage on circuit 39F between TB46 L and TB45 X This voltage should be 18vdc 1vdc 8 Return to the cab and check the speedometer dis...

Page 882: ...n 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 15 Press and hold the SELECT button on the dashb...

Page 883: ... hold 20 alpha numeric characters On the Truck Configuration screen enter the frame serial number in the appropriate field Press the Save Changes button to program the change into the payload meter 25 Setting the Customer Unit Number NOTE Most mining operations assign a number to each piece of equipment for quick identification This number or name can be entered in the Customer Unit Number field I...

Page 884: ...ed 33 Confirm that the inclinometer is within range and record the value 34 Confirm that the body up input is working cor rectly Place a steel washer on the body up switch The real time data screen should indi cate No Remove the washer and the real time data screen should indicate Yes The Haul Cycle State should change to Dumping 35 Confirm that the brake lock input is working cor rectly Turn the ...

Page 885: ...ght rear suspension low Right front suspension low 49 Close all screens and disconnect the laptop from the PLMIII system PLMIII CHECKOUT PROCEDURE CONFIRMATION Flashburn Programming General Instructions Before beginning be sure the kms file required to program the product and you know where to find it on your computer Programming will reset all the truck configuration information NOTE Before start...

Page 886: ...ng the Payload Data Manager software on the laptop computer Flashburn Back Next Cancel Select the serial communications port to use between the computer and the target device For most computers this will be COM 1 1 Power OFF 2 Select Port 3 Select File 4 Power ON COM 1 Flashburn Back Next Cancel Select the file that will be used to program the target device This file will end with the KMS extensio...

Page 887: ...tem Value Initials PLMIII Software Version User switch and display works properly Left Front Pressure Right Front Pressure Left Rear Pressure Right Rear Pressure Inclinometer Green light works properly Amber light works properly Red light works properly Brake Lock input works properly Body Up input works properly Speed input works properly Date Truck Signature ...

Page 888: ...60 Payload Meter III 02 05 M20008 NOTES PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM L G HAGENBUCH holder of U S Patent Numbers 4 831 539 and 4 839 835 ...

Page 889: ...EM M31 3 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 SYSTEM ELECTRICAL SCHEMATICS M31 8 ...

Page 890: ...M31 2 Reserve Engine Oil System M31004 NOTES ...

Page 891: ...l cleanup The normal supply system capacity of oil carried in the reserve tank is roughly equivalent to the volume in the engine In the process of continuous adjust ment of the engine oil level there is a constant circu lation of oil between the engine and the reserve tank The volume of oil in the tank becomes part of the working oil for the engine Oil change intervals may usually be extended in p...

Page 892: ...tes pump 2 which returns oil from reserve tank 2 and raises the engine oil level until air is no longer drawn by pump 1 Pump 2 then turns off The running level is continuously adjusted at the control point by alter nating between withdrawal and return of oil at the engine oil pan The oil returning to the engine oil pan is below the normal operating level to prevent aeration of the oil LED Monitor ...

Page 893: ...luminated push pull POWER ON switch that powers the fill sys tem Start switch 3 is a momentary push button switch that opens the fill valve mounted on the reserve tank to begin the automatic filling of the reserve tank Supply oil under pressure flows through the fill valve and into the tank Filling Procedure Remote fill feature NOTE This procedure adds oil to the reserve tank 1 Connect the pressur...

Page 894: ...ignal LED to verify that the engine is being maintained at the preset running oil level The signal should alternate between periods of steady on and flashing Every 500 Hours 1 Change all engine and system filters if applica ble 2 More system failures result from bad electrical connections than all other causes combined Check electrical system connections for tight ness corrosion and physical damag...

Page 895: ...oove on its outlet 2 Loosen the hose at the inlet of pump 1 to admit air Pump 2 should then run and the signal should be flashing Verify proper pumping of pump 2 by loosening the hose at its outlet to see that oil is coming through 3 Re tighten the inlet hose on pump 1 The pump should again receive oil and the flashing should stop NOTE There is a condition that would show a level higher than the c...

Page 896: ...l System M31004 SYSTEM ELECTRICAL SCHEMATICS FIGURE 31 4 FILL SYSTEM SCHEMATIC 1 Fill Valve 2 Oil Level Sensor top of reserve oil tank 3 15 Amp Circuit Breaker 4 Battery Disconnect Box 5 Ground Wire 6 Remote Fill Control Box ...

Page 897: ...N01020 Index N1 1 SECTION N OPERATOR CAB INDEX TRUCK CAB N2 1 CAB COMPONENTS N3 1 OPERATOR COMFORT N4 1 OPERATOR CAB CONTROLS N5 1 ...

Page 898: ...N1 2 Index N01020 NOTES ...

Page 899: ... Door Jamb Bolt Adjustment N2 7 Door Handle Plunger Adjustment N2 8 Replace Door Glass N2 9 Replace Door Window Regulator N2 13 Replace Door Handle or Latch Assembly N2 14 Door and Door Hinge Seal Replacement N2 14 Door Opening Seal Removal N2 15 Installation N2 15 GLASS REPLACEMENT N2 16 Adhesive bonded Windows N2 16 Replacement Procedure N2 16 WINDSHIELD REAR GLASS N2 18 Removal N2 18 Installati...

Page 900: ...N2 2 Truck Cab N02019 NOTES ...

Page 901: ...various wiring harnesses Hydraulic components are located outside of the interior and are accessed through covers 2 Figure 2 1 on the front of the cab DO NOT attempt to modify or repair damage to the ROPS structure without written approval from the manufacturer Unauthorized repairs to the ROPS structure will void certification If modifica tion or repairs are required contact the servicing Komatsu ...

Page 902: ... 5 located under hydraulic cabinet 6 Remove cable and hose clamps as needed for cab removal 7 Close heater shutoff valves located at the water pump inlet housing on the right side of the engine and at the water manifold Disconnect heater hoses at each valve and drain coolant into a container 8 Remove clamps and heater hoses from fittings underside of deck below heater Federal regulations prohibit ...

Page 903: ...rench Adaptor 2 After cab is positioned insert the remaining cap screws and hardened washers 32 total Tighten the cap screws to 950 N m 700 ft lbs torque 3 Route wire harnesses to the electrical connec tors on the rear corner of the cab 5 Figure 2 2 Align cable connector plug key with recepta cle key and push plug onto receptacle Carefully thread retainer onto receptacle and tighten securely Insta...

Page 904: ...oor panel for access to power win dow motor harness connector Disconnect motor and remove cab harness from door 4 Remove the retainer clip and bolt clip from the travel limiting strap 5 Insert lifting sling through door and attach to hoist Remove cap screws a swivel socket works best securing door hinge to cab and lift door from cab 6 Place door on blocks or on a work bench to pro tect the window ...

Page 905: ...he door itself will have to be adjusted Or if the paper slips out easier at the bottom than at the top the door will have to be adjusted If seals are tight at bottom of door but not at top place a 4 x 4 block of wood at the bottom edge of the door below the handle Close the door on the wood block and press firmly inward on the top corner of the door Press in one or two times then remove the wood b...

Page 906: ...side seal to prevent dust and moisture from entering the cab Door Handle Plunger Adjustment If the door handle becomes inoperative it can either be adjusted or replaced The following is a procedure for adjusting the exterior door handle plunger 1 Determine the amount of free play in the door release plunger by pushing in on the plunger until it just contacts the door release mecha nism Measure the...

Page 907: ... door release lever to see if pawls open If pawls do not open replace assembly c Close pawls again d Press the outside door button to see if pawls open e If mechanism operates properly go on to STEP 6 If mechanism does not work prop erly replace with a new door latch assembly then continue with STEP 6 6 Remove the mounting screws 3 from the out side door handle With the door handle removed adjust ...

Page 908: ...el toward the cab to disengage the window regulator roller from the track on the bottom of the glass Then slide the panel away from the cab to disengage the other top roller and the lower roller from their tracks Place the panel out of the way after removal 7 Remove 2 screws Figure 2 8 holding the roller track to the bottom of the door glass 8 Support glass in door frame as shown 1 Fig ure 2 9 Rem...

Page 909: ... place tilt frame out at the top Lift frame and glass straight up and out of door Bracket 2 Figure 2 12 at bottom of glass must clear the door frame if still on glass 11 Move window glass and frame to an area where the glass can be removed Slide the glass down and out of the window channels 12 Before installing new window glass first inspect the window frame In each corner there is an L shaped bra...

Page 910: ...s which holds it to the door frame Screws along the bottom of window frame may be shorter than the ones along the sides and top These screws must be used in this area to pre vent the window glass from being scratched or cracked See Figure 2 11 17 Install trim material over the top of screws that holds the window frame to the door Use a flat blade screwdriver to assist with installing the trim mate...

Page 911: ...ews that retain panel to door frame 23 Hook up electrical connector for the window regulator Install the two cap screws that hold the door strap bracket to the door frame 24 Align door check strap opening with holes in the bracket and install bolt Install the hair pin clip See Figure 2 6 Replace Door Window Regulator 1 Follow steps 1 6 procedure for door glass replacement 2 Move inner panel assemb...

Page 912: ...er 2 are behind the latch assembly 5 Install new latch assembly and align mounting holes Install 4 mounting screws Be sure they are tight 6 Align inside door handle and install cap screw and nut 3 Figure 2 14 7 Follow steps 20 23 of the door glass replace ment procedure to complete the repair Door and Door Hinge Seal Replacement 1 The door assembly seal has only three mem bers to it sides and top ...

Page 913: ...t 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 into the corners 2 Continue going all the around the opening 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 t...

Page 914: ... used be cer tain to follow that manufacturer s instructions for use including the use of any primers and double the allowances for proper curing time Replacement Procedure The first concern with all glass replacement is SAFETY Wear heavy protective gloves and safety eyeglass goggles when working with glass 1 Using chosen cut out tool slice into existing urethane adhesive and remove window 2 Caref...

Page 915: ...glass edges from Step 4 9 Immediately install glass to the vehicle Care fully locate the glass in place with the black masking side towards the adhesive Carefully press firmly but not abruptly into place assur ing that the glass is properly seated DO NOT POUND THE GLASS INTO PLACE 10 Using a wooden prop and furnace duct tape hold the glass in place for at least two 2 full hours or double the adhes...

Page 916: ...he following installation easier a Install the weatherstrip around the opening in the cab for the glass Start with one end of the weatherstrip at the center lower part of the window opening and press the weather strip over the edge of the opening b Continue installing weatherstrip while going all the around the opening When the ends of the weatherstrip meet at the starting point at the lower cente...

Page 917: ...erstrip and push in on the locking lip 2 Figure 2 18 or 2 19 to secure the glass in the weather strip 4 If windshield was being replaced lower wind shield wiper arms blades back to the glass FIGURE 2 19 Rear Window 1 Glass 2 Locking Lip 3 Weatherstrip Material 4 Sheet Metal ...

Page 918: ...N2 20 Truck Cab N02019 NOTES ...

Page 919: ...IELD WIPERS N3 3 WIPER MOTOR N3 3 Removal N3 3 Installation N3 3 WIPER ARM N3 3 Removal N3 3 Installation N3 4 WIPER LINKAGE N3 4 Removal N3 4 Installation N3 4 WINDSHIELD WASHER N3 5 Operation N3 5 Service N3 5 OPERATOR SEAT N3 6 Adjustment N3 6 Seat Removal N3 7 Seat Installation N3 7 ...

Page 920: ...N3 2 Cab Components N03025 NOTES ...

Page 921: ...into position on plate 5 2 Install three cap screws 6 with flat washers 7 and lock washers 8 Tighten cap screws to 8 9 N m 71 79 in lbs torque 3 Align the motor output shaft with the wiper link age Install nut 10 and while holding the link age stationary tighten nut to 22 24 N m 16 18 ft lbs torque 4 Reconnect the wiper motor harness connector 5 Verify the wipers operate properly and park in the p...

Page 922: ...ion 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 Insta...

Page 923: ... is activated washing solution is pumped through the outlet hose 3 and fed to a jet located in each of the windshield wiper arms Service If windshield washer maintenance is required check the strainer opening for obstructions and inspect the hoses for damage Check the voltage to the pump from the control switch If the pump is inoperable replace it with a new pump assembly Note The pump is only ava...

Page 924: ... 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 Horizonta...

Page 925: ...es tether to floor 2 Remove seat assembly from cab to clean work area for disassembly Seat Installation 1 Mount seat assembly to seat riser Install cap screws 10 Figure 3 5 lockwashers flatwash ers and nuts Tighten cap screws to standard torque 2 Fasten tether straps to floor with cap screws 11 flatwashers and lockwashers Tighten cap screws to standard torque ...

Page 926: ...N3 8 Cab Components N03025 NOTES ...

Page 927: ...ES N4 8 PRINCIPLES OF REFRIGERATION N4 8 Air Conditioning N4 8 Refrigeration The Act Of Cooling N4 9 The Refrigeration Cycle N4 9 AIR CONDITIONER SYSTEM COMPONENTS N4 10 Compressor Refrigerant Pump N4 10 Service Valves N4 10 Condenser N4 10 Receiver Drier N4 10 Expansion Block Valve N4 11 Accumulator N4 11 Evaporator N4 11 ELECTRICAL CIRCUIT N4 12 Thermostat N4 12 Compressor Clutch N4 12 Trinary S...

Page 928: ...ing the A C System N4 24 SYSTEM REPAIR N4 24 System Flushing N4 25 A C DRIVE BELT CHECKOUT PROCEDURE N4 26 Pulley Alignment N4 26 Belt Tension Check N4 26 COMPONENT REPLACEMENT N4 28 Hoses and Fittings N4 28 Lines N4 28 Expansion Valve N4 28 Receiver Drier N4 28 Thermostat N4 28 Compressor N4 29 Accumulator N4 29 Clutch N4 29 Servicing the Compressor Clutch N4 30 Pulley Removal N4 32 Clutch Coil C...

Page 929: ...ion setting 0 Temperature Control Knob Knob 2 Figure 4 1 allows the operator to select a comfortable temperature Rotating the knob counterclockwise blue arrow will select cooler temperatures Full counterclockwise position is the coldest air setting Rotating the knob clockwise red arrow will select warmer temperatures Full clockwise position is the warmest heater setting Directional Control Knob Kn...

Page 930: ...the heater valve All five relays require 12VDC through the coil which is supplied by a 24VDC to 12VDC converter 2 One relay Relay 1 switches 24 volt current to actu ate the A C compressor clutch The temperature con trol switch heater valve and the actuator motors all operate on 12 VDC current Heater Core Heater core 48 Figure 4 4 receives engine coolant through heater valve 14 when heat is selecte...

Page 931: ...s 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 ment from one mode to the other Verify voltage 12 VDC is present at the actuator when the toggle switch is closed or absent when the toggle switch is opened If the correct voltages are present...

Page 932: ...irculation Air Filter 20 Knob 21 Filter Holder 22 Foam Insulation 23 Nut 24 Flatwasher 25 Cover 26 Louver 27 Louver Adapter 28 Foam 29 Plate Coil 30 Evaporator Core 31 O Ring 32 Expansion Valve 33 Control Panel 34 Plate 35 Light 36 Overlay 37 Knob 38 Switch Blower 39 Potentiometer 40 Switch 41 Plunger 42 Disc Temperature 43 Screw 44 Discharge Flapper 45 Door Front 46 Gasket 47 Grommet 48 Heater Co...

Page 933: ...mostatic Switch 3 Battery Supply 4 Circuit Breaker 5 Blower 6 Temperature Sensor 7 Evaporator 8 Expansion Valve 9 Suction Line 10 Test Gauges Manifold 11 Compressor 12 Refrigerant Container 13 Magnetic Clutch 14 Compressor Drive Pulley 15 Receiver Drier 16 Discharge Line 17 Condenser 18 Accumulator ...

Page 934: ...ation from heat sources is very important to the efficiency of the sys tem It is advisable to close all vents even the intakes of pressurization systems when there are high humidity conditions The general cleanliness of the system and compo nents is important Dust or dirt collected in the con denser evaporator or air filters decreases the system s cooling capacity The compressor condenser evaporat...

Page 935: ...and forces it through the discharge valve high side on to the condenser Ambient air passing through the condenser removes heat from the circulating refrigerant resulting in the conversion of the refrigerant from gas to liquid The liquid refrigerant moves on to the receiver drier where impurities are filtered out and moisture removed This component also serves as the tempo rary storage unit for som...

Page 936: ... radi ator fan moves more than 50 of condenser air flow unless travel speed is at least 25 mph Ram air condensers depend upon the vehicle move ment to force a large volume of air past the fins and tubes of the condenser The condenser is usually located in front of the radiator or on the roof of the truck Condensing of the refrigerant is the change of state of the refrigerant from a vapor to a liqu...

Page 937: ...the com ponent The moisture is absorbed by the desiccant where it is safely isolated from the rest of the system The storage of the liquid refrigerant is temporary When the liquid vaporizes into a gas it will be pulled from the bottom of the accumulator into the compres sor This process not only allows the accumulator to act as a storage device but also protects the com pressor from liquid sluggin...

Page 938: ...a positive OFF position as a means to turn the clutch off regardless of temperature The bellows type thermostat has a capillary tube con nected to it which is filled with refrigerant The capil lary tube is attached to the bellows inside of the thermostat Expansion of the gases inside the capil lary tube exerts pressure on the bellows which in turn closes the contacts at a predetermined tempera tur...

Page 939: ...the ambient temperature is too cold system pressure will drop below the low range and the pressure switch will disengage the clutch Fan Clutch The mid range function actuates the engine fan clutch if installed High Pressure This switch opens and disengages the compressor clutch if system pressure rises above the 2068 2413 kPa 300 350 psi range After system pressure drops to 1448 1724 kPa 210 250 p...

Page 940: ...he system Although accidental release of refrigerant is a remote possibility when proper procedures are followed the following warnings must be observed when servicing A C systems Provide appropriate protection for your eyes goggles or face shield when working around refrigerant A drop of the liquid refrigerant on your skin will produce frostbite Wear gloves and exercise extreme care when handling...

Page 941: ...C system prior to servicing Mixing different types of refrigerant will damage equipment Dedicate one recovery recycle sta tion to each type of refrigerant processing to avoid equipment damage DISPOSAL of the gas removed requires laboratory or manufacturing facilities Test equipment is available to confirm the refrigerant in the system is actually the type intended for the system and has not been c...

Page 942: ...n the system are quick disconnect type with no external threads They do contain a Schrader type valve The low side fitting has a smaller diameter than the high side attachment Protective caps are provided for each service valve When not being used these caps should be in place to prevent contamination or damage to the service valves Vacuum Pump The vacuum pump Figure 4 9 is used to completely evac...

Page 943: ... free end of the center hose contains a 1 2 in ACME female nut and a shutoff device within 12 inches of the hose end These special hoses and fittings are designed to minimize refriger ant loss and to preclude putting the wrong refrigerant in a system NOTE When hose replacement becomes necessary the new hoses must be marked SAE J2916 R 134a Functions of the manifold gauge set are included in many o...

Page 944: ...s the con nections are the same The procedures performed next will vary depending what type of equipment is being used If a recovery recycling station is being used complete servicing can be accomplished Using only a set of gauges will limit the servicing to only adding refrigerant or observing pressures Purging Air From Service Hoses The purpose of this procedure is to remove all the air trapped ...

Page 945: ...uch Check connections near the expansion valve the inlet side should be warm and the outlet side cold 9 After a minimum of 10 minutes has elapsed and the system has stabilized observe the gauge readings Compare the readings to the specifi cations in Table 1 NOTE Pressures may be slightly higher in very humid conditions and lower in very dry conditions Pressures listed in the table are during compr...

Page 946: ...m is opened 1 Remove the compressor from the truck With the compressor positioned horizontally remove the drain plug and capture the oil in a clear graduated container Rock the compressor back and forth and rotate the shaft to facilitate oil removal Under no circumstances should the A C com pressor be stood upright onto the clutch assem bly Damage to the compressor clutch will result leading to pr...

Page 947: ...ants that are associated with mobile systems Therefore recycled refrigerant from mobile systems is only acceptable for reuse in mobile systems Reclaimed Refrigerant Reclaimed refrigerant has been filtered through a more thorough filtering process and has been pro cessed to the same standards of purity as virgin refrigerant Because of this reclaimed refrigerant is acceptable for use in all systems ...

Page 948: ...shaft seal may dry out and leak slightly The centrifugal force of the clutch pulley spinning can also cause the problem When the sys tem is operated and lubricant wets the seal the leak may stop Such leaks can often be located visually or by feeling with your fingers around the shaft for traces of oil The R 134a itself is invisible odorless and leaves no trace when it leaks but has a great affinit...

Page 949: ... to the correct power source 3 Drain the recovered oil through the valve marked oil drain on the front of the machine 4 Place the controller knob in the ON position The low pressure gauge will show a rise 5 Immediately switch to the OFF position and allow the pressure to stabilize If the pressure does not rise to between 34 69 kPa 5 10 psi switch the controller ON and OFF again 6 When the pressure...

Page 950: ...po nents are repaired or replacement parts are secured and the A C system is reassembled Evacuation removes air and moisture from the system Then the A C system is ready for the charging process which adds new refrigerant to the system SYSTEM REPAIR The following service and repair procedures are not any different than typical vehicle service work How ever A C system components are made of soft me...

Page 951: ...rom the system Other methods may be harmful to the environment as well as air conditioning components 1 Remove the compressor receiver drier expan sion valve and accumulator 2 Inspect all other components such as the con denser evaporator hoses and fittings If any of these items are damaged or highly contami nated replace the components 3 Flush the remaining hoses with a flushing unit Use only R13...

Page 952: ...gure 4 16 for the proper distance from the centerline of the drive pulley to the centerline of the compressor pulley Set the tension tool accordingly on the deflection scale by moving the deflection O ring to the corresponding distance on the scale 3 Slide the O ring for the force scale to zero 4 Find the approximate center of the belt between the two pulleys Place the tip of the tool onto the out...

Page 953: ...N04031 10 06 Operator Comfort N4 27 FIGURE 4 15 BELT ALIGNMENT TOOL 1 AC Compressor Pulley 2 Drive Pulley 3 Alignment Tool FIGURE 4 16 BELT TENSION DIMENSIONS 346 mm 13 63 in ...

Page 954: ... the system is opened for any service The receiver drier has a pressure switch to control the clutch and should be removed and installed onto the new unit NOTE Do not use PAG oil to lubricate O rings or fit tings PAG oil will attract moisture and will corrode fit tings when used externally Use only clean mineral oil to lubricate fittings and O rings during assembly Thermostat A thermostat can be s...

Page 955: ...ch and clutch drive pul ley Sometimes it may be necessary to use shims or enlarge the slots in the compressor mounting bracket to achieve proper alignment Excessive clutch plate wear is caused by the plate rubbing on the clutch pulley when the clutch is not engaged or the clutch plate slipping when the clutch coil is energized A gap that is too small or too large between the plate and clutch pulle...

Page 956: ... Remove the belt guard from the front of the air conditioning compressor 2 Remove the drive belt from compressor belt pulley 3 Remove locknut 4 Figure 4 17 using thin wall socket 1 Figure 4 18 or the equivalent RECOMMENDED TOOLS FOR COMPRESSOR CLUTCH REMOVAL AND INSTALLATION J 9399 Thin Wall Socket J 9403 Spanner Wrench J 25030 Clutch Hub Holding Tool J 9401 Clutch Plate and Hub Assembly Remover J...

Page 957: ... clutch plate and hub assembly remover 2 Figure 4 19 into the hub of clutch assembly 1 Hold the body of the remover with a wrench and tighten the center screw to pull the clutch plate and hub assembly from the compressor 6 Remove square key 1 Figure 4 20 from the keyways 1 Thin Wall Socket 2 Clutch Hub Holding Tool 3 Clutch Hub FIGURE 4 18 1 Clutch Assembly 2 Clutch Plate Hub Assembly Remover FIGU...

Page 958: ...ge to inter nal components as well as external components Pulley Removal 8 Use retaining ring pliers 3 Figure 4 22 to remove pulley retainer ring 2 from pulley 1 9 Pry the absorbent sleeve retainer from the neck of the compressor and remove the sleeve 10 Install pulley puller 1 Figure 4 23 and puller pilot 3 onto the compressor as shown If a multiple groove pulley is used install puller legs J 240...

Page 959: ...er or the equivalent ensures that the force driving the bearing into position acts on the inner race of the bearing Applying force to the outer race of the bearing will result in bearing damage 2 Ensure the pulley rotates freely If the pulley does not rotate freely remove the pulley and check for damaged components Replace any damaged components and reinstall the pulley 3 Install the pulley retain...

Page 960: ...0 0 017 in If the gap is not within the specification check for proper installation of the square key 6 Install the drive belt onto the compressor Ensure that the proper tension on the belt is attained Refer to the belt tension chart in the appropriate engine manual for the proper speci fications 7 After assembly is complete burnish the mating parts of the clutch by operating the air condi tioning...

Page 961: ...e is below that of the out side air in this case at least 749 3 mm 29 5 in of vacuum is needed the boiling point of water will be lowered to 22 C 72 F Thus any moisture in the system will vaporize and be drawn out by the pump if the pump is run for approximately an hour The fol lowing steps indicate the proper procedure for evacu ating all moisture from the heavy duty air conditioning systems Do n...

Page 962: ... some cases 45 minutes of evacuation may not be sufficient to vaporize all of the moisture and draw it out of the system If it has been verified that no system leaks exist and gauge readings increase after 45 minutes extend the evacuation time to ensure total moisture removal TABLE 2 ALTITUDE VACUUM VARIATIONS Altitude Optimal Vacuum Meters Feet Above Sea Level Cm Hg In Hg 0 76 0 29 92 305 1000 73...

Page 963: ... the difference is shown on the scale On certain types of equipment it is also possible to add any necessary lubricant when charging the system If a scale is not used when charging R 134a into a system it is difficult to tell if the correct charge has been achieved The sight glass can provide some indication but it is not a reliable tool for determining proper charge 1 Charge the A C system with 3...

Page 964: ...ter valve Check for malfunction or leaking With the heat switch set to COLD the heater hoses should be cool System ducts and doors Check the ducts and doors for proper function Refrigerant charge Make sure system is properly charged with the correct amount of refrigerant Cab filters Ensure the outside air filter and inside recirculation filter are clean and free of restriction Condenser Check the ...

Page 965: ...witch may have compressor Refrigerant excessively low leak in system 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 pressor has shut down due to faulty pressure the system if necessary Replace the receiver drier clutch disengaged Possible Causes Suggested Corrective Actions Recover the refrigerant and use a sca...

Page 966: ...around the compressor shaft seal area When the leak is found recover refrigerant from the system and repair the leak Replace the receiver drier or accumulator because the desiccant may be saturated with moisture Check the compressor and replace any refrigerant oil lost due to leakage Evacuate and recharge the system with refrigerant using a scale Check A C operation and performance Leaks in the sy...

Page 967: ... a little nitrogen or any substance below 32 F on the capillary coil needle should drop and read at a lower suction pressure on the gauge This indicates the valve was partially open and that your action closed it Repeat the test but first warm the valve diaphragm or capillary with your hand If the low side gauge drops again the valve is not stuck Repair Procedure Inspect the expansion valve screen...

Page 968: ...utes Carefully spray nitrogen or another cold substance on the cap Repair Procedure If the test did not result in illary tube coil bulb or head of the valve The low pressure suction side gauge needle should now drop on the gauge This indicates the valve has closed and is not stuck open Repeat the test but first warm the valve diaphragm by warming with hands If the low side gauge shows a drop again...

Page 969: ...the compressor flushing of the system will be required It will also be necessary to replace the receiver drier Always check the oil level in the compressor even if a new unit has been installed Rotary compressors have a limited oil reservoir Extra oil must be added for all truck installations Tighten all connections and evacuate the system Recharge the system with refrigerant using a scale Check s...

Page 970: ...ate clearance about 38 mm between it and the radiator Check the radiator pressure cap and cooling system including the fan fan clutch drive belts and radiator shutter assembly Replace any defective parts and then recheck A C system operation gauge readings and performance If the problem continues the system may be over charged Recover the system refrigerant Use a scale to recharge the system using...

Page 971: ...heck Verify clutch is engaging 2 Condenser Clean dirt bugs leaves etc from coils w compressed air Verify engine fan clutch is engaging if installed Check inlet outlet for obstructions or damage 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 e...

Page 972: ...N4 46 Operator Comfort 10 06 N04031 NOTES ...

Page 973: ...10 Directional Control Lever N5 10 Override Fault Reset Switch N5 11 Engine Stop Switch N5 11 L H Window Control Switch N5 11 R H Window Control Switch N5 11 Hoist Control Lever N5 11 Raising The Dump Body N5 11 Lowering The Dump Body N5 11 Retard Speed Control RSC Adjust Dial N5 12 Retard Speed Control RSC Switch N5 12 Data Store Button N5 13 VHMS Snapshot In Progress Light N5 13 Link Energized L...

Page 974: ...itioner Vents N5 18 Engine Oil Pressure Gauge N5 19 Right Turn Signal Indicator N5 19 Tachometer N5 19 High Beam Indicator N5 19 Speedometer Payload Meter Display N5 19 Left Turn Signal Indicator N5 19 Water Temperature Gauge N5 19 Lamp Test Switch N5 19 Light Switch N5 19 Ladder Light Switch N5 20 Manual Backup Switch N5 20 Fog Lights Optional N5 20 Payload Meter Switch N5 20 Panel Light Dimmer N...

Page 975: ...Retard Pedal 4 Throttle Accelerator Pedal 5 Heater Air Conditioner Vents 6 Heater Air Conditioner Controls 7 Instrument Panel 8 Grade Speed Retard Chart 9 Radio Speakers 10 Warning Alarm Buzzer 11 Radio AM FM Stereo Cassette 12 Warning Lights Dimmer Control 13 Warning Status Indicator Lights 14 Air Cleaner Vacuum Gauges 15 Windshield Wipers ...

Page 976: ...ti function turn signal switch 4 Figure 5 2 is used to activate the turn signal lights the windshield wipers and to select either high or low beam head lights Turn Signal Operation Move the lever upward to signal a right turn An indicator in the top center of the instrument panel will illuminate to indicate turn direction selected Refer to Instrument Panel and Indicator Lights in this section Move...

Page 977: ...ering column Installation 1 Insert cap screw 10 with lockwashers 11 and flatwashers 5 through brackets 8 9 and then through steering column flange Add sec ond flat washer 5 and nut 13 to each cap screw to hold parts together Tighten nuts securely 2 Slide the entire assembly down the tapered blocks until the brackets 8 9 contact the mounting surface in the cab Install cap screws 4 and 12 with washe...

Page 978: ...kph 3 mph When dynamic retarding is in operation engine rpm will automatically go to an advance retard speed set ting This rpm will vary depending on temperature of several electrical system components Dynamic retarding will be applied automatically if the speed of the truck obtains the maximum speed set ting programmed in the control system software When dynamic retarding is activated an indicato...

Page 979: ...IMUM retarding limits at various truck speeds and grades with a fully loaded truck This decal in the truck may differ from the decal below due to optional truck equipment such as wheel motor drive train ratios retarder grids tire sizes etc Always refer to this decal in the operator s cab and follow these recommendations for truck operation The operator must reference this chart before descending a...

Page 980: ...must use the service brakes to quickly slow the truck to maximum continuous retarding limits or less Do not LIGHTLY apply the service brakes when attempting to slow the truck on a downhill grade Overheating of the brakes will result FULLY apply the brakes within safe limits for road con ditions in order to quickly slow the truck to max imum continuous retarding limits or less NOTE The three minute...

Page 981: ... way communications radio Warning Light Dimmer Control Warning light dimmer control 12 Figure 5 1 permits the operator to adjust the brightness of warning indi cator lights 13 Status Warning Indicator Light Panel Panel 13 Figure 5 1 contains an array of indicator lights to provide the operator with important status messages concerning selected truck functions Refer to Instrument Panel and Indicato...

Page 982: ... in PARK the parking brake indi cator light A3 overhead panel Figure 5 8 will be illuminated The directional control lever handle must be in PARK to start the engine NOTE Do not move the directional control lever to the PARK position at the shovel or dump With key switch ON and engine on Sudden shock caused by loading or dumping could cause the system s motion sensor to release the park brake The ...

Page 983: ...truck L H Window Control Switch Switch 5 Figure 5 4 is spring loaded to the OFF position Pushing the front of the switch raises the left side cab window Pushing the rear of the switch lowers the window R H Window Control Switch Switch 6 Figure 5 4 is spring loaded to the OFF position Pushing the front of the switch raises the right side cab window Pushing the rear of the switch lowers the window H...

Page 984: ...ch 9 ON and start with dial 8 rotated toward fastest speed while driv ing truck at desired maximum speed Relax throttle pedal to let truck coast and turn RSC adjusting dial slowly counterclockwise until dynamic retarding is activated Dynamic retarding will now be activated automatically anytime the set speed is reached the RSC switch is on and throttle pedal is released With RSC switch on and dial...

Page 985: ...TIC PORTS The diagnostic ports shown in Figure 5 5 are located on the back wall of the cab next to the D I D Panel VHMS Diagnostic Port Diagnostic port 1 Figure 5 5 is used to download truck operation data from the VHMS controller Interface Module IM Diagnostic Port Diagnostic port 2 is used to connect the interface module to a computer for installing software Payload Meter Diagnostic Port Diagnos...

Page 986: ...t cooler temperatures Full counterclockwise position is the coldest air setting Rotating the knob clockwise red arrow will select warmer temperatures Full clockwise position is the warmest heater setting Directional Control Knob Knob 3 Figure 5 6 directs heated air to different areas of the cab The full counterclockwise position directs air to the floor vents only Turning the knob one position clo...

Page 987: ... switch and indi cates that function has not been activated To activate a function push on the top portion of the switch At this time the amber LED will be illuminated and the green LED will be OFF To de activate a function push on the lower portion of the switch At this time the green LED will be illuminated and the amber LED will be OFF NOTE The green LED light in the hazard light switch head li...

Page 988: ... 9 Engine Oil Pressure Gauge 10 Right Turn Signal Indicator Light 11 Digital Tachometer 12 High Beam Headlight Indicator 13 Speedometer Payload Meter Display 14 Left Turn Signal Indicator 15 Water Temperature Gauge 16 Lamp Check Switch 17 Headlight Panel Illumination Light Switch 18 Ladder Light Switch 3 Way 19 Backup Light Switch 20 Fog Light Switch 21 Payload Meter Mode Switch 22 Panel Illuminat...

Page 989: ...he top of the switch again to activate the timer delay MOMENTARY position Release the switch and allow it to return to the ON position When the delay timer has been activated the timer delay indicator light C4 Figure 5 8 in the overhead status panel will illuminate to indicate that the shutdown timing sequence has started The engine will continue to idle for approxi mately five minutes to allow fo...

Page 990: ...ter the rest mode after stopping An amber yellow indicator light in the overhead panel B6 Figure 5 8 will illuminate when the rest state has been requested and entered Wheel Brake Lock Control Switch 6 Figure 5 7 should be used when the engine is running dur ing dumping and loading operations only The brake lock switch actuates the hydraulic brake system which locks the rear wheel service brakes o...

Page 991: ...te that the left turn signals are operating when the turn sig nal lever on the steering column is moved downward Moving the lever to its center position will turn the indicator off Water Temperature Gauge Gauge 15 Figure 5 7 indicates the temperature of the coolant in the engine cooling system The tempera ture range after engine warm up and truck operating under normal condi tions should be 85 97 ...

Page 992: ...ment that are useful in foggy conditions and heavy rain Pressing the top of the rocker switch turns the fog lights on Pressing the bottom of the switch turns the lights off Payload Meter Switch Payload meter switch 21 Figure 5 7 is a two way momentary rocker switch The top position is the SELECT position The SELECT position is used to step through the different displays The lower posi tion is the ...

Page 993: ...1 Figure 5 8 that will illuminate when the temperature exceeds a certain level when the needle enters the red zone If this condition occurs the operator should safely stop the truck move the directional control lever to PARK and operate engine at 1200 1500 rpm to reduce system temperature If temperature gauge does not move into the green range after a few minutes and the red overhead indicator lig...

Page 994: ...rk Brake Applied Amber 24VIM 52AL B3 Service Brake Applied Amber 12MD 44L C3 Body Up Amber 12MD6 63L D3 Dynamic Retarding Amber 12MD 44DL E3 Stop Engine Red 12M 31MT A4 Starter Failure Amber 21SL 24VIM B4 Manual Back Up Lights Amber 12MD 47L C4 5 Min Shutdown Timer Amber 12MD 23L1 D4 Retard Speed Control Amber 12MD 31R E4 Check Engine Amber 12MD7 419 Row Column Indicator Description Indicator Colo...

Page 995: ...reen range after a few minutes and the red overhead indicator light does not go out stop the engine and notify maintenance personnel imme diately B1 Low Steering Pressure When the key switch is turned ON the low steering pressure warning light will illuminate until the steering system hydraulic pressure reaches 15 858 kPa 2300 psi The warning alarm will also turn on and both will remain on until t...

Page 996: ...ed to allow the operator to safely stop the truck A2 Low Hydraulic Tank Level This warning light indicates the oil level in the hydraulic tank is below recommended level Dam age to hydraulic pumps may occur if operation continues Stop the truck and turn the engine off Notify maintenance personnel immedi ately B2 Automatic Lubrication Sys tem Pressure This amber light will illuminate if the automat...

Page 997: ... dynamic retarding function of the truck is being used E3 Stop Engine This red engine monitor warning light will illuminate if a serious engine malfunction is detected in the electronic engine control system Electric propulsion to the wheelmotors will be discontinued Dynamic retarding will still be available if needed to slow or stop the truck Stop the truck as quickly as possible in a safe area a...

Page 998: ...wer This red no retard no propel indicator light indicates a fault has occurred which has elimi nated the retarding and propul sion capability A warning buzzer will also sound If this condition occurs the operator should safely stop the truck move directional control lever to PARK shutdown the engine and notify maintenance personnel immediately B5 Propulsion System Warn ing When this amber indicat...

Page 999: ...n is not avail able This light is activated when the instrument panel rest switch is turned ON and the AC drive system is de ener gized The three link energized lights one on rear of the center console inside the operator cab and two on the deck mounted control cabinets should NOT be illuminated at this time C6 Propel System Not Ready The amber indicator light func tions during start up much like ...

Page 1000: ...tely after receiving 24V power from the key switch the VHMS controller begins the power up initialization sequence This sequence takes about three seconds during which time the red LED digits 4 Figure 5 10 display a circular sequence of flashing LED segments During normal truck operation the red LED digits on the VHMS controller will count from 00 99 continu ously When the key switch is turned OFF...

Page 1001: ...tware 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 Basic Precautions When using this truck there is no particular need to operate the VHMS system Never disassemble repair or modify the VHMS sys tem This may cause failure or fire on the machine or this system Do not touch the system when oper...

Page 1002: ...65 Auxiliary Control Cabinet Terminal C Fuses 17 24 Ground Level Shut Down Pwr FB1 17 15 Key Switch Supply 11KS Auxiliary Control Cabinet FB1 18 15 Payload Meter Lights 39J Auxiliary Control Cabinet FB1 19 5 Payload Meter System 39G Auxiliary Control Cabinet FUSE BLOCK 2 Terminal A Fuses 1 12 24VDC Battery Power FB2 1 15 Engine Service Lights 11SL Auxiliary Control Cabinet FB2 2 15 Dome Fog Hour M...

Page 1003: ...FB3 18 20 R H Window 12 V 67R Auxiliary Control Cabinet FB3 19 20 L H Window 12 V 67P Auxiliary Control Cabinet FUSE BLOCK 4 Terminal A Fuses 1 12 FB4 1 10 Brake Circuits 71BC Auxiliary Control Cabinet FB4 2 5 Payload Meter III 712PL Auxiliary Control Cabinet FB4 3 5 Interface Module 87 Auxiliary Control Cabinet FB4 4 10 VHMS Module 71VHM Auxiliary Control Cabinet FB4 5 5 Modular Mining Hub 712MM ...

Page 1004: ...B18 12 5 Stop Lights 44A RB3 Auxiliary Control Cabinet CB19 12 5 Backup Lights and Horn 79A RB3 Auxiliary Control Cabinet CB20 12 5 Engine Control Power 23D RB4 Auxiliary Control Cabinet CB21 12 5 Service Lights Horn Solenoid 11A RB4 Auxiliary Control Cabinet CB22 12 5 Engine Run Relay 439E RB4 Auxiliary Control Cabinet CB23 12 5 Headlights Left Low Beam 11DL RB5 Auxiliary Control Cabinet CB24 12 ...

Page 1005: ...P01024 Index P1 1 SECTION P LUBRICATION AND SERVICE INDEX LUBRICATION AND SERVICE P2 1 AUTOMATIC LUBRICATION SYSTEM P3 1 ...

Page 1006: ...P1 2 Index P01024 NOTES ...

Page 1007: ...e Oil Tank Filling Procedure Remote fill P2 4 LUBRICATION CHART P2 5 10 HOUR DAILY INSPECTION P2 6 50 HOUR LUBRICATION AND MAINTENANCE CHECKS P2 9 100 HOUR LUBRICATION AND MAINTENANCE CHECKS P2 10 250 HOUR LUBRICATION AND MAINTENANCE CHECKS P2 11 500 HOUR LUBRICATION AND MAINTENANCE CHECKS P2 14 500 HOUR LUBRICATION AND MAINTENANCE CHECKS Continued P2 15 1000 HOURS LUBRICATION AND MAINTENANCE CHEC...

Page 1008: ...P2 2 Lubrication and Service 10 06 P02050 NOTES ...

Page 1009: ...wn and body down oil should be visible in the top sight gauge If hydraulic oil is not visible in the top sight gauge follow Adding Oil instructions below Adding Oil Keep the system open to the atmosphere only as long as absolutely necessary to lessen the chances of system contamination Service the tank with clean Type C 4 hydraulic oil only All oil being put into the hydraulic tank must be filtere...

Page 1010: ...of the reserve oil system Never add oil to the engine unless it has been drained If the engine oil has been drained from the oil pan the new oil must be added to the engine oil pan before starting DO NOT use the oil in the reserve tank to fill an empty engine with oil After an oil change both the engine and reserve tank must be full of oil before starting the engine Reserve Oil Tank Filling Proced...

Page 1011: ...P02050 10 06 Lubrication and Service P2 5 LUBRICATION CHART ...

Page 1012: ...rve engine oil tank the oil should be visible in the center middle sight gauge If not add oil to the reserve tank until oil is visible in the top sight gauge Also with the engine running check operation of the LED indicator light See below for description of LED light signals Refer to Figure 2 1 LED Light Signals Steady Pump 1 is withdrawing oil from the engine sump and bringing down the oil level...

Page 1013: ...eck the air cleaner vacuum gauges in the operator cab Figure 2 3 The air cleaner s must be serviced if the gauge s shows the following maximum restriction Komatsu SDA16V160 or SSDA16V160 Engines 25 in of H2O vacuum Refer to Section C in the shop manual for servicing instructions for the air cleaner elements Empty the air cleaner dust caps NOTE After service push the reset button on face of gauge t...

Page 1014: ... drain valve on each fuel separator 12 AUTOMATIC LUBE SYSTEM Check the grease reservoir fill as required Lube Key D When filling the reservoir check the grease filter indicator Clean or replace the grease filter if the indicator detects a problem Inspect the system and check for proper operation Ensure the following important areas are receiving adequate amounts of grease Lube Key D Steering Linka...

Page 1015: ...___ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1 FUEL FILTERS Change the fuel filters fuel separators Refer to engine manufacturer s maintenance manual for fuel filter replacement instructions 2 HYDRAULIC SYSTEM FILTERS Replace filter ele ments only after the initial 50 100 and 250 hours of operation then at each 500 hours of...

Page 1016: ... a new or rebuilt component installation check Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1 HYDRAULIC SYSTEM FILTERS Replace filter ele ments only after the initial 100 and 250 hours of operation then at each 500 hours of operation t...

Page 1017: ...extended beyond 250 hours Refer to engine Operation Maintenance manual for specific oil and filter change intervals The Centinel system is a duty cycle dependent lubrication management system whereby oil is blended with the fuel and burned and an extension of oil change intervals can occur a Change engine oil Lube Key A b Replace engine oil filters NOTE When installing spin on filter elements foll...

Page 1018: ... TANK Drain water and sediment from the fuel tank Refer to Shop Manual Section B Fuel Tank Cleaning 5 STEERING LINKAGE Check the torque on pin retaining nuts 1 Figure 2 6 on the steering linkage 712 N m 525 ft lbs Check the torque on tie rod retaining nuts 2 420 N m 310 ft lbs 6 HYDRAULIC PUMP DRIVESHAFT U JOINTS Add one or two applications of grease to each grease fitting Non moly grease only Che...

Page 1019: ...ectrolyte level and add water if necessary 11 BODY UP HOIST LIMIT SWITCHES Check oper ation of the switches Clean the sensing areas of any dirt accumulation and inspect the wiring for any signs of damage 12 WHEEL MOTOR BLOWER If equipped Grease motor blower shaft bearings Lube key D 13 G E PREFILTER BLOWER If equipped Add one to two applications of grease to the grease fitting Lube key D 14 AC DRI...

Page 1020: ...ual for more information on proper suspension extension and maintenance procedures 5 THROTTLE AND BRAKE PEDAL Lubricate the trea dle roller and hinge pins with lubricating oil Lift the boot from the mounting plate and apply a few drops of lubricating oil between the mounting plate and the plunger 6 HOIST ACTUATOR LINKAGE Check operation Clean lubricate and adjust as necessary 7 PARKING BRAKE Refer...

Page 1021: ...r operation Wheel motor gear oil must be filtered or changed every 2500 hours of operation thereafter 12 VHMS DATA DOWNLOAD Using a laptop PC with the VHMS Technical Analysis Tool Box program per form a data download from the VHMS controller Send the data to WebCARE using the FTP feature Refer to Section D in the shop manual for more detailed instructions 13 FRONT BRAKE DISC Measure the thickness ...

Page 1022: ...eaning compound Flush with water Refill the sys tem with anti freeze and water solution Check the Cooling System Recommendation Chart in this sec tion for the correct mixture Refer to the engine manu facturer s Operation and Maintenance Manual for the correct additive mixture 3 FUEL TANK Remove the breather and clean in sol vent Dry with pressurized air and reinstall 4 OPERATOR S SEAT Apply grease...

Page 1023: ... changed more frequently depending on mine conditions and the results of the oil sample tests Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1 AIR CLEANERS Clean the Donaclone tubes in the pre cleaner section of the air filter Use low pr...

Page 1024: ...k Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1 WHEEL MOTORS Clean the area around the grease ports to prevent dirt or other contaminates from entering Remove the six grease port plugs on each wheel motor Grease the inboard and outboard whe...

Page 1025: ...Control Valve P3 5 Solenoid Valve P3 5 Vent Valve P3 5 Lubrication Cycle Timer P3 5 Pump Cutoff Pressure Switch P3 5 Grease Pressure Failure Switch P3 5 Pressure Gauge P3 5 Injectors P3 5 SYSTEM OPERATION P3 6 Normal Operation P3 6 System Priming P3 7 Filter Assembly P3 7 LUBRICANT PUMP P3 8 Pump Housing Oil Level P3 8 Pump Pressure Control P3 8 Pressure Control Valve Adjustment P3 8 INJECTORS SL ...

Page 1026: ...oller Check P3 11 Lubrication Controller Operation P3 11 Lubrication Controller Components P3 11 Lubrication Controller Adjustment P3 11 SYSTEM TROUBLESHOOTING CHART P3 13 PREVENTIVE MAINTENANCE PROCEDURES P3 15 Daily Lubrication System Inspection P3 15 250 Hour Inspection P3 15 1000 Hour Inspection P3 15 ...

Page 1027: ...roke is transferred through the outlet check and discharged to the outlet port Over pressurizing of the system modifying parts using incompatible chemicals and fluids or using worn or damaged parts may result in equipment damage and or serious personal injury DO NOT exceed the stated maximum working pressure of the pump or of the lowest rated component in the system Do not alter or modify any part...

Page 1028: ...earing 10 R H Hoist Cylinder Top Bearing 11 R H Hoist Cylinder Bottom Bearing 12 Rear Axle Pivot Pin 13 R H Anti Sway Bar Bearing 14 R H Suspension Top Bearing 15 Truck Frame 16 Vent Hose 17 Pipe Plug Oil Level 18 Pressure Switch N O 17 237 kPa 2500 psi 19 Grease Pump 20 Vent Valve 21 Filter 22 Grease Supply to Injectors 23 Injectors 24 Pressure Switch N O 13 790 kPa 2000 psi NOTE The above illust...

Page 1029: ...he amount of oil flow to the hydraulic motor The flow control valve has been factory adjusted and the setting should not be disturbed Solenoid Valve Solenoid valve 5 Figure 3 1 when energized allows oil to flow to the hydraulic motor Vent Valve With vent valve 7 Figure 3 1 closed the pump con tinues to operate until maximum grease pressure is achieved As this occurs the vent valve opens and allows...

Page 1030: ...e pressure reaches pressure switch 18 Figure 3 2 setting the switch contacts will close and energize the relay RB7 K5 removing power from the hydraulic motor pump solenoid and the pump will stop The relay will remain energized until grease pressure drops pres sure switch opens again and the timer turns off 7 After the pump solenoid valve is de energized hydraulic pressure in the manifold drops and...

Page 1031: ...t 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 grou...

Page 1032: ...ve Adjustment 1 With the truck engine on activate the test switch 2 Figure 3 5 to start the hydraulic motor and pump 2 Loosen the locknut on the pressure control 1 Figure 3 5 by turning the nut counterclockwise 3 Turn the valve stem counterclockwise until it no longer turns The valve stem will unscrew until it reaches the stop it will not come off NOTE This is the minimum pressure setting which is...

Page 1033: ...attained by turning the adjust ing screw 1 fully counterclockwise until the indicating pin just touches the adjusting screw At the 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...

Page 1034: ...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...

Page 1035: ...e pressure switch will detect supply line pressure and will reset the timer at a set pressure If the pump fails to reach the set pressure within the dip switch setting 30 seconds or 120 seconds the controller will ini tiate an alarm The third dip switch is for selecting the units for the off time to be used in conjunction with off time switch 1 Hours or minutes may be selected The fourth dip switc...

Page 1036: ...P3 12 Automatic Lubrication System P03030 FIGURE 3 7 LUBRICATION CYCLE TIMER 1 Off Time Switch 2 Mode Switch 3 Cover ...

Page 1037: ...ged Pump Will Not Build Pressure Air trapped in lubricant supply line Lubricant supply line leaking Vent valve leaking Pump worn or scored Prime system to remove trapped air Check lines and connections to repair leakage Clean or replace vent valve Repair or replace pump assembly Refer to Service Manual for rebuild instructions Injector Indicator Stem Does Not Operate NOTE Normally during operation...

Page 1038: ...UMP ON LED Does Not Light Printed circuit board failure or key pad failure Remove and replace Bearing Points Excessively Lubricated Controller memory mode is to OFF Switch controller memory mode to ON Injector output adjustment setting too high Readjust to lower setting Bearing Points Are Not Sufficiently Lubricated Timer controller cycle time setting too low Set to longer cycle time or reevaluate...

Page 1039: ...ter bypass indi cator when filling reservoir Replace element if bypassing b Check reservoir for contaminants Clean if required c Check that all filler plugs covers and breather vents on the reservoir are intact and free of contaminants 4 Inspect all bearing points for a bead of lubricant around the bearing seal It is good practice to manually lube each bear ing point at the grease fitting provided...

Page 1040: ...P3 16 Automatic Lubrication System P03030 NOTES ...

Page 1041: ... 5 Body Position Indicator B3 8 Body Sling Cable B3 7 Body Up Switch D3 15 Brake Accumulators J3 19 Brake Circuit J2 1 Bleeding Procedures Front J5 10 Rear J6 32 Checkout Procedure J4 1 Troubleshooting J4 9 Brakes Front J5 1 Brake Manifold J3 24 Brake Pad Conditioning Front Brakes J5 9 Rear Brakes J6 30 Brakes Rear J6 1 Brake Valve J3 3 Test and Adjustment J3 13 C Cab N2 1 Door Repair N2 6 Glass R...

Page 1042: ...and Tires G2 1 Fuel Tank B4 3 H Heater Air Conditioner N4 3 Actuators N4 5 Hoist Circuit Operation L7 1 Hoist Cylinder Limit Switch D3 16 Hoist Pilot Valve L8 10 Hoist Cylinders L8 14 Hoist Relief Valve L10 16 Hoist Valve L8 3 Hub Wheel G3 1 HYDRAIR II Suspensions Front H2 1 Rear H3 1 Oil and Nitrogen Specifications H4 11 Hydraulic Hoist Pump L3 3 Schematic R1 1 Steering Brake Pump L4 15 Strainer ...

Page 1043: ... Radiator C3 4 Rear Axle G4 1 Rear HYDRAIR II Suspension H3 1 Rear Tire and Rim G2 5 Retarder Pedal Electronic E2 46 Rims G2 8 Rock Ejector B3 8 Reserve Engine Oil System M31 1 S Safety Rules A3 3 Software Propulsion Control System E2 26 Seat Operator N3 6 Service Capacities P2 1 Solenoid Bleeddown L4 14 Special Tools M8 1 Specifications HYDRAIR II Oil H4 11 HYDRAIR II Nitrogen H4 11 Hydraulic Oil...

Page 1044: ... 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 W Warnings and Cautions A4 1 Weights Truck A2 4 Wheel Bearing Adjustment Front Tire Removed G3 11 Tire M...

Page 1045: ...R01077 2 06 System Schematics R1 1 SECTION R SYSTEM SCHEMATICS INDEX HYDRAULIC BRAKE SCHEMATIC HH360 HYDRAULIC SCHEMATIC HH361 830E AC ELECTRICAL SCHEMATIC XS3200 ...

Page 1046: ...R1 2 System Schematics 2 06 R01077 NOTES ...

Page 1047: ...42 kPa 1500 psi BRAKE LOCK PRESSURE 15 858 kPa 2300 psi LOW BRAKE PRESS SW Closes below 15 858 kPa 2300 psi 22 063 to 24 132 kPa 3200 to 3500 psi STEERING PRESSURE SWITCH Closes below 8618 kPa 1250 psi PARK BRAKE PRESSURE SWITCH Closes below 17 237 kPa 2500 psi PARK BRAKE PRESSURE REGULATOR 14 479 517 kPa 2100 75 psi AUTOMATIC APPLY 9653 kPa 1400 psi NITROGEN 9653 kPa 1400 psi NITROGEN 517 34 kPa ...

Page 1048: ......

Page 1049: ...XS3201 JUNE 05 ELECTRIC SCHEMATIC INDEX AND SYMBOLS 830E AC A30001 and UP SHEET 1 OF 35 ...

Page 1050: ...XS3202 3 MAY 06 ELECTRIC SCHEMATIC GE SYSTEM BLOCK DIAGRAM 830E AC A30001 and UP SHEET 2 OF 35 ...

Page 1051: ...XS3203 2 MAY 06 ELECTRIC SCHEMATIC MAIN PROPULSION SCHEMATIC 830E AC A30001 and UP SHEET 3 OF 35 ...

Page 1052: ...XS3204 JUNE 05 ELECTRIC SCHEMATIC GE 24 15V PWR DISTRIBUTION 830E AC A30001 and UP SHEET 4 OF 35 ...

Page 1053: ...XS3205 1 JAN 06 ELECTRIC SCHEMATIC G E INVERTER FIRING 830E AC A30001 and UP SHEET 5 OF 35 ...

Page 1054: ...XS3206 1 JAN 06 ELECTRIC SCHEMATIC G E INVERTER FIRING 830E AC A30001 and UP SHEET 6 OF 35 ...

Page 1055: ...XS3207 2 JAN 06 ELECTRIC SCHEMATIC ENGINE I O 830E AC A30001 and UP SHEET 7 OF 35 ...

Page 1056: ...XS3208 1 JAN 06 ELECTRIC SCHEMATIC G E 24V DIGITAL I O 830E AC A30001 and UP SHEET 8 OF 35 ...

Page 1057: ...XS3209 1 JAN 06 ELECTRIC SCHEMATIC CONTROL PANEL ANALOG INPUTS 830E AC A30001 and UP SHEET 9 OF 35 ...

Page 1058: ...XS3210 2 MAY 06 ELECTRIC SCHEMATIC 24V POWER DISTRIB CKT PROTECT 830E AC A30001 and UP SHEET 10 OF 35 ...

Page 1059: ...XS3211 2 MAY 06 ELECTRIC SCHEMATIC OPER CAB OVERHEAD WARNING LIGHTS 830E AC A30001 and UP SHEET 11 OF 35 ...

Page 1060: ...XS3212 2 MAY 06 ELECTRIC SCHEMATIC OPER CAB OVERHEAD WARNING LIGHTS 830E AC A30001 and UP SHEET 12 OF 35 ...

Page 1061: ...XS3213 2 MAY 06 ELECTRIC SCHEMATIC OPER CAB OVERHEAD WARNING LIGHTS 830E AC A30001 and UP SHEET 13 OF 35 ...

Page 1062: ...XS3214 3 MAY 06 ELECTRIC SCHEMATIC OPER CAB OVERHEAD WARNING LIGHTS 830E AC A30001 and UP SHEET 14 OF 35 ...

Page 1063: ...XS3215 1 SEP 05 ELECTRIC SCHEMATIC AUTO LUBE SYSTEM W WARNING 830E AC A30001 and UP SHEET 15 OF 35 ...

Page 1064: ...XS3216 2 JAN 06 ELECTRIC SCHEMATIC OPER CAB GAUGES OPTION SWITCHES 830E AC A30001 and UP SHEET 16 OF 35 ...

Page 1065: ...XS3217 1 JAN 06 ELECTRIC SCHEMATIC HEATER AIR CONDITIONER CONTROLS 830E AC A30001 and UP SHEET 17 OF 35 ...

Page 1066: ...XS3218 JUNE 05 ELECTRIC SCHEMATIC WORK LIGHTS AND HORN 830E AC A30001 and UP SHEET 18 OF 35 ...

Page 1067: ...XS3219 1 JAN 06 ELECTRIC SCHEMATIC RETARD LIGHTS BACKUP LTS HORNS 830E AC A30001 and UP SHEET 19 OF 35 ...

Page 1068: ...XS3220 3 MAY 06 ELECTRIC SCHEMATIC OPERATOR DRIVE SYSTEM CONTROLS 830E AC A30001 and UP SHEET 20 OF 35 ...

Page 1069: ...XS3221 1 MAY 06 ELECTRIC SCHEMATIC RADIO WINDOWS WIPER CONTROL 830E AC A30001 and UP SHEET 21 OF 35 ...

Page 1070: ...XS3222 1 MAY 06 ELECTRIC SCHEMATIC TURN SIGNAL CLEARANCE LIGHTS 830E AC A30001 and UP SHEET 22 OF 35 ...

Page 1071: ...XS3223 JUNE 05 ELECTRIC SCHEMATIC FOG LIGHTS AND HEAD LIGHTS 830E AC A30001 and UP SHEET 23 OF 35 ...

Page 1072: ...XS3224 1 JAN 06 ELECTRIC SCHEMATIC OPERATOR CAB INSTRUMENT LIGHTS 830E AC A30001 and UP SHEET 24 OF 35 ...

Page 1073: ...XS3225 2 MAY 06 ELECTRIC SCHEMATIC KEY SWITCH 5 MINUTE IDLE 830E AC A30001 and UP SHEET 25 OF 35 ...

Page 1074: ...XS3226 1 JAN 06 ELECTRIC SCHEMATIC QSK 60 START CIRCUIT 830E AC A30001 and UP SHEET 26 OF 35 ...

Page 1075: ...XS3227 2 MAY 06 ELECTRIC SCHEMATIC ENGINE CIRCUITS CUMMINS QSK 60 830E AC A30001 and UP SHEET 27 OF 35 ...

Page 1076: ...XS3228 2 JAN 06 ELECTRIC SCHEMATIC PAYLOAD METER 3 CIRCUITS 830E AC A30001 and UP SHEET 28 OF 35 ...

Page 1077: ...XS3229 1 JAN 06 ELECTRIC SCHEMATIC DIAG PORTS DISPATCH SYSTEM 830E AC A30001 and UP SHEET 29 OF 35 ...

Page 1078: ...XS3230 1 JAN 06 ELECTRIC SCHEMATIC PARK BRAKE GE I O 830E AC A30001 and UP SHEET 30 OF 35 ...

Page 1079: ...XS3231 1 JAN 06 ELECTRIC SCHEMATIC WINDSHLD WIPER TURN SIG CNTRLS 830E AC A30001 and UP SHEET 31 OF 35 ...

Page 1080: ...XS3232 2 JAN 06 ELECTRIC SCHEMATIC VHMS INTERFACE ORBCOM MODULES 830E AC A30001 and UP SHEET 32 OF 35 ...

Page 1081: ...XS3233 1 JAN 06 ELECTRIC SCHEMATIC BATTERY BOX 830E AC A30001 and UP SHEET 33 OF 35 ...

Page 1082: ...XS3234 2 JAN 06 ELECTRIC SCHEMATIC CIRCUIT LOCATOR SHEET 830E AC A30001 and UP SHEET 34 OF 35 ...

Page 1083: ...XS3235 3 Jan 06 ELECTRIC SCHEMATIC COMPONENT LOCATOR SHEET 830E AC A30001 and UP SHEET 35 OF 35 ...

Page 1084: ......

Page 1085: ...www komatsuamerica com Komatsu America Corp 2300 N E Adams Street Peoria IL 61639 Phone 309 672 7577 Fax 309 672 7072 Copyright 2006 Komatsu Printed in U S A ...

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