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Komatsu 830E, Shop Manual

The Komatsu 830E is a heavy-duty mining truck designed for optimal performance and efficiency. To fully utilize its features, ensure you have the Shop Manual, which provides comprehensive instructions. Download the manual for free at manualshive.com, to unlock the full potential of your Komatsu 830E.

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E2-52

Electrical Propulsion Components

2/02 E02016

TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.)

PAR

No.

DESCRIPTION

UNITS

COUNT CONDITIONS

120

RP4

Occurrences

Refer to Table I, TWO DIGIT DISPLAY CODES

121

RP5

Occurrences

122

RP6

Occurrences

123

RP7

Occurrences

124

RP8

Occurrences

125

RP9

Occurrences

126

FORWARD

Occurrences

127

REVERSE

Occurrences

130

Analog Output

Occurrences

131

Analog Read Back

Occurrences

132

Analog Input

Occurrences

133

Frequency Input

Occurrences

137

Startup Fault

Occurrences

145

Diode Fault

Occurrences

146

Motor 1 
Overcurrent

Occurrences

147

Motor 2 
Overcurrent

Occurrences

148

MFld Marm

Occurrences

149

MF Overcurrent

Occurrences

150

Motor Stall

Occurrences

151

Motor Spin

Occurrences

152

Alternator Tertiary 
Overcurrent

Occurrences

153

Motor Tertiary 
Overcurrent

Occurrences

154

+15V Power

Occurrences

155

-15V Power

Occurrences

156

+19V Power

Occurrences

157

Motor Polarity

Occurrences

161

Retard Grid 1

Occurrences

162

Retard Grid 2

Occurrences

163

Blower Fault

Occurrences

164

M1 Overtemp

Occurrences

165

M2 Overtemp

Occurrences

Summary of Contents for 830E

Page 1: ...CEBM013200 Shop Manual DUMP TRUCK SERIAL NUMBERS A30708 A30732 ...

Page 2: ......

Page 3: ...tten authorization from KAC It is the policy of the Company to improve products whenever it is possible and practical to do so The Company reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously Because of continuous research and development periodic revisions may be made to this publication Customers s...

Page 4: ...NOTES ...

Page 5: ...ques are provided in the text in bold face type such as 100 ft lbs 135 N m torque All torque specifications have 10 tolerance unless otherwise specified A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig nates the Truck Model Number Product Identification Number vehicle serial number and Maximum G V W Gross Vehicle Weight rating T...

Page 6: ...ies 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 precautions 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 dam...

Page 7: ... 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 A00032 KOMATSU MODEL 830E TRUCK ...

Page 9: ... ...

Page 10: ... ...

Page 11: ... power if the steering hydraulic pressure is reduced below an established minimum OPERATOR S CAB The Operator s Cab has been engineered for opera tor comfort and to allow for efficient and safe opera tion of the truck The cab contains an integrated ROPS and is fully insulated to reduce noise and vibration The tinted safety glass windshield and side windows provide excellent visibility The seat is ...

Page 12: ...A2 2 Major Component Description A02063 830E MAJOR COMPONENTS ...

Page 13: ...to improved design for greater load support rims are not interchangeable with other manufacturer s rims Rim Size 29 in 737 mm X 57 in 1448 mm X 6 in 152 mm 24 VDC ELECTRIC SYSTEM Batteries Four 12 Volt Batteries in Series Parallel 220 Ampere Hour Capacity w Disconnect Switch Alternator 24 Volt 260 Ampere Output Lighting 24 Volt Starters 2 24 Volt SERVICE CAPACITIES U S Gallons Liters Crankcase 74 ...

Page 14: ... m3 Struck 153 yd3 117 m3 Loading Height Empty 22 ft 1 in 6 71 m Dumping Angle 45 Non heated Body w Exhaust Mufflers Standard WEIGHT DISTRIBUTION Empty Vehicle Pounds Kilograms Front Axle 177 217 80 384 Rear Axle 172 792 78 377 Total 350 009 158 761 Loaded Vehicle Pounds Kilograms Front Axle 283 595 128 636 Rear Axle 566 405 256 917 Total 850 000 385 553 Not To Exceed 850 000 lbs 385 553 kg includ...

Page 15: ...s safety pins and seat belts and use these safety features properly NEVER remove any safety features ALWAYS keep them in good operating condition Improper use of safety features could result in serious bodily injury or death CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing jewelry and loose long hair They can catch on controls or in moving parts and cause serious injury or death Also do...

Page 16: ...hine and use the hand hold and steps Never hold any control levers when getting on or off the machine Always maintain three point contact with the hand holds and steps to ensure that you support yourself When bringing tools to the operator s compartment always pass them by hand or pull them up by rope If there is any oil grease or mud on the hand holds or steps wipe it off immediately Always keep ...

Page 17: ...pressure before removing the cap ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled If you handle materials containing asbestos fibers follow these guidelines as given below NEVER use compressed air for cleaning Use water for cleaning to keep down the dust Operate the machine with the wind to your back whenever possible Use an approved respirator if nece...

Page 18: ...orized regional Komatsu distributor Even if the ROPS is installed it cannot show its full effect if the operator does not fasten the seat belt properly Always fasten the seat belt when operating PRECAUTIONS FOR ATTACHMENTS When installing and using optional equipment read the instruction manual for the attachment and the information related to attachments in this manual Do not use attachments that...

Page 19: ...stence of obstacles before starting operations Always determine the travel roads in the work site and maintain them so that it is always safe for the machines to travel If travel through wet areas is necessary check the depth and flow of water before crossing the shallow parts NEVER be in water which is in excess of the permissible water depth FIRE PREVENTION Thoroughly remove wood chips leaves pa...

Page 20: ...e rear view mirror to a position where the operator can see best from the operator s seat and keep the surface of the mirror clean If any glass or light should break replace it with a new part Insure headlights work lights and taillights are in proper working order Check that the machine is equipped with the head lamps and working lamps needed for the operating conditions OPERATING THE MACHINE WHE...

Page 21: ...ng brake applied when the truck is parked and unattended DO NOT leave truck unattended while engine is running When parking park a safe distance from other vehicles as determined by 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 CHECK WHEN TRAVELING IN REVERSE Before operati...

Page 22: ...test slope so always travel slowly and avoid sudden starting turning or stopping Be extremely careful when carrying out snow clearing operations The road shoulder and other objects are buried in the snow and cannot be seen When traveling on snow covered roads always install tire chains AVOID DAMAGE TO DUMP BODY When working in tunnels on bridges under electric cables or when entering a parking pla...

Page 23: ...ing position then load the body uniformly Do not leave the operator s seat during the loading operation PARKING THE MACHINE Choose a horizontal road surface to park the machine If the machine has to be parked on a slope always put blocks under all the wheels to prevent the machine from moving When parking on public roads provide fences and signs such as flags or lights on the machine to warn pedes...

Page 24: ...F position Avoid short circuiting the battery terminals through accidental contact with metallic objects such as tools across the terminals When removing or installing check which is the positive terminal and negative terminal Tighten the battery cap securely Tighten the battery terminals securely Loosened terminals can generate sparks and lead to an explosion STARTING WITH BOOSTER CABLES ALWAYS w...

Page 25: ...e radiator always move the shift control lever to the Neutral N position and set the parking brake lever to the PARKING position Always carry out the work with two people One person should sit on the operator s seat to stop the engine if necessary NEVER move any controls not needed to operate When servicing the machine be careful not to touch any moving part or get clothing caught Put blocks under...

Page 26: ...gets into the electrical system there is danger that the machine may not move or may move unexpectedly Do not use water or steam to clean the sensors connectors or the inside of the operator s compartment Use extreme care when washing the electrical control cabinet Do not allow water to enter the control cabinet around the doors or vents Do not allow any water to enter the cooling air inlet duct a...

Page 27: ...nt HANDLING HIGH PRESSURE HOSES Do not bend high pressure hoses or hit them with hard objects Do not use any bent or cracked piping tubes or hoses They may burst during use Always repair any loose or broken fuel hoses or oil hoses If fuel or oil leaks it may cause a fire PRECAUTIONS WITH HIGH PRESSURE OIL Do not forget that the work equipment circuits are always under pressure Do not add oil drain...

Page 28: ... go down then carry out the inspection and maintenance in accordance with the procedures given in this manual ROTATING FAN AND BELT Keep away from rotating parts and be careful not to let anything get caught in them If your body or tools touch the fan blades or fan belt they may be cut off or sent flying so never touch any rotating parts WASTE MATERIALS Never dump waste oil in a sewer system river...

Page 29: ...l explode and this may lead to serious personal injury Explosions differ from punctures or tire bursts because the destructive force is extremely large Therefore the following operations are strictly prohibited when the tire is under high internal pressure Welding the rim Building fires or carrying out welding near the wheel or tire If the proper procedure for carrying out maintenance or replaceme...

Page 30: ...______________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _________________________________...

Page 31: ...remove any control circuit cards on Electric Drive Dump Trucks or any of the AID cir cuit control cards Always fasten the welding machine ground lead to the piece being welded grounding clamp MUST BE ATTACHED AS NEAR AS POSSIBLE to the weld area Never allow welding current to pass through ball bearings roller bearings suspensions or hydraulic cylinders Always avoid laying welding cables over or ne...

Page 32: ...A3 18 General Safety and Operating Instructions A03020 NOTES ...

Page 33: ... repeated from the same point and in the same direc tion before every shift many potential problems may be avoided or scheduled for maintenance UNSCHEDULED downtime and loss of production can be reduced Local work practices may prevent an operator from performing all tasks suggested here but to the extent permitted the operator should follow this or similar routine 1 Start at left front of truck W...

Page 34: ...A3 20 General Safety and Operating Instructions A03020 ...

Page 35: ...y abnormal condition Check hoist limit switch and clear any mud debris from contacts 15 Perform the same inspection on the right rear suspension as done on the left 16 Move on around the right dual tires inspect between the tires for rocks and for condition of the rock ejector inspect the tires for cuts or damage and for correct inflation 17 Perform the same inspection for wheel lugs wedges wheel ...

Page 36: ... floor as necessary Insure steering wheel con trols and pedals are free of any oil grease or mud 31 Stow personal gear in cab so that it does not interfere with any operation of the truck Dirt or trash buildup specifically in the operator s cab should be cleared Do not carry tools or sup plies in cab of truck or on the deck 32 Adjust seat and steering wheel so that it is com fortable for use 33 If...

Page 37: ...e truck until low pressure and warning systems are normal and the cool ant temperature is at least 160 F 71C 2 Become thoroughly familiar with steering and emergency controls Test the truck steering in extreme right and left directions If the steering system is not operating properly shut engine down immediately Determine the steering sys tem problem and have repairs made before resuming operation...

Page 38: ...ake periodically during shift Use parking brake ONLY for parking Do not use park brake for loading dumping Do not attempt to apply parking brake while truck is moving Do not use Brake Lock or Emergency Brake if equipped for parking With engine stopped hydraulic pressure will bleed down allowing brakes to release 8 Check brake lock performance periodically for safe loading and dump operation 9 Proc...

Page 39: ...tion Dynamic Retarding should be used to slow and control the speed of the truck Dynamic Retarding is available in Forward Reverse at all truck speeds above 0 mph kph however as the truck speed slows below 3 mph 4 8 kph the avail able retarding force may not be effective Use the service brakes to bring the truck to a COMPLETE stop Dynamic Retarding will NOT hold a stationary truck on an incline us...

Page 40: ...cles and for personnel working in the area 4 When pulling in under a loader or shovel follow Spotter or Shovel Operator signals The truck operator may speed up loading operations by observing the location and loading cycle of the truck being loaded ahead then follow a sim ilar pattern 5 When being loaded operator should stay in truck cab with engine running Place Selector Switch in Neutral and app...

Page 41: ... tail of body will not clear the crusher wall in the fully raised position b Shift Selector Switch to Forward release Brake Lock depress Override button and drive forward to clear the material Stop shift Selector Switch to Neutral apply Brake Lock and lower body again NOTE Failure to hoist the body after making an unsuccessful attempt at lowering the body may result in the dump body suddenly lower...

Page 42: ...he parking brake must be applied and or chocks placed fore aft of wheels so that the truck cannot roll Each truck should be parked at a reasonable distance from another 3 Haul roads are not safe parking areas In an emergency pick the safest spot most visible to other machines in the area If the truck becomes disabled where traffic is heavy mark the truck with warning flags in daylight or flares at...

Page 43: ...ruck for ground level engine shutdown DELAYED ENGINE SHUTDOWN PROCEDURE 1 Stop the truck out of the way of other traffic on a level surface and free of overhead power lines or other obstructions in case dump body should need to be raised a Reduce engine speed to low idle b Place the directional Selector Switch in Neutral c Apply the Parking Brake switch Be sure the Parking Brake Applied indicator ...

Page 44: ...il tank for the engine is designed to add more oil capacity to the engine and to make less fre quent servicing of the engine oil The circulation of oil between the engine sump and reserve tank increases the total volume of working oil This dilutes the effects of contamination and loss of additives and maintains the oil quality over longer periods A filter in the supply circuit protects the pumping...

Page 45: ...e dipstick at every shift change If the oil level in the engine is incorrect check for proper operation of the reserve engine oil system The oil level in the reserve tank must also be checked at every shift change Oil must be visible in the middle sight gauge 12 If not add oil to the reserve tank by using the quick fill system utilizing the tank fill pump 3 For filling instructions refer to the Lu...

Page 46: ...A3 32 General Safety and Operating Instructions A03020 NOTES ...

Page 47: ...e warning stresses the importance of read ing the operator s manual before operation A Grade Speed plate is located on the left front post of the operator s cab and provides the recommended MAXIMUM speeds to be used when descending var ious grades with a loaded truck Always refer to the decal in operator s cab This decal in the truck may differ from the decal shown here due to OPTIONAL truck equip...

Page 48: ...motion sensor to RELEASE the park brake The Wheel Brake Lock switch is for holding the truck while parked at the shovel during loading or while dumping It applies the rear service brakes only If the brake treadle valve does not operate apply this brake to stop the truck Do NOT use this brake as a parking brake when leaving the truck With engine shut down the hydraulic system will eventually bleed ...

Page 49: ...t of and to the rear of the 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 alert technicians not to work on the truck with the body in the raised position unless body up retention device pins or cable is in position A plate on the side of the hydraulic t...

Page 50: ...level is below top of sight glass A warning plate is attached to the frame above the hydraulic system APU quick disconnect fittings to alert technicians that high pressure hydraulic oil is present during operation Care must be taken when it is necessary to open the hydraulic system There is always a chance of residual pressure being present Open fittings slowly to allow any pressure to bleed off b...

Page 51: ...ed grounding clamp MUST BE ATTACHED AS NEAR AS POSSIBLE to the weld area Never 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 voltage could be induced into the electrical harness and possibly cause damage to components A WARNING plate is located above the...

Page 52: ...ne turn off the key switch and open the drain valves on all three accumulators to bleed the hydraulic pressure before loosening or disconnecting a brake line This WARNING plate attached to the automatic lube system grease reservoir warns the technician not to remove the reservoir cover The grease reservoir should be filled through the grease filter to prevent contamination of the grease supply Thi...

Page 53: ...17 alpha numeric characters are used to identify 5 charac teristics of the machine The 5 characteristics are detailed below WMC Character positions 1 2 and 3 identify the World wide Manufacturer Code WMC The WMC desig nates 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...

Page 54: ...gs and Cautions A04046 The Lubrication Chart is located on the right hand side of the radiator grille and is for reference Refer to the Lubrication Section in this manual for more complete lubrication instructions ...

Page 55: ... stress and pos sible breakage of the fasteners may result Where 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 1 10 on the threads and seats unless specified otherwise NOTE Always be sure threads of fasteners and tapped...

Page 56: ...ompany also American Oil Co GULF NORUST 3 from Gulf Oil Company MOBILARMA 355 Product No 66705 from Mobil Oil Corporation RUST BAN 326 from Humble Oil Company RUSTOLENE B GREASE from Sinclair Oil Com pany RUST PREVENTIVE GREASE CODE 312 from the Southwest Grease and Oil Company NOTE This list represents the current Engineer ing approved sources for use in Komatsu manufac ture It is not exclusive O...

Page 57: ... 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 0 625 0 875 14 32 5 12 ...

Page 58: ... 60 3 73 3 87 4 01 30 4 15 4 29 4 43 4 56 4 70 4 84 4 98 5 12 5 26 5 39 40 5 53 5 67 5 81 5 95 6 09 6 22 6 36 6 50 6 64 6 78 50 6 92 7 05 7 19 7 33 7 47 7 61 7 74 7 88 8 02 8 16 60 8 30 8 44 8 57 8 71 8 85 8 99 9 13 9 27 9 40 9 54 70 9 68 9 82 9 96 10 10 10 23 10 37 10 51 10 65 10 79 10 93 80 11 06 11 20 11 34 11 48 11 62 11 76 11 89 12 03 12 17 12 30 90 12 45 12 59 12 72 12 86 13 00 13 14 13 28 1...

Page 59: ...7 225 437 49 120 248 9 15 59 104 220 428 46 115 239 12 10 50 102 215 419 43 110 230 15 5 41 99 210 410 41 105 221 18 0 32 96 205 401 38 100 212 21 5 23 93 200 392 35 95 293 23 10 14 91 195 383 32 90 194 26 15 5 88 190 374 29 85 185 29 20 4 85 185 365 27 80 176 32 25 13 82 180 356 24 75 167 34 30 22 79 175 347 21 70 158 37 35 31 77 170 338 18 65 149 40 40 40 74 165 329 15 60 140 43 45 49 71 160 320...

Page 60: ...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 ft 2 0 001 cu centimeters cm3 cu i...

Page 61: ... 0 1 23 4 5 67 5 789574 0 ...

Page 62: ... 7 4 4 0 5 0 8 3 7 4 4 2 1 5 4 4 4 A 4 4 4 8 8 4 0 4 5 67 5 789574 0 1 23 ...

Page 63: ... 7 5 0 3 A B 594 5 4 5 4 7 2 C 4 7 D 7 D 1 5 4 4 4 5 5 8 D 0 A 4 4 4 3 8 2 0 1 23 4 5 67 5 789574 0 ...

Page 64: ... 4 1 5 4 4 4 0 3 9 2 C C 0 4 5 67 5 789574 0 1 23 ...

Page 65: ... 0 0 1 5 5 5 2 3 4 5 1 1 1 0 0 1 23 4 5 67 5 789574 0 ...

Page 66: ... 4 5 6 8 4 4 E C 4 4 4 E C 4 4 7 D 5 6 7 5 9 4 4 8 5 4 4 4 5 0 D 9 0 4 5 67 5 789574 0 1 23 ...

Page 67: ...3 5 5 4 5 2 8 5 5 D 4 4 1 1 1 6 1 1 7 8 5 5 0 1 23 4 5 67 5 789574 00 ...

Page 68: ... 2 8 0 7 5 2 5 8 F 03 4 5 67 5 789574 0 1 23 ...

Page 69: ...1 C 8 D 8 6 4 G 5 4 8 D 8 F 4 4 4 G 1 8 D 0 1 23 4 5 67 5 789574 02 ...

Page 70: ... 6 8 7 0 H 8 9 9 8 A 5 A 3 4 2 4 5 0 3 2 8 9 8 4 8 0 4 0 C 5 7 4 4 7 5 5 7 4 4 7 4 0 4 5 67 5 789574 0 1 23 ...

Page 71: ... 0 6 8 7 0 H 8 9 4 4 6 4 7 6 8 9 8 A 5 A 3 4 2 G 0 4 5 3 2 8 5 1 4 4 9 4 0 6 C 5 4 9 4 9 5 9 G C 8 5 7 4 4 7 5 5 7 4 4 7 0 0 1 23 4 5 67 5 789574 0 ...

Page 72: ... 2 3 2 G 8 4 8 8 4 D 2 6 7 0 4 1 3 2 G 8 5 4 8 8 4 5 5 0 4 5 67 5 789574 0 1 23 ...

Page 73: ... 45 0 H 3 H 4 8 0 6 3 8 5 A D 6 7 A B 6 C 7 A D 5 E 2 2 8 8 A A 5 8 8 4 8 8 5 5 8 4 3 H A 0 3 4 9 2 8 8 0 1 23 4 5 67 5 789574 0 ...

Page 74: ... 6 7 8 5 8 5 5 5 5 4 8 8 4 8 8 4 0 4 8 8 4 3 2 4 8 8 4 5 5 4 7 8 8 4 0 4 5 67 5 789574 0 1 23 ...

Page 75: ... 9 6 7 4 C F F F 0 0 8 0 0 F 0 88 1 6 7 G 6 G 8 G 8 4 6 7 4 4 0 2 0 1 23 4 5 67 5 789574 0 ...

Page 76: ... 8 4 5 D 5 8 7 5 5 67 8 C3 C 5 6 7 4 0 3 2 H H H H 4 6 G 8 6 7 4 E 8 I 2 5 8 5 8 4 4 6 6 8 1 0 4 5 67 5 789574 0 1 23 ...

Page 77: ... G 5 5 5 5 5 5 G 6 5 6 G 5 5 5 5 4 D 0 5 D 6 7 4 3 G 5 8 2 C 5 D 0 1 23 4 5 67 5 789574 0 0 ...

Page 78: ... 0 3 4 5 67 5 789574 0 1 23 ...

Page 79: ... A 6 8 4 J 4 02 6 2 8 J 1 C E 2 3 4 1 5 8 5 0H 5 0H 8 5 0H 0 3 02 2 3 E C E 5 5 5 0 1 23 4 5 67 5 789574 0 2 ...

Page 80: ...0 4 5 67 5 789574 0 1 23 ...

Page 81: ...and Left Hand Deck Components B2 3 Fuel Tank B2 4 Removal B2 4 Installation B2 4 DUMP BODY B3 Removal B3 1 Installation B3 2 Body Pads B3 3 Adjustment B3 4 Body Guide B3 4 Body up Retention Cable B3 4 Body Position Indicator B3 5 Rock Ejectors B3 5 Inspection B3 5 Hoist Limit Switch B3 5 Body Up Switch B3 5 B01018 Index B1 1 ...

Page 82: ...NOTES B1 2 Index B01018 ...

Page 83: ...o mount and dismount the truck In addition a vertical ladder 6 is available if emergency exit from the cab is necessary Anti skid material is placed at various places on the decks and ladder platform 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 ...

Page 84: ...d equip ment Refer to figure 2 1 for location and nomenclature of parts described Removal 1 Open battery disconnect switch at battery box on right deck 2 Remove clamps and electrical cables a Remove power cables routed to retarding grids 3 Figure 2 2 b Remove cables from batteries c Remove all 24 volt wiring clearance lights ground straps etc that will interfere with deck and ladder removal d Remo...

Page 85: ...other wiring or hoses that may be attached The deck supports and attachment points shown for the RH deck in Figure 2 2 are also typical of the LH deck mounts If cab removal is required refer to Section N for removal instructions Before performing deck removal or repairs be certain the battery disconnect switch is open and all hydraulic pressure has been released prior to removing any hoses electri...

Page 86: ...kets 10 Lift tank from brackets and move to work area 11 Inspect rubber dampeners 2 Figure 2 4 and replace if necessary Installation 1 Lower tank into position over upper mounting brackets 2 Install caps lockwashers and capscrews at upper mounting trunnions 1 Figure 2 3 and tighten to 459 ft lbs 622 N m torque 3 Install lower mount flatwashers 3 Figure 2 4 and capscrews 4 and tighten to 310 ft lbs...

Page 87: ...and over head structures or electric power lines Be sure that the lifting device is rated for at least a 45 ton capacity 2 Remove mud flaps and rock ejectors from both sides of the body Remove electrical cables lu brication hoses etc attached to the body 3 Attach chains around upper end of hoist cylinders to support them after the mounting pins are re moved 4 Remove pin retainer capscrew 4 Figure ...

Page 88: ... frame Align body pivot and frame pivot holes 2 Install shims 9 Figure 3 1 in both body pivots as required to fill the outside gaps and center the body on the frame pivot Do not install shims at the inside A minimum of 1 shim is required at the outside end of both frame pivots 3 If not already installed install retainer 1 and capscrews 2 to hold bushing 12 in place Tighten capscrews to 40 ft lbs 5...

Page 89: ...event dump body from lowering 2 Remove hardware attaching pads to the dump body Refer to Figure 3 4 3 Remove body pad and shims Note number of shims installed at each pad location The rear pad on each side should have one less shim than the other pads 4 Install new pads with the same number of shims as removed in step 3 5 Install the mounting hardware and tighten to 65 ft lbs 88 1 N m torque 6 Rem...

Page 90: ...ould be centered between the wear plates 3 with a maximum gap of 0 19 in 4 8 mm at each side when new 2 If gap becomes excessive replacement parts should be installed Refer to the Parts Catalog BODY UP RETENTION CABLE Any time personnel are required to perform main tenance on the vehicle with the dump body in the raised position the body up retention cable MUST be installed 1 To hold the dump body...

Page 91: ...e truck parked on a level surface the arm structure Refer to Figure 3 7 should be approxi mately 3 50 in 88 mm 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 necesary to to obtain NO GAP 3 If the arm 1 becomes bent it must be removed and straightened 4 The wear plates 2 m...

Page 92: ...NOTES B3 6 Dump Body B03018 ...

Page 93: ...C4 1 ALTERNATOR REMOVAL PROCEDURE C4 1 Engine Alternator Mating C4 3 Measuring Procedure C4 3 Joining Alternator and Engine C4 5 ENGINE C4 6 Removal C4 6 Installation C4 6 AIR FILTRATION SYSTEM C5 1 AIR CLEANER C5 1 Operation C5 1 General Service Information C5 1 MAIN FILTER ELEMENT C5 1 SAFETY FILTER ELEMENT C5 2 Air Intake Troubleshooting C5 3 AIR CLEANER ASSEMBLY CLEANING C5 3 Main Filter Eleme...

Page 94: ...C1 2 Index C01024 NOTES ...

Page 95: ...rial from entering 4 It is not necessary to remove the grille or radiator prior to the removal of the power module If radia tor removal is desired or if only radiator repair is necessary refer to Cooling System in this sec tion Removal 1 Disconnect batteries using the following proce dure in this order a Open battery disconnect switch located on battery equalizer box on deck of truck b Remove batt...

Page 96: ...ve from truck 9 Close both cab heater shutoff water valves dis connect water lines and drain water from the heater core Secure water lines away from engine compartment so as not to interfere with power module removal 10 Remove capscrews 2 Figure 2 2 and nuts secur ing left 1 and right 3 exhaust ducts to turbo charger outlets Remove V band clamps 5 and support clamps 4 Remove exhaust ducts and move...

Page 97: ...front subframe support to main frame Install safety chain around the front engine sub frame cross member and main frame to prevent the power module from rolling forward when the sub frame rollers are installed FIGURE 2 3 AIR INTAKE DUCTS Note Illustration shows engine equipped with two stage turbo chargers Single stage turbo charger equipped engine ducts and supports are similar 1 Hump Hose 2 Supp...

Page 98: ...ucture Refer to Figure 2 6 17 Attach hoist to lift points 2 Figure 2 4 at engine alternator cradle structure Raise the rear portion of engine subframe and install subframe rollers Refer to Figure 2 5 Lower the rear portion of the subframe carefully until the rollers rest on the main frame guide rail FIGURE 2 4 ENGINE MODULE INSTALLATION 1 Pump Driveshaft 2 Rear Module Lift Eye 3 Cap 4 Capscrews 5 ...

Page 99: ...ain 21 Raise the power module slightly to determine if module is on an even plane Move the power module straight out of truck to a clean work area for disassembly For further disassembly of the engine alternator and radiator refer to the appropriate section of this manual Installation 1 Inspect the main frame guide rails Remove any debris which would interfere with power module installation 2 Clea...

Page 100: ... exhaust ducts 1 3 Figure 2 2 Install capscrews 2 washers and nuts to secure ducts to turbochargers Install V band clamps 5 and support clamps 4 20 Connect the cab heater inlet and outlet hoses and open both valves 21 Connect the hydraulic pump drive shaft 1 Figure 2 4 to the companion flange on the alternator Tighten capscrews to standard torque 22 Connect wheel motor cooling blower air outlet ho...

Page 101: ...y is used 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 180 F 82 C and are fully open at 202 F 94 C In addition a fuel cooler located on the lower right corner of the radiator assembly reduces fuel tem perature after fuel leaves the engine ...

Page 102: ...e 3 2 removal a Remove lower left grille section for access to condenser hoses 1 Attach an air conditioner manifold gauge set at the compressor Refer to Heater Air Conditioning in Section M for detailed information 2 Completely evacuate the refrigerant from the air conditioning system NOTE Follow all local laws concerning the evac uation and handling of refrigerants 3 After system is evacuated rem...

Page 103: ...ly 4 200 lbs 1907 kg Be sure lifting device is capable of lifting the load 9 Remove radiator support struts 3 upper sup port rods and hardware 2 Figure 3 3 attach ing radiator assembly to power module subframe 10 Lift radiator enough to separate from mounts on subframe and move forward until shroud clears the engine fan Do not allow shroud to contact fan blades 11 Move assembly to a work area and ...

Page 104: ...ten capscrews clamping halves together to 25 ft lbs 34 N m torque 10 Attach hoses to fuel cooler 11 Route A C condenser hoses to condenser and attach Install lower grille sections Install receiver drier 10 hoses Connect pressure switch 11 12 Install surge tank hoses and electrical wiring to the coolant level probe 9 Figure 3 4 Clamp hoses and electrical cables to the shroud Install surge tank cove...

Page 105: ...ximately 7 700 lbs 3493 kg Use a lifting device that can han dle 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 capscrews 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 EN...

Page 106: ...e removal of the capscrews at all locations Be sure all the capscrew threads are completely disengaged from the alternator housing 1 6 Take up slack in hoist and remove capscrews 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 reinsta...

Page 107: ...apter 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 0 005 0 015 in 0 13 0 38 mm 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...

Page 108: ...our locations 90 apart and average the measurements 1st measurement _________________________ 2nd measurement ________________________ 3rd measurement ________________________ 4th measurement _________________________ Dimension A ____________________ Average e Add 0 010 to Dimension A f Record d e as Measurement A _________________________ 5 Determining Shims Compare Measurement C Step 3 c with Me...

Page 109: ...ng capscrews 3 Figure 4 2 to 345 ft lbs 465 N m 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 measure total crankshaft end play Record Total Crankshaft End play ____________ 8 Compare the step 7 value to the measurement taken before alternator was installed on engine The total Engine Cr...

Page 110: ...ea for further disassembly Service Complete instructions covering the disassembly assembly and maintenance of the engine and its components can be found in the engine manufac turer s service manual Installation 1 Align engine to subframe and install front mounting capscrews and lockwashers 5 Fig ure 4 7 Align and install rear engine mount ing capscrews and lockwashers 2 through cradle structure bu...

Page 111: ...ould be cleaned or replaced when the gauges read between 20 and 25 inches H2O vac uum or when a warning message is presented on the overhead display by the HMS system Refer to Filter Service Procedure for maintenance and cleaning instructions 3 Check to insure air inlet is not obstructed plugged or damaged 4 Check all connections between air cleaner outlet and engine intake manifold to insure they...

Page 112: ...as become clogged and should be discarded and replaced with a new one 1 Shut down the engine Clean the dirt and dust off the element end cover 2 Loosen wing nut 5 Figure 5 2 and remove end cover 8 and main element 10 3 Remove indicator nut 7 holding safety element in place Remove safety element 9 Inspect gas ket 14 and replace if necessary 4 Remove any dust lodged in the clean air outlet and aroun...

Page 113: ...te element back and forth in the solution to free element of dirt deposits DO NOT soak ele ments for more than 24 hours b Rinse element with a stream of fresh water in the opposite direction of normal air flow until rinse water runs clear Maximum permissible water pressure is 40 psi 276 kPa A complete thorough rinse is essential c Dry the element thoroughly If drying is done with heated air the ma...

Page 114: ...ed into the engine intake area 1 Dust can best be removed with a stiff fiber brush DO NOT use a wire brush Dust may also be removed effectively using compressed air 2 Heavy plugging of tubes may require soaking and washing of complete precleaner section The fol lowing instructions cover these procedures NOTE The precleaner section may be separated from the air cleaner assembly without dismounting ...

Page 115: ...ion should be mixed 50 Oakite 202 and 50 fresh water Soak precleaner section for 30 minutes rinse clean with fresh water and blow dry completely 7 Check precleaner gaskets 13 carefully for any evidence of air leaks replace if necessary 8 Install precleaner section with serviceable gas kets on air cleaner assembly and install all mount ing hardware removed 9 With a serviceable gasket 2 install dust...

Page 116: ...NOTES C5 6 Air Filtration System C05012 4 98 ...

Page 117: ... D2 6 Advanced System Troubleshooting D2 8 24VDC Electric Starter System With Prelub D2 10 Operation D2 10 Maintenance D2 11 Troubleshooting D2 12 24VDC ELECTRICAL SYSTEM COMPONENTS D3 1 Passenger Seat Base Compartment D3 1 Components D3 1 Alarm Indicating Device A I D System D3 4 Battery Equalizer Box D3 6 Body Up switch D3 7 Hoist Limit Switch D3 7 24 Volt Relay and Diode Boards D3 8 Circuit Bre...

Page 118: ...he plug in circuit cards must be removed or reinstalled be cer tain the control power switch is OFF When removing a G E Propulsion system circuit board a grounding strap should be worn to dissipate static electrical charges Extreme care should be exercised to prevent damage to the various semi conduc tor devices and low impedance circuits under test When using an ohmmeter to check diodes transisto...

Page 119: ...umption of water indicates leakage or overcharging Normal water usage for a unit operat ing eight hours per day is about one to two ounces per cell per month For heavy duty operation 24 hour normal consumption should run about one to two ounces per cell per week Any appreciable increase over these figures should be considered a danger signal Troubleshooting Two most common troubles that occur in t...

Page 120: ...cid batteries discharge slowly when not in use This self discharge takes place even though the battery is not connected in a circuit and is more pronounced in warm weather than in cold The rate of self discharge of a battery kept at 100 F 38 C is about six times that of a battery kept at 50 F 19 C and self discharge of a battery kept at 80 F 27 C is about four times that one at 50 F 10 C Over a th...

Page 121: ...rd 6 protects maintenance personnel from the rotating fan when the engine is operating TROUBLESHOOTING PROCEDURES On Truck Most 24 volt charging system problems can be diag nosed with the alternator installed on the truck operating under normal conditions Many problems can be attributed to loose or corroded cable connec tors It is essential that all battery charging circuit cables are in satisfact...

Page 122: ...ect battery disconnect switch The following tests require working near the engine when running Use caution when working near engine fan alternator fan and belt Test Procedure 1 Start engine accelerate to high idle and observe meters If voltmeter reading exceeds 30 5 volts stop engine immediately and refer to Table II If batteries are sufficiently discharged amps should be high 240 amps 10 and volt...

Page 123: ...pin F to ground 3 Observe meter readings If voltage or amperage rises the alternator is OK The regulator is defective and should be replaced If grounding the harness male pin has no effect the alternator is defective and should be replaced FIGURE 2 2 TEST METER HOOKUP 1 Alternator Under Test 2 0 to 400 AMP Ammeter 3 0 to 40 VDC Voltmeter 4 Alternator B Terminal 5 Alternator Ground Terminal 6 Truck...

Page 124: ...PUT Causes of high voltage Wrong regulator High regulator set point Defective regulator Defective alternator NO VOLTAGE OUTPUT Causes of no voltage output No drive belt No battery B voltage at alternator s B terminal except isolator type systems No link from R terminal to energize E terminal on alternator when engine operating Defective regulator Defective alternator TOOLS AND EQUIPMENT 1 Voltmete...

Page 125: ...mps over several hours without raising their internal tempera ture more than a few degrees Group 31 batteries may accept rates up to 5 amps over several hours with minimal temperature rise Medium amps are defined as some multiple of the low amp value perhaps 30 amps for the Group 8D and 10 15 amps for the Group 31 This rate of amperage will cause a rise in battery temperature over a long period of...

Page 126: ...TERNATOR With engine running measure value of AC voltage from R terminal to Ground If no AC volts are present alternator is not capable of turning on regulator NOTE On a new first time start up of an alternator the alternator may test at less than 5 volts on R terminal The cause of this problem may be loss of residual magnetism within the alternator during shipping and handling of the alternator T...

Page 127: ... voltmeter into E terminal of connector and Ground negative probe of voltmeter to alternator ground terminal If meter shows no voltage alternator is defective Replace alternator If meter shows battery voltage circuit is good Continue test Insert probe of voltmeter into B pin in connector Insert negative probe of voltmeter into B pin in connector This is power circuit for voltage regulator If circu...

Page 128: ...mer is activated current flows through fusible link 9 to the prelube motor 10 driving the prelube pump but does not allow the starter motors to engage the starter 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 2 5 psi 17 2 kPa the circuit to the t...

Page 129: ... engine starter solenoids 8 for engine cranking fol lowing a 3 second delay 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 operat...

Page 130: ...y 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 Starter 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 connection ...

Page 131: ...erative and no prelubrica tion no delay and crank this indicates a possible fail ure 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 starter delays then cranks the Prelube Timer Solenoid is bad Replace the timer solenoid assembly b If the starter is still inoperative check the truck starter switch ci...

Page 132: ...e from excessive speed until the keyswitch is released When the keyswitch 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 t...

Page 133: ...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 Connect a voltmeter from the motor terminal to the motor frame b Use an RPM indicator to measure armature speed c Connect a carbon pile across one battery to limit battery voltage to 20 VDC Do not apply voltages in excess of 20...

Page 134: ...ect field coil connector 42 from sole noid motor terminal and lead from solenoid ground terminal 3 Remove the brush inspection plug 52 and brush lead screws 15 4 Remove the attaching bolts 34 and separate the commutator end frame 1 from the field frame 35 5 Separate the nose housing 69 and field frame 35 from lever housing 78 by removing attaching bolts 70 6 Remove armature 45 and drive assembly 7...

Page 135: ...D02023 24 VDC Electric Supply System D2 17 FIGURE 2 8 CRANKING MOTOR ASSEMBLY ...

Page 136: ...cted by resol dering or welding the leads in the riser bars using rosin flux and turning down the commu tator in a lathe to remove the burned material The insulation should then be undercut 2 Short circuits in the armature are located by use of a growler When the armature is revolved in the growler with a steel strip such as a hacksaw blade held above it the blade will vibrate above the area of th...

Page 137: ...om the solenoid switch terminal S to the solenoid motor M or MTR terminal Figure 2 11 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 readin...

Page 138: ...e 45 Figure 2 8 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 139: ...described in Cranking Motor Removal 2 Disconnect cables from the switch terminals and wires from coil terminals Figure 2 14 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 capscrews and washers Remove switch from mounting bracket 4 The switch coil circuit can be tested a...

Page 140: ...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 141: ...er 17 Figure 3 1 Lubrication cycle frequency can be adjusted by removing the timer cover and selecting one of five different timing intervals available System on time is automatically determined by the timer and is not adjustable Refer to Section P for additional automatic lubrication system details 5 MINUTE IDLE TIMER COMPONENTS The 5 minute idle timer circuit automatically provides approximately...

Page 142: ...5 Minute Idle Timer 7 5 Minute Idle Contactor 8 Inclinometer 9 Hoist Control 10 Compartment Service Light 11 Brake Warning Buzzer BWB 12 5 Minute Idle Relay 13 Connector RP226 14 Connector RP231 15 Connector RP230 16 AID Module 17 Lube System Cycle Timer 18 Data Store Switch 19 QUANTUM Diagnostic Port Engine 20 CENSE Diagnostic Port Engine 21 G E Propulsion System Diagnostic Port 22 For Optional E...

Page 143: ... minutes the voltage drops to 0 The 5 minute idle indicator lamp on the overhead display is ON when circuit 712 reads 24 volts 3 Repeat step 1 While monitoring voltage at cir cuit 712 turn the key switch OFF Turn the engine shutdown switch off Verify voltage at circuit 712 drops to 0 when the shutdown switch is turned to OFF DATA STORE SWITCH The Data Store switch 18 allows a technician to store p...

Page 144: ...onents described below Prior to welding on the truck disconnect the AID system plug in cards Diode Matrix Without Sound The Diode Matrix Without Sound Card 2 Figure 3 2 consists of a series of diodes capable of working with eight different indicator circuits The indicator light can be a flashing light by connecting it to the 12F cir cuit or a steady light by connecting it to the 12M cir cuit In ad...

Page 145: ...e resistance at which the circuit is activated NOTE Some electronic engine controls monitor coolant temperature If the engine controls monitor the circuit a 2KΩ resistor is installed to replace the temperature sensor and disable the AID system circuit The Latch Circuit monitors the accumulator pre charge pressure switches When one of the pressure switches closes Q5 will be turned off which supplie...

Page 146: ...loose cables ground connections etc Use the following procedure to check the battery equalizer 1 Check the circuit breakers a If a circuit breaker has opened check cir cuits and repair cause b Reset circuit breaker 2 Check battery voltage with the battery equalizer connected and the engine running a Verify battery charging alternator output is 27 8 to 28 2 volts 3 If alternator voltage is outside ...

Page 147: ...itch actuates a solenoid in the hoist circuit to stop the hoist cylinders short of full exten sion and prevent possible damage to the dump body or hoist cylinders The hoist limit switch is located inside the right frame rail above the rear suspension The switch must be properly adjusted at all times Improper adjustment or loose mounting bolts may cause false signals or damage to the switch assembl...

Page 148: ...ll be ON only when that particular control circuit has been switched ON and the relay coil is being ener gized The light will not turn on if the relay board does not receive the 24 volt signal to turn ON a compo nent or if the relay coil has an open circuit The red Breaker Open light if ON indicates that a circuit breaker on that relay board is in the OFF position A light on the overhead display p...

Page 149: ... one of the same amperage capacity as the one being removed 1 Place battery disconnect switch in the OFF position 2 Unplug all wiring harness es from relay board Remove four relay mounting screws and remove relay board from truck 3 Remove four hold down screws 3 one in each corner in circuit breaker cover plate and all circuit breaker screws Remove cover plate from circuit breakers FIGURE 3 6 TYPI...

Page 150: ...y remove the circuit panel card from the relay board 3 Line up the new circuit panel in slots and with the socket on the relay board and install care fully 4 Install two mounting screws 6 RELAY BOARD COMPONENTS Relay Board 1 Turn Signal 1 Flasher Power Light Green This light will be ON when the turn signals or hazard lights are activated K1 light will be ON during right turn signal operation K2 li...

Page 151: ...leed Down Light Green This light is ON when the bleeddown solenoid is being ener gized The bleeddown timer will energize the solenoid for two to three minutes after key switch is turned OFF 2 5 amp circuit breakers CB20 CB22 1 15 amp circuit breaker CB21 4 Relays Park Brake Failure K1 Cranking Oil Pressure Interlock Relay K2 Horn Relay K3 Body Up Relay K4 Relay Board 5 Head Lights 1 Light Display ...

Page 152: ...ontrol the position of the relay The terminals of the switched circuit from the relay contacts are labeled as follows NC Normally Closed COM Common NO Normally Open COM terminal is for the voltage source protected by a circuit breaker coming into the relay which will supply the electrical power for the component being controlled NC terminal is connected through the relay to the COM terminal when t...

Page 153: ...re 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 diode and the black lead on the other diode lead the meter should read between 1000 and 2000 ohms...

Page 154: ...ab Power Distribution Module CB34 10 Air Dryer Heater Operator Cab Power Distribution Module CB35 10 Lincoln Lube Solenoid Operator Cab Power Distribution Module CB36 10 Cigar Lighter Operator Cab Power Distribution Module CB37 10 Windshield Washer Wiper Operator Cab Power Distribution Module CB38 5 Fuel gauge Engine Temperature Gauge Operator Cab Power Distribution Module CB39 5 Radiator Pressure...

Page 155: ... Statex Configuration Files E2 30 Programming the Truck E2 41 PTU Hookup E2 41 Download Configuration Files E2 43 Event Data E2 45 Statistical Data E2 47 Statistical Data Codes Counters Table III E2 49 Statistical Data Codes Profiles Table IV E2 54 Truck Specific Information E2 58 Temporary Truck Settings E2 59 Miscellaneous Software Features E2 60 Saving Data E2 60 PTU Abbreviations E2 61 MISCELL...

Page 156: ... the control power switch is Off Wear a properly grounded wrist strap when removing a card to prevent damage caused by static electricity After card removal place in a static proof bag or container 4 Extreme care should be exercised to prevent damage to the various semi conductor devices and low impedance circuits under test When using an ohmmeter to check diodes transis tors and low power conduct...

Page 157: ...ing air across the grids The cooling air blower connected in line to the rear of the alternator provides cooling air for the static exciters alternator and wheel motors during truck operation Refer to the following information for detailed descrip tions of component functions CONTROL SYSTEM The Statex III control system electronics provide all of the functions necessary to initiate and regulate op...

Page 158: ...he level of current in these field coils determine motor horsepower output The main output voltage from the Alternator generated by the rotation of the Alternator rotor and regulated by its exciter field coil is 3 phase high voltage AC This AC power is fed to a rectifier panel to convert AC to DC for use in the Motorized Wheel armatures The output of the FM528 rectifier panel is variable high volt...

Page 159: ...s in this panel are protected by a cover which is hinged at the bottom swings up and latches at the top The card complement of the FL275 panel consists of the following five cards 17FB100 Power Supply P1 17FB101 144 Central Processing Unit CPU 17FB102 140 Analog Input Output A1 17FB103 Digital Input Output D1 17FB104 Digital Input Output D2 NOTES Later model trucks shipped July 2001 and later are ...

Page 160: ... into the wrong card slot 1 To install a card carefully insert it into its top and bottom card slots Slide the card into the panel until the locking quick release levers are close to the panel edges 2 Hold the levers and gently press the card further into the panel feeling the card and backplane connectors start to engage When the card is inserted far enough for the locking levers to catch on the ...

Page 161: ... to control the actions of the system While executing the program reading and writing of data is often necessary This data is stored in a ran dom access memory RAM A RAM is a temporary storage device that is if power to the RAM is lost the data is cleared The RAM stores all types of data such as input status from external devices fault information specific program addresses etc The final result is...

Page 162: ...Flash chips on the CPU card from CFG files on the PTU hard drive This is done initially during factory checkout and can be redone in the field using the PTU NOTE This MUST be done if the FB101 144 card is changed PTU Portable Test Unit Code The PTU program is used to enable menu driven view ing of truck data in the CPU while the truck is moving or stationary Using the PTU it can also be used to vi...

Page 163: ... state This state can only be entered if there are no restriction flags set in the software such as brake ser vice or park ACCINH DUMPBS NAFLT or GND FLT In this state contactor sequence is initiated If all contactors necessary for acceleration are in their cor rect positions then the state machine enters the accelerate state If the contactor sequence does not complete successfully then a fault NA...

Page 164: ...r is in the wrong posi tion a number seventeen 17 would be displayed Referring to Table I you could see that a problem exists with the RP1 contactor You can also see that the last LED is illuminated and the first LED is extin guished This means that event 17 is the last one stored in the 2 Digit Display To view the first event simply press the previous search key up arrow If the first event were b...

Page 165: ...ols how often a truck operator may reset the operating restrictions caused by an event type using the Dump Override Switch DOS switch in the cab If the Active Events Count is equal to the Lockout DOS Limit for a given type the Override switch DOS will have no effect on operating restrictions caused by that event The Active Events Count for that type will not be decayed by the Decay Active Events C...

Page 166: ...depressing the Override switch DOS When the Override switch is depressed the restriction is removed unless the Active Events Count for 1 or more event types is equal to the Lockout Limit If such is the case acceleration inhibit restriction will remain in effect until it is reset with the 2 Digit Display or the PTU When reset via the 2 Digit Display RESET button the Override switch must be depresse...

Page 167: ...own In the following order check for Moisture in motors grids power cables motor flash insulation failure in power circuit defective FB102 140 card 1800 5 20 5 02 High Level Ground Fault System Event In ACCEL No propel and turn on SYSFLT light In RETARD Turn on SYS FLT light only A ground fault is detected if leakage current to ground truck chassis exceeds 400 ma There is a 0 05 second delay on sh...

Page 168: ...0 3600 3 10 2 18 RP2 Contactor System Event In ACCEL No propel and turn on SYSFLT light In RETARD Turn on SYS FLT light only RP2 Contactor command and feedback do not agree Check for Same as No 10 3600 3 10 2 19 RP3 Contactor System Event In ACCEL No propel and turn on SYSFLT light In RETARD Turn on SYS FLT light only RP3 Contactor command and feedback do not agree Check for Same as No 10 3600 3 1...

Page 169: ...ck For Same as No 10 3600 3 10 2 30 Analog Output See Subcodes Recorded in memory only No truck shutdown Analog input exceeds 10V for 05 seconds Software error bad FB101 or FB102 140 card Check subcodes Table II with PTU for more detail N A N A 5 0 31 Frequency Output Recorded in memory only No truck shutdown Engine RPM signal 500 or 2300 N A N A 5 0 32 Analog Input See Subcodes Recorded in memory...

Page 170: ...n RETARD Turn on SYS FLT light only Current in motor fields exceeds limits Limit is a function of being in retard or acceleration 3600 3 10 4 50 Motor Stall System Event In ACCEL No propel and turn on SYSFLT light In RETARD Turn on SYS FLT light only Motors stalled with motor current above 1000 amps inverse time function Could be caused by overloaded truck grade or rolling resis tance too high Che...

Page 171: ...ng cabling to motors or shunts defective FB102 140 card 3600 3 10 2 59 PTU Configura tion System Event In ACCEL No propel and turn on SYSFLT light In RETARD Turn on SYS FLT light only PTU configuration inputs are inconsistent 3600 3 4 2 61 Retard GridMotor 1 Failure System Event In RETARD Turn on SYS FLT light only M1 amps less than 20 and M2 amps greater than 500 for 5 seconds Check for loose cab...

Page 172: ...h special sensors installed and options activated 72 Engine Sensor Warning Recorded in memory Turn On ENGSERV Light An engine sensor is in the warning zone Check engine sensor or FB102 140 card N A N A 10 1 73 Engine Sensor Shutdown In ACCEL No propel and turn on SYSFLT lightand ENGSDWN Light In RETARD Turn on SYS FLT and ENGSDWN light Engine sensor in shutdown zone Check for Same as No 72 3600 2 ...

Page 173: ...ht In RETARD Turn on SYS FLT light only Battery volts low Less than 21 volts for 4 seconds and engine speed greater than 600 rpm Check for Check 24V alter nator or batteries 3600 3 10 2 91 Battery Volts High Recorded in memory only Battery volts high Greater than 32 volts for 4 seconds Check 24V alternator regula tor N A N A 10 1 92 Bad Engine Sensor Recorded in memory only Engine sensor output ou...

Page 174: ...PS A D Scaled output 3500 or 3500 for 1 0 second 23 MF_AMPS A D Scaled output 1500 or 1500 for 1 0 second 24 ALT_F_AMPS A D Scaled output 800 or 30 for 0 5 seconds 25 ENGHPCUT A D Scaled output 4 95 or 4 95 for 1 0 second 26 SRS A D Scaled output 23 or 1 for 1 0 second 27 RPINHI A D Scaled output 23 or 1 for 1 0 second 28 ALTFVOLT A D Scaled output 1000 or 25 for 1 0 second 29 ALT_OUT_VOLT A D Sca...

Page 175: ...st for bad address failed 4 CLOCK INTERRUPT Test of interrupt circuitry failed 5 FLASH CRC Checksum failed for OBJ application code 6 SRAM TEST Static RAM read write test failed 7 BRAM CRC Battery backed RAM checksum failed 8 BRAM BATTERY CHK Battery voltage low for BRAM 9 DATE TIME CHECK Hour 24 day 32 Check for realistic date and time 10 BUCK RAM STACK Check of static RAM used by buck 11 INTERRU...

Page 176: ...ressure in warning zone for 10 sec 3 CRANKCASE PRES SURE Crankcase pressure 16 in H2O for 5 sec 4 COOLANT TEMP Coolant temperature 205 F for 10 sec 5 ENGINE OVERSPEED RPM 2375 rpm for 2 sec ENGINE SENSOR 92 1 COOLANT PRESSURE Sensor output 0 2 VDC or 4 8 VDC for 4 sec 2 OIL PRESSURE Sensor output 0 2 VDC or 4 8 VDC for 4 sec 3 CRANKCASE PRES SURE Sensor output 0 2 VDC or 4 8 VDC for 4 sec 4 COOLAN...

Page 177: ...ew Statex III trucks or a mine that was updating software from previous release versions It is assumed the technician is familiar with the basic operation of a laptop computer OPERATIONAL HINTS Here are a few things to remember about the use of the PTU and software Some instructions in this manual call for the user to type certain operating commands These commands are shown in a typewriter style t...

Page 178: ...ired for some trucks in a fleet equipped with the FB101 card and others equipped with the FB144 card the Enhanced version 1 00 and version 14 00 are automatically installed in different directories on the PTU HARD DISK SPACE REQUIREMENTS Software installation will require approximately 3 2 megabytes of disk space on the PTU hard disk Addi tional space will be required for saving event and sta tist...

Page 179: ...ess than but very close to 460K available the software may appear to function properly until features such as retreiving and saving an event to a file are attempted at which point the program will terminate To determine the amount of free memory available start the software program and on the Main Menu observe the amount of free memory displayed in the upper right corner of the screen see Figure 2...

Page 180: ...PTU CPU communication is done through this selection To enter this selection a log on with an appropriate password is required and the serial communication cable should be attached VIEW PTU SAVED FILES Used to examine the contents of saved event files in the PTU No password is required Can only be used to playback events already stored in a file name LIST STAT DATA FILES Used to examine the statis...

Page 181: ...E02016 2 02 Electrical Propulsion Components E2 25 ...

Page 182: ...ERSION PROCEDURE Use the following procedure to convert configuration files used with previous versions of software for use in the current version Search for old CFG filenames 1 Select the previous software version by typing oldge at the DOS C prompt 2 Select TRUCK SETUP CFG from the GE OHV STATEX III MENU and press ENTER 3 The cursor should be at number 1 Press ENTER The screen shown in Figure 2 ...

Page 183: ...n 14 00 software to Enhanced ver sion 1 00 d Select MAIN MENU if not converting files For the following example UPDATE v12 10 STD CFGS was selected and the screen in Figure 2 7 appears 8 Note the screen shows a series of options labelled F1 through F9 referring to the Func tion Keys F1 through F9 and provides a description of each F1 provides a Help Screen to assist you directly on the screen F2 n...

Page 184: ...racters If there are more letters in the old name than in the new simply erase them using the space bar If an error is made in naming this file the operation can be cancelled any time before ENTER is pressed by first pressing ESC This returns the cursor to its origi nal starting position where it can once again be moved with the arrow keys A note to this effect is displayed at the bottom of the sc...

Page 185: ...dy been created The computer is looking at the first file and is asking which of these three options to apply Since the first file has already been created the correct option is S for Skip continue NOTE This feature can be used to change a file name which was already created by selecting O or abort the last changes made by selecting A 22 Press S Note the computer went directly to the second file a...

Page 186: ...o the list of files available and the num ber of STATEX truck configurations will increase 0 Source Directory When the TRUCK SETUP CONFIGURATION MINE MENU first appears a default source directory used to store truck configuration files will appear in line 0 In some cases it may be beneficial to create other directories for storing truck configuration files For example a mine operating several mode...

Page 187: ... the file was created 5 GE file name 6 GE filename extension DEL Choosing delete will prompt for a Y N input to delete the selected file or not When many files are listed it is helpful to sort the file names in a different order from what they appear For example to sort the files by truck ID press the 3 key If the Delete key DEL is chosen the file next to the cursor will be deleted after the promp...

Page 188: ...arrow to move the cursor to the menu posi tion VIEW TRUCK CONFIGURATION SCREEN DATA CURVES SCREEN and press ENTER or press 2 An example of a model 830E truck configuration is shown in Figure 2 10 2 Press any key to view the second screen TRUCK CONFIGURATION DATA CURVES SCREEN An example of the data curves is pro vided in Figure 2 11 3 Press any key to return to the TRUCK CONFIG URATION MINE MENU F...

Page 189: ...type in the information and press ENTER When finished entering serial numbers exit the screen by moving the cursor to the leave truck serial numbers screen selection and press ENTER 4 View Options NOTE The options on this screen can be changed only by the manufacturer 1 Use the Down arrow to move the cursor to the menu position VIEW OPTIONS and press ENTER or press 4 The screen shown in Fig ure 2 ...

Page 190: ...operating on the truck N System not installed on the truck i Optional motor 1 temperature sensor installed Y Motor 1 temperature sensor option is installed N Ignore this input j Optional motor 2 temperature sensor installed Y Motor 2 temperature sensor option is installed N Ignore this input k AS switch overrides retard speed control Y Pressing the accelerator pedal will override the retard speed ...

Page 191: ...lways set to N to select automatic In this condition the system will automatically adjust the electrical system load to maintain the ENGINE FULL LOAD RPM value specified in step d b Ignore high idle switch when empty Y Operator request for high idle is ignored if sensors indicate truck is empty N Load weighing sensors do not affect idle selection Note This option is only applicable when OEM option...

Page 192: ...celerator pedal is cali brated to have zero accel request h Percent accel pedal travel full request Used to enter the percent of pot reference volts at which the accelerator pedal is cali brated to have full accel request Note Refer to Statex III Electrical System Checkout Procedure Throttle System Check and Adjustment for accelerator pedal calibration i Percent retard pedal travel Off request Use...

Page 193: ...mpty truck b Empty overspeed detect mph Overspeed retarding pickup setting in miles per hour for an empty truck c Empty overspeed dropout mph Speed at which overspeed retarding is released in miles per hour for an empty truck d Empty speed override mph Speed override value in miles per hour for an empty truck It must be at least 1 mph lower than the empty overspeed detect value e Empty maximum ret...

Page 194: ...Current Year 2002 The Mine may choose to set up its own system for naming and recording the Truck configuration files cur rently installed on its trucks but it is strongly recom mended that a file naming system be established NOTE The file name length is limited to 8 characters maximum followed by a period then followed by a maximum 3 characters 1 From the TRUCK SETUP CONFIGURATION MINE MENU scree...

Page 195: ... Type in the new file name M123131A 202 in the example shown The original filename will disap pear as the new name is typed 6 Press ENTER to save the new file name into the directory shown on line 8 7 Move the cursor to line 1 and press ENTER or press 1 This will display the list of configuration files as shown in Figure 2 17 Verify the new file name has been added to the list 8 When finished with...

Page 196: ...passwords and privilege levels below their own NOTE On some PTUs some difficulty has been experienced if passwords were entered which have zeros The problem was found to be caused by the PTU being in the Numlock mode or Keypad mode on some PCs This interprets a section of the normal keypad as a numeric keypad and hence produces the wrong characters PTU USER PRIVILEGE LEVELS Level Privelege Screen ...

Page 197: ... menus on the portable computer If installed a previous software version can be accessed by typing oldge3e or oldge if version 14 is installed at the DOS prompt Select Configuration File 1 Use the arrow keys to move the cursor to select SELECT TRUCK SETUP 2 Select the proper Truck Configuration file by mov ing the cursor to the correct file and pressing ENTER 3 The GE OHV STATEX III MENU will reap...

Page 198: ... the PROGRAM TRUCK YES NO MENU will be YES RELOAD PRO GRAM INTO TRUCK 2 If code has not been installed the truck CPU is not programmed and an error message will appear as shown in Figure 2 20 If this happens the downloading selection will be YES INSTALL PROGRAM INTO TRUCK FIGURE 2 19 PTU MAIN MENU FIGURE 2 20 PTU CPU COMMUNICATION ERROR MESSAGE Unable to successfully communicate with vehicle after...

Page 199: ...arrow keys to move the cursor to desired program truck selection a NO Return to Engine Stopped Test Menu This selection will take the computer back to the SPECIAL CONTROL ENGINE STOPPED TEST MENU If for some reason programming is not desired select this choice b YES RELOAD PROGRAM INTO TRUCK Use whenever the truck CPU has already been programmed and re programming is desired This selection is appr...

Page 200: ...splayed is correct press ENTER at the No Do not reset date and time selection 5 Use the arrow keys to move the cursor to the var ious other selections 6 Type the day of the month 1 thru 31 and press ENTER 7 Press the Down arrow key Type the month as a two digit number 01 thru 12 and press ENTER 8 Press the Down arrow key Type the year as a two digit number 00 thru 99 and press ENTER 9 Press the Do...

Page 201: ...l be displayed The PTU user should always keep the truck driver informed of this control 2 Select YES on the caution screen Figure 2 21 and press ENTER The SPECIAL OPERATION MENU will be displayed 3 Use the arrow keys to move the cursor to the EVENT DATA MENU selection and press ENTER The Event Data Menu screens will be displayed a If no event data has been stored the screen will indicate 0 zero e...

Page 202: ...e typed as A ev001 b After entering the appropriate name press ENTER The information will then be trans ferred from the CPU to the PTU and stored under the file name assigned The transfer may take several minutes to complete depending on the number of events being saved to the file After the file transfer is com plete a message will appear stating Received xxxxxx bytes Returning to PTU Press Space...

Page 203: ...re 2 21 and press ENTER The SPECIAL OPERATION MENU will be displayed 3 Use the arrow keys to move the cursor to the STATISTICAL DATA MENU selection and press ENTER The STATISTICAL DATA MENU screen will be displayed Selections available on this menu are as follows VIEW COUNTERS The STATISTICAL COUNTERS SCREEN displays the number of times various operations have occurred in the history of the truck ...

Page 204: ...he This Qtr value as this quarter becomes last quarter The third counter This Qtr keeps a moment by moment count of occurrences of the parameter The counts are not reset to zero until midnight of the next quarter The fourth counter This Day keeps a moment by moment count of occurrences of the parameter just as This Qtr except the This Day count is reset to zero every midnight whether it is a quart...

Page 205: ...sion mode is requested Clock will stop when propulsion mode is no longer requested or when all restrictive faults are reset 10 Truck Operating Hours Hours Sum of propulsion mode retard mode coast mode and idle hours 11 Propulsion Mode Net KW Hours Hours Net KW hours generated by the alternator in propulsion mode 12 Retard Mode KW Hours Hours KW hours generated by the alternator in retard mode 13 T...

Page 206: ...k 8 MPH Occurrences Number of times service brake has been applied with truck speed above 8 MPH 50 Park Brake Occurrences Number of times Park Brake Off has changed from false to true 51 Service Brake Occurrences Number of times Service Brake Pressure Switch has changed from false to true 52 Loaded Switch Occurrences Number of times Two Speed Overspeed has changed from false to true empty to loade...

Page 207: ...urned On when truck speed is above 0 3 MPH 72 Alternator Field Too Hot Occurrences Number of times estimated alternator field temperature has exceeded 220 C 80 M1 Amps Propel Seconds Refer to Table IV PROFILES 81 M2 Amps Propel Seconds 82 M1 Amps Retard Seconds 83 M2 Amps Retard Seconds 84 MF Amps Propel Seconds 85 MF Amps Retard Seconds 86 Net Input Engine HP Hours 87 Net Input Engine KW Hours 88...

Page 208: ...Occurrences 133 Frequency Input Occurrences 137 Startup Fault Occurrences 145 Diode Fault Occurrences 146 Motor 1 Overcurrent Occurrences 147 Motor 2 Overcurrent Occurrences 148 MFld Marm Occurrences 149 MF Overcurrent Occurrences 150 Motor Stall Occurrences 151 Motor Spin Occurrences 152 Alternator Tertiary Overcurrent Occurrences 153 Motor Tertiary Overcurrent Occurrences 154 15V Power Occurrenc...

Page 209: ...173 Engine Oil Pres sure Shutdown Occurrences 174 Engine Coolant Pressure Warning Occurrences 175 Engine Coolant Press Shutdown Occurrences 176 Engine Crankcase Pressure Occurrences 177 Engine Coolant Temperature Occurrences 178 Engine Service Occurrences 179 Engine Shutdown Occurrences 180 Engine Speed Retard Occurrences 181 Motor 1 Voltage Limit Occurrences 182 Motor 2 Voltage Limit Occurrences ...

Page 210: ...nt in each bucket 9 1351 to 1450 10 1451 to 1550 11 1551 to 1800 12 1801 to 2150 13 2151 to 2300 14 2301 to 2600 15 2601 to 2900 16 2901 to 3200 17 3201 above PAR No DESCRIPTION COUNT CONDITIONS BUCKET No CURRENT VALUE AMPS 82 M1 Amps Retard in seconds This is a histogram of Motor 1 armature current in retard mode Sample time is 1 0 second The clock will start whenever retard mode is selected The ...

Page 211: ... selected The histogram breaks the current spectrum into 17 buckets defined at right and displays the time spent in each bucket 9 276 to 300 10 301 to 325 11 326 to 375 12 376 to 450 13 451 to 550 14 551 to 650 15 651 to 800 16 801 to 950 17 951 to 9999 PAR No DESCRIPTION COUNT CONDITIONS BUCKET No NET INPUT HP RANGE 86 Net Input Engine Horsepower in minutes This is a histogram of net input horsep...

Page 212: ...o 200 12 201 to 210 13 211 to 220 14 221 to 230 15 231 to 240 16 241 to 250 17 251 to 9999 PAR No DESCRIPTION COUNT CONDITIONS BUCKET No TRUCK SPEED MPH ENGINE SPD RPM 90 Truck Speed MPH in seconds This is a histogram of truck speed for all modes of operation Sample time is 1 0 second The clock will start whenever control power CPR is on The buckets are defined in the Truck Speed column at right 1...

Page 213: ...nto 17 buckets defined at right and displays the time spent in each bucket 1 20 below 2 21 to 40 3 41 to 50 4 51 to 60 5 61 to 70 6 71 to 80 7 81 to 90 8 91 to 100 99 MFSE Temp C in seconds This is a histogram of Motor Field Static Exciter temperature Sample time is 60 0 seconds The clock will start whenever control power CPR is on The histogram breaks the temperature spectrum into 17 buckets defi...

Page 214: ...AL OPERATION MENU will be displayed 3 Use the arrow keys to move the cursor to the TRUCK SPECIFIC INFORMATION MENU selection and press ENTER Selections available on this menu are VIEW OEM CONFIGURATION OPTIONS This selection permits reviewing the setup informa tion programmed into the truck configuration file by Komatsu These options cannot be changed by mine personnel VIEW MINE CONFIGURATION OPTI...

Page 215: ...will be displayed 3 Use the arrow keys to move the cursor to the TEMPORARY TRUCK SETTINGS MENU selection and press ENTER Selections available on this menu are SPEED SETTINGS New speed setting values may be typed over the existing values to override the current configuration file settings 1 Move the cursor to the speed to be changed and type the first digit of the speed desired 2 A screen will appe...

Page 216: ...RY EVENT DATA COLLECTION INTERVAL and press ENTER MISCELLANEOUS FEATURES SAVING DATA Various screens showing event data digital input and output test data real time data etc can be saved to the PTU Many screens will have a selection labelled GET1 When selected the data gathered and displayed on the screen will be suspended and can then be saved per manently to a file If this selection is available...

Page 217: ...ENTER 3 The GE STATEX III PTU ABBREVIATIONS screen will appear with instructions for viewing the information 4 When finished viewing press the SPACE bar to leave the screen OTHER MENU SELECTIONS Software menu items not covered in this section of the manual are normally used for truck checkout and trou bleshooting only Refer to Section E3 for information regarding use of the following selections fr...

Page 218: ...ake and retarder application Figure 2 29 Others utilize a single pedal combining service brake retarder application as shown in Figure 2 30 Refer to Section J Brake Circuit Component Service for retarder pedal removal and installation procedure for a single pedal system Pedal potentiometer replacement instructions on the following page are applicable to either type The retard pedal is suspended fr...

Page 219: ... 2 29 and lock washers but do not tighten 3 Rotate potentiometer counterclockwise until mounting slots contact the mounting screws and tighten screws 5 to 10 20 in lbs 1 13 2 26 N m torque 4 Install grommet 3 and potentiometer cover Tighten screws to 10 20 in lbs 1 13 2 26 N m torque 5 Install cable clamps and tighten screws to 35 45 in lbs 3 4 5 1 N m torque 6 Inspect assembly and verify proper w...

Page 220: ...witch and control power On and place the selector switch in FORWARD 2 Depress the throttle pedal until the propulsion contactors pull in 3 After 101 seconds or the value entered on the TRUCK SPECIFICS SCREEN the Motor Blower warning light on the instrument panel should turn on If the switch requires adjustment refer to instructions in Miscellaneous Component Test and Adjustment in the STATEX III E...

Page 221: ...will vary depending on the truck model and optional equipment installed Components in the electrical control cabinet and other areas of the truck are identified with abbreviated name labels These abbreviations also appear on schematics and may be referenced in checkout procedures Refer to the list of abbreviations at the end of this section for a full name description This system is capable of dev...

Page 222: ...Retard Power Contactor No 1 5 Cabinet Service Light Switch 6 Control Power Switch 7 Control Power Light 8 Two Digit Display Panel 9 Propulsion Load Control Panel FL275 10 Diagnostic Data Reader Connector 11 Statex Channel A PTU Connector 12 Statex Channel B Connector 13 Ground Bus No 3 14 Synchronizing Transformer No 2 15 Synchronizing Transformer No 1 16 Motor Field Static Exciter 17 Alternator F...

Page 223: ...fier 6 8 Isolation Amplifier 7 9 Ground Bus 1 10 Isolation Amplifier 8 11 Isolation Amplifier 4 FIGURE 2 35 CONTROL CABINET VIEW B FIGURE 2 36 CONTROL CABINET VIEW D 1 Propulsion Load Con trol Panel PLCP 2 Relay Board RB6 1 Alt Field Current Limit Resistor Panel 2 Load Test Links 3 Voltage Measuring Module 1 4 Voltage Divider Resis tor Panel 3 5 Fault Detection Panel 6 Diode Fault Detection Transf...

Page 224: ...tor Field Discharge Resistor 3 Motor Field Discharge Resistor 4 Control Power Diode 1 5 Control Power Diode 2 6 Control Power Relay 7 Alternator Field Relay 8 Shunt 7 9 Shunt 6 10 Shunt 2 11 Shunt 1 12 12VDC Stand off 13 24VDC Stand off 14 Relay Board 1 15 Relay Board 2 16 Relay Board 3 17 Relay Board 4 18 Relay Board 5 ...

Page 225: ...E02016 2 02 Electrical Propulsion Components E2 69 FIGURE 2 38 RETARDING GRIDS CONTACTORS R H DECK 1 Retarding Grids and Blower s 2 Retarding Contactor Box ...

Page 226: ...e Resistor GFIP Ground Fault Interrupt Panel GFR Alternator Field Relay GRR Ground Relay Resistor ISOA3 8 Isolation Amplifiers No 3 through 8 KS KeySwitch M1 Wheel Motor No 1 Left Hand M2 Wheel Motor No 2 Right Hand MF1 2 Wheel Motor Field No 1 2 MFC Motor Field Contactor MFDR Motor Field Discharge Resistor MFSE Motor Field Static Exciter OR Override Pushbutton P1 2 Propulsion Contactor No 1 2 PBR...

Page 227: ...opulsion Components E2 71 CARD IDENTIFICATION LIST 17FL275 PANEL STATEX III 17FB100 Power Supply 17FB101 144 Central Processing Unit CPU 17FB102 140 Analog Input Output 17FB103 Digital Input Output 17FB104 Digital Input Output ...

Page 228: ...E2 72 Electrical Propulsion Components 2 02 E02016 NOTES ...

Page 229: ...ockout Test DDEC MTU Engines E3 12 1 5 Retard Contactors Operation Check E3 13 1 6 Ground Fault Sensing Check E3 13 1 7 Ground Fault in Retard Operation Check E3 13 1 8 Override Operation Check E3 14 1 9 Anti Reversal Function AR Check E3 15 1 10 Overspeed Retard Operation Check E3 15 1 11 Hoist Interlock Operation Check E3 16 1 12 Motor Blower Fault Light Operation Check E3 17 2 0 DIGITAL INPUT O...

Page 230: ...IN RETARDING E3 41 8 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT E3 42 8 1 Brake System Interlocks Check E3 42 8 2 Blower Loss Pressure Switch Adjustment E3 43 8 3 SYNC Transformer Checkout E3 43 8 4 Power Contactor Position Sensor Adjustment E3 43 8 5 Battery Boost Adjustment E3 44 8 6 Isolation Amplifier Voltage Module Test E3 44 8 6 1 Voltage Measuring Module Test VMM1 VMM2 E3 44 8 6 2 ISO AM...

Page 231: ... panel must be removed a wrist ground strap MUST be worn to ground personnel to the truck chassis to prevent static discharge damage to the cir cuit boards After the board has been removed from the panel it must immediately be placed in a static free protec tive bag Sample PTU screens illustrated in the following pages show menus and data screens as they appear in the April 2001 STATEX III Enhance...

Page 232: ...tor on rear of PTU 3 Turn PTU power on After warm up and self test type gemenu3e or gemenu if using version 14 00 software at the C prompt and press the ENTER key Do not type quotes 4 From the GEOHV STATEX III Main MENU select PTU TALK TO TRUCK and press ENTER 5 At PTU LOGON screen enter your name and assigned password Press ENTER 6 When the GE STATEX III PTU MAIN MENU appears move the cursor to S...

Page 233: ...stored events may be uploaded to a file for storage by selecting GE engineering format event data and following directions on the subsequent screens 13 To erase the event data currently stored select erase event data yes no menu from the EVENT DATA MENU screen a On the screen titled RESET ALL YES NO MENU move the cursor to YES Erase Truck Events and press ENTER b Exit back to the GE STATEX III MEN...

Page 234: ...ulate body down condition If hydraulic pressure is low connect a jumper wire between circuit 73S and 710 This step will be necessary if all hydraulic brakes are installed and engine is not running CONTROL SYSTEM SELF TEST 1 Set up PTU as described previously using the communication port in the electrical cabinet 2 Turn control power switch On 3 Verify the two digit display shows 00 after a 10 seco...

Page 235: ...switch should be in the Off Normal position and the accelerator pedal released If unable to adjust properly replace ACC card 6 Measure the voltage between circuits 76L and 710 Read 25 25 to 28 vdc If voltage is low recharge truck batteries 7 With the Normal Advance Idle switch in Off Normal position turn key switch Off then On Measure voltage between circuits 510 to 952 Repeat 3 times If voltage e...

Page 236: ...s are also included in the following procedure for retard pedal setup which can be performed in conjunction with accelerator pedal setup on trucks equipped with the Fuel Saver circuitry Turn Key Switch and Control Power On Set up PTU as described previously using the communication port in the electrical cabinet Start the GE software program be typing gemenu3e if using Statex III Enhanced version 1...

Page 237: ...mple 87 2 Note It is also necessary to perform the above procedure for the retard pedal as described in the following step Retard pedal values should be recorded at this time as follows 2 Record the retard pedal percent values shown on the MONITOR ANALOG INPUT CHAN NELS screen a Pedal OFF note on paper the value shown on the PTU screen for ret pedal For exam ple 9 7 b Depress the retard pedal and ...

Page 238: ...he cursor to percent retard pedal travel full request Type the value recorded in step 2 b above and press ENTER 9 Move the cursor to LEAVE TRUCK SPECIFICS SCREEN and press ENTER 10 At the TRUCK SETUP CONFIGURATION MINE MENU select 7 Save a truck configuration filename and press ENTER 11 The current filename will be displayed Press ENTER to accept this name Type y to over write the old file with th...

Page 239: ...710 Read 12 50 vdc minimum If out of tolerance replace retard pedal resistor c DDEC equipped trucks only Use the DDR to read PTO counts or measure voltages at circuits 510 to 952 shown in the following table 5 Depress the throttle pedal fully and again read the PTO Counts If values change replace ACC Card Release throttle and retard pedals 1 2 2 Electronic Retard Pedal Fuel Saver Equipped Trucks a...

Page 240: ...me and assigned password Press ENTER c When the GE STATEX III PTU MAIN MENU Figure 3 6 appears move the cursor to NORMAL OPERATION and press ENTER d A screen appears with the message Selection of NORMAL OPERATION gives truck con trol to the driver Continue With the cursor at the Yes option press ENTER e The NORMAL OPERATION MENU Figure 3 7 will appear Select MONITOR REAL TIME DATA and press ENTER ...

Page 241: ...TU display will be highlighted for a brief moment If the Selector Switch is moved to change the Reverser from FORWARD or NEUTRAL to REVERSE REV on the PTU display will be highlighted for a brief moment This occurs very quickly and may not be visible on some PTU s The FOR and REV signals are used to momentarily energize the Reverser solenoids when a directional change is requested 1 Move Selector S...

Page 242: ...t Reverser shifts to forward position to the right and back up lights and horn are de energized 1 4 Propulsion Lockout Test DDEC MTU Engine Trucks Only 1 Move Selector Switch to FORWARD turn Control Power Switch to On and depress throttle pedal until propulsion contactors MF P1 P2 GF and GFR pick up AS MF P1 P2 GF GFR a Verify feedback signals are present MFFB P1FB P2FB GFFB GFRFB Detroit Diesel D...

Page 243: ...lector Switch in FORWARD and depress throttle 2 Propulsion contactors MF P1 P2 GF and GFR should pick up AS MF P1 P2 GF GFR a Verify feedback signals are present MFFB P1FB P2FB GFFB GFRFB 3 Momentarily jumper from circuit 71 to terminal A on GFIP GFAULT 4 All contactors should drop out immediately and remain open and Electric System Fault light in cab should illuminate and remain On even after cir...

Page 244: ...F and GFR should pick up MF P1 P2 GF GFR a Verify the feedback signals MFFB P1FB P2FB GFFB GFRFB 3 Depress retard pedal RS 4 Verify that propulsion contactors MF P1 P2 GF and GFR drop out and then retard contactors RP1 RP2 MF GF GFR RP3 RP4 RP5 and RP6 RP9 if used pick up MF GF and GFR must pick up after RP1 and RP2 but timing is very close RP1 RP2 MF GF GFR RP3 RP4 RP5 RP6 RP7 RP8 RP9 a Verify th...

Page 245: ...tay in forward position to the right 6 Release throttle and remove oscillator Remove jumpers and reconnect speed sensor wires at terminal board 7 Reverser should shift to REVERSE position to the left a Verify the feedback signal REVFB 8 Move selector switch to NEUTRAL 1 10 Overspeed Retard Operation Check Disconnect wheel motor speed sensor wires 77 77A 714 714A at control cabinet terminal board J...

Page 246: ... and depress throttle Propulsion contactors MF P1 P2 GF and GFR should energize FORIN AS MF P1 P2 GF GFR a Verify feedback signals are present FORFB MFFB P1FB P2FB GFFB GFRFB 2 If truck body is raised or not installed momentarily remove metal washer from Body Up Switch If body is installed and in down position momentarily open circuit 71F DBUP 3 Propulsion contactors should drop out 4 Operate Over...

Page 247: ...y value the Motor Blower Off Light should turn On and event code 63 should appear on the two digit display BLOWP BLOWFAULT 4 Put selector switch in NEUTRAL depress override pushbutton and press reset button on two digit display to clear event code NOTE If Motor Blower Fault Light is not operational refer to Miscellaneous Component Test and Adjustment for switch adjustment procedure Return to Main ...

Page 248: ...ERATION will override truck driver controls until you exit to the PTU main menu Continue b With the cursor next to Yes press ENTER 6 The SPECIAL CONTROL ENGINE STOPPED TEST MENU should appear on the screen 7 Select MANUAL DIGITAL OUTPUT TEST Press ENTER key 8 The MANUAL DIGITAL OUTPUT TEST SCREEN Figure 3 9 should appear on the PTU screen This screen is divided into four sections a ENGINE PARA the...

Page 249: ...Non Fuel Saver Only Press retard pedal true inverse display retard request 0v input Pedal released false regular display no request 28v input DOS DUMP OVERRIDE SWITCH Press override switch true inverse display switch depressed RSC RETARD SPEED CON TROL SWITCH Pull retard speed control switch to On position true inverse display switch depressed DBUP DUMP BODY UP SWITCH Remove wire 71F true inverse ...

Page 250: ... 0v input Turn park brake switch to OFF false regular display release brake request 28v input KEYSW KEY SWITCH Key switch On true inverse display Key switch Off false regular display CPSFB CONTROL POWER SWITCH Control power switch On true inverse display Control power switch Off false regular display ENGSERV ENGINE SERVICE SIGNAL Jumper 419 to GND at the junction box true inverse display with jump...

Page 251: ...he OUTPUT DEVICE CHECKOUT column e Status of related feedback input name DI NAME if used on the MANUAL DIGITAL OUT PUT TEST SCREEN changes from false regular display to true inverse display 2 Set digital output driver Off a With cursor still on the same output name DO NAME press ENTER key again to change status of selected output from on to off b The display status of the output name DO NAME on th...

Page 252: ...ONTACTOR OUTPUT RP11 energized RP11 on RP1FB true RP11 de energized RP11 off RP1FB false RP2 RP2 CONTACTOR RP2 energized RP2 on RP2FB true RP2 de energized RP2 off RP FB false RP22 RP22 CONTACTOR RP22 energized RP22 on RP2FB true RP22 de energized RP22 off RP2FB false RP3 RP3 CONTACTOR RP3 energized RP3 on RP3FB true RP3 de energized RP3 off RP3FB false RP4 RP4 CONTACTOR RP4 energized RP4 on RP4FB...

Page 253: ...y de ener gized Retard dash light off OVRSPD OVERSPEED LIGHT Output OVRSPD on Measure approx 3 Ohms at 73V to 710 Output CPRL on Relay energized Measure infinite Ohms at 73V to 710 CPRL CONTROL POWER RELAY LATCH Output CPRL on Relay energized CPRL light is on NOTE Verify System Fault Light is not On prior to checking next output FDIODE_LT FAILED DIODE LIGHT Output FAILDIODE on Elect System Fault L...

Page 254: ...O TRUCK on GE OHV STATEX III MENU Press ENTER key 2 At Enter your name type your name Press ENTER key 3 At Enter your password type your password Press ENTER key 4 The GE STATEX III PTU MAIN MENU should appear on the screen 5 Move cursor to select NORMAL OPERATION Press ENTER key a A screen will appear that states Selection of NORMAL OPERATION gives truck control to the driver Continue b With the ...

Page 255: ...on b Remove jumper attached to GFIP terminal A PTU screen should read approximately 0 ma c Press Override switch and reset button on 2 digit display to clear event code to 00 d Jumper 24 vdc circuit 71 to GFIP terminal D to simulate a High Ground fault Read approximately 535 ma on PTU screen Event code 02 should appear on the 2 digit display The Electrical System Fault light should turn on e Remov...

Page 256: ...nd voltmeter Reconnect wire to terminal B 3 MOTOR 2 ARMATURE CURRENT ISOA4 motor 2 amps 0 0 a Repeat same test procedure used on motor 1 amps except substitute ISOA4 instead of ISOA3 4 MOTOR FIELD CURRENT ISOA5 motor field amps 0 0 Screen value amps 400 x input voltage a Test zero offset on isolation amplifier ISOA5 using same procedure as on motor 1 amps b Remove wire from input terminal B on ISO...

Page 257: ...uel Saver equipped trucks a With retard pedal released Read approximately 0 0 volts on PTU screen b Depress retard pedal fully Read approximately 10 0 volts on PTU screen Non Fuel Saver trucks a With retard pedal released Read approximately 0 0 volts on PTU screen b Depress retard pedal fully Read approximately 15 5 volts on PTU screen 8 ACCELERATOR PEDAL acc pedal 0 0 0 0v Note Accelerator pedal ...

Page 258: ...e test procedure used on alternator tertiary current except substitute ISOA7 instead of ISOA6 11 ALTERNATOR OUTPUT VOLTS VMM1 alt output volts 0 0 Screen value volts 200 x analog input volts a Verify that circuit 74C is disconnected at GFR b Disconnect the wires from terminals A and C on VMM1 c Connect digital voltmeter between VMM1 output terminals D and F With no other signal applied Meter shoul...

Page 259: ...minal D c Measure actual voltage of battery used in above step PTU screen should read actual test battery voltage x 10 6 Example If test battery voltage measures 1 550 volts PTU screen should read 16 43 volts d Remove test battery Screen should read 0 volts e Reconnect wires removed in step a MOTOR 1 TEMPERATURE motor 1 temp 0 000 V 0 0 C NOTE Motor Temperature monitoring system is optional a Disc...

Page 260: ...rom the TRUCK SETUP CONFIGURATION MINE MENU screen 16 COOLANT TEMPERATURE eng coolant temp 0 00 V 0 0C a Connect a 1 5 volt battery to circuit 31CT and circuit 0CT at control cabinet terminal board Screen value on PTU should read 1 5 volts 0 C b Remove battery from terminal board 17 COOLANT PRESSURE eng coolant pres 0 00 V 0 0 PSI a Connect a 1 5 volt battery to circuit 31ECP and circuit 0ECP at c...

Page 261: ...p a Screen value on PTU should read approximately 9 0 volts and 25 C c Remove resistor installed above and reconnect sensor wires at TB 1 25 MFSE TEMPERATURE mfse temp 0 000 v 0 0 C a Disconnect MFSE temperature sensor wires at terminal board TB 1 located on the face of the MFSE 72TM at terminal F and 0TM at E b Connect a 100K ohm resistor across wires removed in step a Screen value on PTU should ...

Page 262: ...of tach c Remove oscillator 2 ENGINE COMMAND engine command 0 0 rpm Applicable to Fuel Saver equipped trucks only The value displayed is the engine RPM com mand controlled by the FL275 panel based on various truck operating condition inputs Input cannot be tested 3 MOTOR 1 SPEED Motor 1 0 0 rpm 0 0 mph Screen value rpm 1 0 x input frequency 787 or 788 motors Screen value rpm 2 0 x input frequency ...

Page 263: ... mph Com pare value displayed with value given in MAXIMUM TRUCK SPEED CHART Refer to Miscel laneous Charts Maximum Allowable Truck Speeds Return to Main Menu 1 This completes Analog and Frequency Input Checks 2 Move cursor to select EXIT on the menu and press ENTER key 3 Select EXIT as necessary until returned to GE STATEX III PTU MAIN MENU 4 Move cursor to select EXIT on this menu and press ENTER...

Page 264: ...made with control power On and the selector switch in FORWARD Obtain speed event setting information and extended range retarding pickup speeds from the truck configuration file and use the Retard State Logic screen as instructed below Setup PTU 1 With the GE OHV STATEX III MENU on the screen select TRUCK SETUP CFG 2 At the TRUCK SETUP CONFIGURATION MINE MENU screen select the proper truck configu...

Page 265: ...ck Overspeed Settings Check 1 Remove jumper 71 to 73LS to simulate a Loaded Truck 2 While observing the RETARD STATE LOGIC SCREEN increase the oscillator frequency from minimum until the retard contactors RP1 and RP2 pick up in overspeed 3 Verify the M1 SPD and M2 SPD mph readings agree with values recorded from the truck con figuration file OVERSPEEDS ENTRY SCREEN 4 Lower the oscillator frequency...

Page 266: ... 714A wires 7 Remove jumpers from 77 77A 714 and 714A 8 Reconnect external 77 and 714 wires 9 Reconnect circuit 73LS if truck has two speed overpseed Return to Main Menu 1 This completes the speed event checks Be certain all wiring has been restored to original con dition 2 Leave the PTU RETARD STATE LOGIC SCREEN screen by moving cursor to select Exit on the menu and press ENTER key 3 Select EXIT ...

Page 267: ... states Selection of NORMAL OPERATION gives truck control to the driver Continue b With the cursor next to Yes press ENTER 6 The NORMAL OPERATION MENU should appear on the screen 7 Move cursor to select RETARD STATE LOGIC Press ENTER key 8 The RETARD STATE LOGIC SCREEN screen should appear Information on this screen will be observed for the following tests 5 1 Overspeed Pickup and Dropout Check 1 ...

Page 268: ... of Retard Speed Control 1 Set the retard speed control switch to Off position and the retard speed control potentiometer to mid range 2 Place selector switch in FORWARD and depress throttle pedal The propulsion contactors should engage Release throttle pedal 3 Turn the retard speed control switch to On position Turn oscillator On and increase frequency until retard contactors pick up 4 Depress th...

Page 269: ... position If load test must be run any longer than to just read horsepower the motor field leads must be disconnected to prevent overheat ing of the motor fields Follow disable procedure below To disable the motor field Disconnect circuit 716E at 1 terminal on the GFM on the MFSE Disconnect circuit 716F at 2 terminal on the GFM on the MFSE PTU Setup Select the AUTOMATIC LOAD BOX TEST screen as fol...

Page 270: ...ompare the NET HP TO ALTERNATOR value recorded from the PTU screen to the calcu lated Net HP to the alternator using the formula below NET HP TO ALT VOLTS x AMPS 746 x LB Efficiency 6 Verify the ENGINE RPM is approximately equal to the ENGINE LOAD RPM shown at the bot tom of the screen 7 Verify the calculated NET HP TO ALT value is approximately equal to the measured NET HP TO ALTERNATOR value rea...

Page 271: ...itch in FORWARD and depress retard pedal for full retarding 2 The following approximate values should be read from the AUTOMATIC LOAD BOX TEST SCREEN 3 Release retard pedal Put selector switch in NEUTRAL 4 Exit from AUTOMATIC LOAD BOX TEST SCREEN back to the NORMAL OPERATION MENU Select MONITOR ANALOG INPUT CHANNELS 5 Put selector switch in FORWARD and depress retard pedal for full retarding 6 The...

Page 272: ...es released place selector switch in FORWARD and depress the throttle pedal The propulsion contactors should energize It should be possible to remove jumper between 73R and 73P if installed and still get the propulsion contactors to energize 2 With brake lock switch On depress the throttle pedal Propulsion contactors should not energize 3 Turn brake lock switch Off turn emergency brake switch On a...

Page 273: ...at the proper rpm 8 3 SYNC Transformer Checkout NOTE If sync transformer output voltage feeding motor or alternator sync inputs at FB102 140 analog I O card is suspect perform the following check 1 Remove power and check that sync transformers ST1 and ST2 are properly connected 2 Disconnect leads 716C 716D 716H and 716J at sync transformers and read approximately 11 ohms across each transformer se...

Page 274: ...screpancy with the card test procedure results consult the appropriate GE Publication The system utilizes two types of Isolation Amplifiers Iso Amps Two are used for voltage measure ment VMM1 and VMM2 The other six are used for current measurement ISOA 3 ISOA 4 ISOA 5 ISOA 6 ISOA 7 and ISOA 8 8 6 1 Voltage Measuring Module Test VMM1 and VMM2 NOTE There are two recommended test procedures for testi...

Page 275: ...t installed on truck during factory check out this test must be performed during truck check out at mine site If rear wheels are raised off ground 1 Start the engine and place the selector switch in FORWARD 2 Depress the accelerator pedal just far enough to enter propel state and the wheelmotors begin to rotate Verify both wheelmotors turn forward If rear wheels and tires are installed and resting...

Page 276: ...d coils are damaged by contaminants the wheel motor should be removed for repair If moisture is present it may be possible to dry the wheel motor without removal b Remove inspection covers on main alternator to inspect slip rings brushes and check for moisture or other contamination c Inspect cables for damaged insulation d Inspect exposed connections for possible short circuit to nearby metallic ...

Page 277: ...Do not exceed the load limit When finished loading the payload meter display should indicate the tons of material loaded into the truck Switch the brake lock Off The display should change to O for one second then change to the time of day Switch the brake lock On The display should change back to the tons loaded without indicating O for one second 9 4 Zero The Angle Sensor Park the loaded truck on...

Page 278: ...1 5GE776HS9B HS10 28 8 30 X 51 5GE791AS3B AS5B 23 0 33 X 51 5GE791AS4B AS6B 28 8 33 X 51 5GE788DS2 26 075 37 X 57 5GE788ES1 HS2 HS4 26 1 36 X 51 5GE788ES2 FS2 FS4 26 1 37 X 57 5GE788FS1 FS3 21 7 37 X 57 5GE788HS1 HS3 21 7 36 X 51 5GE788HS8 26 825 36 X 51 5GE788HS5 22 354 36 X 51 5GE788HS6 26 825 36 X 51 5GE788FS5 FS7 26 825 37 X 57 5GE788FS6 22 354 37 X 57 5GE787FS5 FS10 36 4 40 X 57 5GE787ES1 2 3...

Page 279: ...4 0 01581 776 28 8 36 x 51 61 1 2750 34 73 79 19 0 01263 791 23 0 33 x 51 57 0 2750 40 57 67 79 0 01475 791 28 8 33 x 51 57 0 2750 32 40 84 88 0 01178 788 26 1 36 x 51 61 1 2320 32 33 71 76 0 01394 788 26 1 37 x 57 65 4 2320 34 60 67 05 0 01491 788 21 7 37 x 57 65 4 2320 41 62 55 74 0 01794 788 21 7 36 x 51 61 1 2320 38 88 59 67 0 01676 788 26 825 36 x 51 61 1 2320 31 48 73 69 0 01357 788 26 825 3...

Page 280: ...0E 1900 2100 75 1675 10 750 25 QSK60 1900 2150 75 1675 10 750 25 DETROIT DIESEL ENGINE OPTION CHART ENGINE MODEL RATED ENGINE RPM TOP NO LOAD RPM RETARDING RPM No Load LOW IDLE RPM 12V149TI Mechanical Governor 1900 2040 10 1675 10 750 25 12V149TI Hydraulic Governor 1900 2040 20 1675 10 750 25 12V149TI DDEC II 1900 1910 5 1675 25 750 25 16V149TI Mechanical Governor 1900 2040 10 1675 10 750 25 16V14...

Page 281: ...ricants G2 6 Tire Installation G2 6 FRONT WHEEL HUB AND SPINDLE ASSEMBLY G3 1 WHEEL HUB AND SPINDLE ASSEMBLY G3 1 Removal G3 1 Spindle Pusher Tool Usage G3 2 Installation G3 3 Disassembly G3 5 Cleaning and Inspection G3 5 Assembly G3 6 Wheel Bearing Adjustment G3 8 Wheel Bearing Adjustment tire mounted G3 8 STEERING CYLINDERS AND TIE ROD G3 10 Spherical Bearing Wear Limits G3 10 Removal G3 11 Inst...

Page 282: ...Eye Bearing G4 2 Disassembly G4 2 Assembly G4 2 Anti Sway Bar G4 4 Removal G4 4 Installation G4 4 Disassembly G4 4 Cleaning and Inspection G4 4 Assembly G4 4 REAR AXLE HOUSING G5 1 Rear Axle Housing G5 1 Removal G5 1 Installation G5 1 Wheel Motor G5 1 Removal G5 1 Cleaning and Inspection G5 2 Installation G5 2 ...

Page 283: ...y with the tire mounted on the rim Remaining gases inside the tire may ignite causing explo sion of tire and rim DO NOT go near a tire if a brake or wheel motor has experienced a fire until the tire has cooled When inflating tires always use a safety cage Never inflate a tire until the lockring is securely in place Do not stand in front of or over the lock ring during inflation procedures Never ov...

Page 284: ...ut is 0 20 in 5mm If run out exceeds specifications then loosen all the nuts and re tighten them evenly as shown in Figure 2 2 3 If run out is OK then tighten each nut using the sequence in Figure 2 2 to 550 ft lbs 746 N m torque 4 Connect the valve stem to the wheel hub 5 Operate truck for one load and retighten wheel nuts as specified in Step 3 Recheck nut torque daily each 24 hours of operation...

Page 285: ...l valve stem vinyl clamp by loosening capscrews Lift valve extension out of vinyl clamp 4 Using a tire handler or hoist and sling if body has been removed as shown in Figure 2 4 to grasp outer wheel assembly Remove wheel nuts 10 Figure 2 4 and wedges 11 securing outer wheel to the wheel motor hub Use a strap or other means to secure inner wheel before removing outer wheel assembly This will preven...

Page 286: ...y 2 Using a lifting device install spacer 6 Figure 2 4 onto wheel motor hub Tap spacer up against inner dual 3 Attach tire handler to outer dual and position onto wheel motor hub Due to its size and weight always keep person nel away from a wheel assembly when it is being removed and installed NOTE Be sure to position outer dual wheel so that tire valve bracket aligns with inner wheel inflation li...

Page 287: ...ble 3 Following tool manufacturers instructions move tire bead in far enough to permit placing a wedge between tire and flange at side of tool 4 Repeat this procedure at locations approxi mately 90 from the first application Continue this procedure 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 ou...

Page 288: ...izon 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 With each tire mounting it is required that a new O ring and a new air valve be installed 1 Before mounting tire to rim remove al...

Page 289: ...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 tire to seat beads of tire and O ring as specified by tire manufacturer Use a safety cage whenever possible Stand to one side as tire is ...

Page 290: ...G2 8 Tires and Rims 04 03 G02004 NOTES ...

Page 291: ...stem for the steering cylinder and tie rod Cap all lines 4 Remove capscrews and washers securing brake line junction block 2 and main brake supply line 1 from spindle assembly Plug or cap all lines to prevent contamination of the hydraulic system 5 If internal work is to be performed remove hub drain plug 24 Figure 3 5 and allow oil to drain 6 Remove lubrication lines from tie rod and steer ing cy...

Page 292: ...in Thread engagement 1 50 in Washer P N WA0365 1 125 in 830E AFE 50 Capscrew P N KC7095 1 25 x 8 in Min thread engagement 1 62 in Washer P N WA0366 1 25 in Note Verify minimum thread engagement on pusher capscrews when inserted 2 After the tool has been installed progressively increase the torque on the capscrews in a circu lar pattern until the tapered piston breaks loose or until the maximum spe...

Page 293: ...78 N m torque b Continue to tighten capscrews in increments of 250 ft lbs 339 N m to obtain a final torque of 1580 ft lbs 2142 N m 6 If removed install steering arm 4 Clean and check the tapped holes in bottom of spindle for damaged threads Retap holes if necessary 830E AFE 32 1 125 in 12NF tap 830E AFE 50 1 25 in 12NF tap 7 Install capscrews 5 and torque to 830E AFE 32 1430 200 ft lbs 1940 271 N ...

Page 294: ...twashers 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 295: ...cup 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...

Page 296: ...ed or scratched b Remove all oil and protective coating from seal and from the seal seat using nonflam mable cleaning solvent make certain all sur faces are absolutely dry c Check seal seat retaining lip for rough tool marks or nicks Smooth any nicks and re clean d Install rubber sealing ring so it seats uni formly in the relief of seal Be sure that it rests uniformly against the retaining lip e U...

Page 297: ... procedure outlined in step 6 10 Check bearing cone 9 for free fit on the spindle 17 then remove 11 Referring to Figure 3 8 lift the hub and carefully lower it down over the spindle To aid installa tion and to prevent damaging the seal the spin dle and hub should be level NOTE All parts must be in place before wheel hub 1 is installed 12 Install outboard pin 25 Figure 3 5 into slot on spindle 17 a...

Page 298: ...al the dimension in step 6 within 0 001 in 0 025 mm NOTE The above procedure results in a shim pack which will provide a 0 007 in 0 178 mm nominal preload for the bearings Shim pack must be compressed when measuring to obtain an accurate measurement 8 Remove capscrews and retainer Install shim pack and then re install retainer all capscrews and hardened washers 9 In successive increments of 250 ft...

Page 299: ...m while rotating the hub 13 Using a depth micrometer measure and record the depth to the end of the spindle from the face of the retainer plate through each of the two holes in the retainer plate adjacent to the cap screws tightened in step 12 14 Add the two depth dimensions measured in step 13 and divide the total by 2 to obtain an aver aged depth dimension Record average Depth da ______________ ...

Page 300: ...l and installation instruc tions are applicable to both Spherical Bearing Wear Limits It is necessary to determine the condition of spherical bearings on steering linkage components for opti mum steering performance Ball diameter new dimensions 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 bea...

Page 301: ...ainers 6 or 7 from 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 Insure 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 capscrews 3 and retainers 6 or 7 ...

Page 302: ...er 3 Capscrew 4 Pin 5 Pin 6 Retainer 7 Retainer 8 Hardened Washer 9 Locknut 10 Bearing Spacer 11 Bearing Retainer 12 Capscrew 13 Lockwasher 14 Bearing 15 Tie Rod End 16 Tie Rod Assembly 17 Capscrew 18 Locknut 19 Main Frame Mount FIGURE 3 13 STEERING CYLINDER 1 Bearing 2 Capscrew 3 Lockwasher 4 Bearing Retainer 5 Rod End EARLIER PRODUCTION ...

Page 303: ...en clamp 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 Installa...

Page 304: ...G3 14 Front Wheel Hub and Spindle 04 03 G03018 NOTES ...

Page 305: ... 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 AK4952 Nose Cone Repair Kit Installation 1 Raise pivot eye into position 2 Be certain spherical bearing inner...

Page 306: ...nd 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 8 75 00 8 7488 in 222 25 222 22 mm Bearing Bore I D 5 9990 6 0000 in 152 37 152 40 mm If bearing carrier 3 is damaged or worn refer to PIVOT EYE REPAIR Assembly 1 Setup an appropriate tool to press spheric...

Page 307: ...650 0 013 mm Assembly 1 Setup an appropriate tool to press bearing car rier 3 Figure 4 2 into the bore of the pivot eye structure 1 Be certain the bearing carrier is pressed fully into the pivot eye bore flush with sides Lube groove in bearing carrier outer diameter must align with lube fitting hole in pivot eye structure NOTE With parts to correct size the fit of the bearing carrier into the bore...

Page 308: ... the spherical bearing Position the other spacer 3 and finish pushing the pin into the other mounting ear If necessary realign the pin with the mounting bracket retainer capscrew hole Install retaining capscrew and locknut Install capscrew 5 and lockwasher 6 if removed 3 Repeat above procedure to install remaining pin spacers and retainer capscrew and locknut Start the pin into the bore of the rea...

Page 309: ...in Section H Suspensions 5 Install wheel motors 6 Hook up lube lines on wheel motors 7 Route electrical cables through cable grips on right hand end of axle 8 Connect electrical cables to motorized wheels inside axle housing using identifications made at removal 9 Reconnect all brake lines air and remaining lube lines Bleed brake and lube lines 10 Reconnect wheel motor cooling air duct and clamp s...

Page 310: ... or exceed Grade 8 specifica tions Replace only with bolts of correct hardness Refer to Komatsu Parts Catalog for correct part num ber Before installation inspect each capscrew for any defects and number of punch marks Replace capscrew and related hardware if two punch marks are evident do not reuse if any defect is suspected Hardware showing signs of rust corrosion galling or local yielding on an...

Page 311: ... H2 5 Major Suspension Rebuild H2 6 Disassembly H2 6 Assembly H2 7 Pressure Test H2 8 REAR SUSPENSION H3 1 Removal H3 1 Installation H3 3 Disassembly H3 5 Assembly H3 5 Pressure Test H3 6 OILING AND CHARGING PROCEDURES H4 1 GENERAL H4 1 EQUIPMENT LIST H4 1 FRONT SUSPENSION H4 3 Front Suspension Oiling H4 3 Front Suspension Nitrogen Charging H4 3 REAR SUSPENSION H4 5 Rear Suspension Oiling H4 5 Rea...

Page 312: ...H1 2 Index 5 03 H01015 NOTES ...

Page 313: ...oot from around sus pension Disconnect pressure sensor 3 Discharge nitrogen pressure from suspension by removing cap from charging valve 5 Figure 2 1 Turn the charging valve swivel nut small hex 3 Figure 2 2 counterclockwise 3 full turns to unseat valve seal DO NOT turn more than three turns DO NOT TURN LARGE HEX 4 see DANGER below Wearing face mask or goggles depress valve stem until all nitrogen...

Page 314: ...nufac turer s instructions for use proper ventilation and or use of breathing apparatus 2 Inspect suspension and frame mounting surfaces and spotfaces for flatness Surface finish must not exceed 250 RMS medium tool cut Surface flatness must be within 0 010 in 0 254 mm 3 Clean and dry all capscrews nuts and washers as stated in Step 1 above NOTE The use of dry threads in this application is not rec...

Page 315: ...showing signs of rust corrosion galling or local yielding on any seat or thread surfaces should be replaced Replace all suspension mounting hardware if the truck was oper ated with the suspension mounting in a loose joint con dition 5 Attach fork truck or lifting device to suspension and mount suspension to the truck frame making certain shear bar 5 Figure 2 3 is flush with end of suspension keywa...

Page 316: ...ng members either the capscrew head or nut is turned until the marked cor ner is adjacent with the marked reference line Check to make sure that the opposite end of the turning member has NOT turned during the tightening procedure NOTE Do not exceed 4 RPM tightening speed Do not hammer or jerk wrench during the tightening procedure e Loosen the top two corner capscrews 1 and the bottom outer four ...

Page 317: ...and buffer seal 24 be certain radius is positioned 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 ...

Page 318: ...gs 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 carefully lift out of housing 5 Remove capscrews and washers 18 19 Fig ure 2 8 Install pusher bolts and remove lower bearing structure 16 6 Remove and discard rod wiper seal 26 lip seal 25 and buffer seal 24 Remove and discard O rings 20 and b...

Page 319: ...t 11 against piston stop Tighten locknut one half turn further until hole for the roll pin 10 is in align ment Install roll pin 7 Attach a lifting device to top side of end cap assembly Lower assembly down on piston 8 Insert steel balls 9 in holes in piston prior to fully seating bearing on top of piston A small amount of petroleum jelly will prevent the balls from drop ping out during assembly 8 ...

Page 320: ...585 1380 kPa through the charging valve and maintain pressure for twenty 20 minutes minimum No leakage is permissible 2 Release pressure from suspension assembly and remove from containment structure Do not remove charging valve 3 Install charging valve guard 4 If suspension is to be stored install suspension oil prior to storage Refer to Front Suspension Oiling this section 5 Protect exposed chro...

Page 321: ...in rework details 1 Remove capscrews washers and metal shield 2 Figure 3 1 from the suspension 2 Remove charging valve cap 1 Figure 3 2 loosen small hex 4 on charging valve and turn counterclockwise three full turns to unseat valve seal Connect suspension charging kit Make certain only the swivel nut turns Turning the complete charging valve assembly may result in the valve assembly being forced o...

Page 322: ... exceed 10 tons of force when applying pressure to the cylinder Damage to the tool or suspension components may result as well as personal injury to maintenance personnel 13 Apply pressure to the cylinder using the hand pump not shown 14 When the cylinder reaches the end of its stroke remove one of the shackles from the cylinder and connect the cylinder shackle directly to the pin removal tool Thi...

Page 323: ...1 align the retaining cap screw hole with the hole in the mounting bore and drive in far enough to hold pin in position 5 Insert the spacer 4 and continue to drive the pin in through the spherical bearing Insert the remaining spacer and continue to drive the pin in until the retaining capscrew hole is aligned with the hole in the pin 6 Install capscrew 2 Figure 3 3 and locknut 3 Tighten to 310 ft ...

Page 324: ...H3 4 Rear Suspensions 4 03 H03015 ...

Page 325: ...on 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 solvent manufacturer s instructions 2 Dry all parts completely using only dry filtered compressed air and lint free wiping materials 3 Inspect all parts for evidence of wear or dam age Inspect...

Page 326: ...nt 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 64 ft lbs 87 N m 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 16 5 ft lbs 22 4 N m torque PRESSURE TEST Af...

Page 327: ... 0 1 2 3 4 5 6 7 5 0 1 23 4 8 8 9 8 6 4 7 1 3 8 6 7 8 4 6 7 8 3 6 7 4 67 654 7 67 4 3 1 5 A A 2 A 6 7 A 6 7 A 6 3 7 B C 6 7 3 6 4 7 ...

Page 328: ...2 6 27 6 7 6 7 6 7 67 B 67 6 7 C 6 27 6 7 2 6 27 67 2 67 6 7 5 0 5 0 0 67 0 6 7 5 4 0 D 6 7 E 4 4 ...

Page 329: ... 5 0 1 0 1 23 4 6 4 7 F 5 G 6 7 3 3 H I 3 HH 2 F 5 6 4 7 2 1 3 C2 4 6 2 7 J 6 J7 6C 7 2 4 6 7 J 6 J7 2J 6B J7 2 44 6 7 J 6 J7 6 C7 J2 4 6 7 J 6 J7 6 2 2 7 J2 4 6 7 J 6 J7 6J2 7 5 063 63 6 1 0 78 4 4 3 3 3 ...

Page 330: ... 4 6 BK 7 5 0 1 5 6 J54 27 H 6 5B7 9 0 6 5 7 01 2 1 3 6 7 4 654 7 8 3 B 6 B7 C 67 4 5 6 B7 J 4 3 654 7 H 6 27 0 L 6 27 1 5 654 27 0 2 5 0 5 0 0 67 0 6 7 4 2 3 A H A A 2 A 3 F B A C A J ...

Page 331: ... 0 0 6 76 6 7 5 5 M A 5 5 0 1 23 4 0 1 5 6 7 6 4 7 G 2 6 7 3 3 H I 5 5 3 HH ...

Page 332: ...B 2 F 5 6 BK 7 5 0 1 3 5 6 J54 27 H 6 5B7 9 0 6 5 7 01 2 1 3 6 7 4 4 2 4 1 3 C2 6 7 J 6 J7 6J2 7 2 6 7 J 6 7 6C 7 2 6 7 J 6 7 2 6 C 7 J2 5 6 7 C 6J 7 6 7 4 4 3 3 ...

Page 333: ...C B 654 7 H 6 27 0 L C N 6 2J 7 5 0 M 6 27 1 J 5 654 27 0 5 0 5 0 5 0 67 0 6 7 A ...

Page 334: ...J 6 BK 2CB 7 H F 2 4 4 4 4 H B2 6 BK 4 7 B G 4O 6 G O 7 A9 J 6 BK 2CB 7 5 5 F 2 5 F 2 5 F 2 5 F 2 B 6 BK 4 7 BB 4 536 9 7 9 4 4 9 7 9 4 4 4 06 0 1 89 6 7 0 0 1 0 6 7 77 2CB 6 K 4 7 C C L 2 L 2 2 3 5 43 1 0 3 JJ JK F 2 B G 46 G 7 K 4 4 3 ...

Page 335: ...Assembly J3 6 Differential Pressure Switch J3 9 Valve Bench Test and Adjustment J3 10 Installation of Brake Pedal Actuator to Brake Valve J3 13 Brake Valves with Integral Mounted Electronic Retard Pedal J3 14 Hydraulic Brake Accumulators J3 15 BRAKE CIRCUIT CHECKOUT PROCEDURE J4 1 Brake Circuit and Brake Valve Troubleshooting J4 7 Hydraulic Brake System Check out Procedure Data Sheet J4 11 ROCKWEL...

Page 336: ...d Conditioning Burnishing Procedure J6 16 Brake Bleeding Procedure J6 18 ROCKWELL DISC PARKING BRAKE J7 1 Park Brake Caliper J7 1 Removal J7 1 Installation J7 2 Parking Brake Adjustment J7 2 Park Brake Caliper Disassembly J7 4 Cleaning and Inspection J7 4 Park Brake Caliper Assembly J7 5 Park Brake Lining J7 6 Replacement J7 6 Park Brake Burnish Procedure J7 6 Brake Bleeding Procedure J7 6 ...

Page 337: ...r 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 All of these components are screw ...

Page 338: ... 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 Low Brake Accumulator Pressure Switch 23 Park Brake Pressure Switch 24 Brak...

Page 339: ...e park brake solenoid is de ener gized 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 running Parking brake switch ON 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 brake The parking brake pres...

Page 340: ...brake pressure light and buzzer will turn on The pressure differential switch com pletes a path to ground in order to turn on the low brake pressure light and buzzer Use of the differ ential pressure switch allows detection of faults between the front and rear circuits such as brake line ruptures poor brake valve tracking line blockage and excessive air or brake displace ment Brake Lock Degradatio...

Page 341: ...ont Brake 13 Spool Return Srping 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 A Adjustment Collar Contact Area B PX Port C Automatic Apply Piston Area D Tank Port E Orfice F Brake Apply Port G Reactionary Pressure Area H Supply Port FIGURE 2 2 BRA...

Page 342: ...1 Actuator Base 2 Brake Valve 3 Orfice Set Screw FIGURE 2 3 BRAKE VALVE PARTIAL CUT AWAY J2 6 Brake Circuit J02032 ...

Page 343: ... 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 installing test gauges always bleed down hydraulic steering and brake accumulators The steering accumula tors can be ...

Page 344: ...ll valve fittings Discon nect wiring harness at differential pressure switch connector 5 If equipped remove retard pedal that is located on brake pedal 6 In the cab at the brake valve remove capscrews and lockwashers securing the brake valve as sembly to the mounting structure 7 Slide brake valve downward and remove from cab 8 Move brake valve assembly to a clean work area for disassembly FIGURE 3...

Page 345: ...d key switch OFF open both brake accumulator bleed down valves Precharge both accumulators NOTE For best performance charge the accumula tors in the temperature conditions the vehicle is ex pected to operate in During the precharge allow temperature of the nitrogen gas to come into equilib rium with the ambient temperature 5 Close both accumulator bleed down valves after precharge is complete NOTE...

Page 346: ...ng the boot and gently lifting from the valve body 7 Remove capscrews 36 Figure 3 5 and the dif ferential pressure switch 35 8 Remove and discard the O ring 27 and face seal 28 9 Loosen the plunger locknuts 2 Loosen the socket head capscrew from the adjustment col lars 1 10 Unscrew and remove the adjustment collars 11 Remove the two socket head capscrews 5 Figure 3 4 that retain the actuator base ...

Page 347: ... O Ring 11 Back up Ring 12 O Ring 13 O Ring 14 Regulator Sleeve 15 Spool Return Spring 16 Reaction Plunger B1 25 O Ring 26 Retaining Plug 27 Base Plate 28 Washer 29 Capscrew 30 Differential Pressure Switch 31 Capscrew 17 Reactio 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 J03022 1 99 Brake Circuit Component Service J3 5 ...

Page 348: ...t each spring carefully for cracks or breaks Any spring with a crack or break must be re placed 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 3 hydraulic oil Take care to k...

Page 349: ... ring 6 onto the largest groove on the bottom on the regulator sleeve 2 Install a split nylon back up ring 4 onto each side of the O ring 5 located in the middle of the regulator sleeve 3 Install one split nylon back up ring behind the O ring 2 located at the top end of the sleeve This O ring is the smallest of the three O rings Position the back up ring so that it is next to the top of the regula...

Page 350: ...l from sleeve before installing sleeve into body 10 Lightly lubricate the O rings 14 16 18 on the regulator sleeve 11 Install the regulator sleeve assembly into the cor rect circuit in the valve Make sure the spring seat is correctly seated in the regulator spring before installing the regulator sleeve assembly Push sleeve into bore until sleeve retaining flange at the base of sleeve contacts the ...

Page 351: ...tach an ohmmeter to switch assembly 3 center terminal and switch body Actuate the switch plunger to verify contacts close when plunger is depressed and contacts open when released Plunger must operate freely in switch body Assembly 1 Install plug 11 Figure 3 9 Tighten plug to 190 210 in lbs 21 5 23 7 N m torque 2 Lightly lubricate Glyde rings on spool assembly 10 and carefully insert in body 4 unt...

Page 352: ... 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 10 TEST BENCH SET UP 1 Motor 2 Pump 3 System Pressure Gauge 4 Needle Valve 9 Simulated Brake Volume 10 Rear Brake Pressure Gauge 11 Relief Valve 5 Needle Valve 6 Brake Valve 7 Front Brake Pressure G...

Page 353: ...ed individually Refer to Figure 3 10 3 Gradually apply pressure on each circuit one at a time to check for leaks around the plunger Make sure the adjustment collar is screwed all the way down on the threads 4 B1 Adjustment Adjust the adjustment collar up counter clockwise starting with one turn in crements until the output pressure at port B1 is 2000 0 75 psi 13 790 0 517 kPa with the adjustment c...

Page 354: ...its must reach the minimum pressure listed below at port B1 and port B2 within 1 0 seconds Measurement of time begins the moment force is applied to move the pedal Rear Brake B1 BR on truck 2000 80 psi 13 790 552 kPa Front Brake B2 BF on truck 3000 150 psi 20 685 1034 kPa 19 With B1 and B2 plugged into a strip chart recorder if available check the modulation by slowly applying pressure until the m...

Page 355: ...lete 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 assem bly will not interfere with pedal travel The spring and spring pivots are different for ped als equipped with and without the electric retard pedal mount...

Page 356: ...pivot shaft 8 Install two retainer clips 6 3 With jam nut 10 loose adjust capscrew 11 until roller on retard pedal just contacts the brake pedal actuator Tighten jam nut 10 4 Connect wiring harness to retard pedal 1 Brake Valve 2 Retainer Clip 3 Pivot Shaft 4 Bushings 5 Shims 6 Retainer Clip 13 Pad 14 Nut 15 Capscrew 16 Electronic Retard Pedal Assembly 17 Brake Pedal Actuator 18 Spring Pivot Lower...

Page 357: ...valve guard and Dyna seal from top of accumulators 3 Depress valve core to release gas precharge pressure from accumulator bladder Refer to Fig ure 3 13 4 Remove accumulator mounting bracket Loosen and remove accumulator from the brake mani fold Plug opening on brake manifold to prevent contamination 5 Transfer accumulator to work area Installation 1 After service repairs or bench test has been co...

Page 358: ...rom foreign matter 3 Check all rubber items for deterioration abrasion marks cracks holes bubbles or any similar de fects 4 Replace all O rings and any other items deemed unsuitable for further usage 5 Bladder may be checked by inflating to normal size and checking with a soapy solution After testing deflate immediately 6 Check plug and poppet valve for proper function ing FIGURE 3 14 LOCKNUT REMO...

Page 359: ...hand Figure 3 20 Remove bladder pull rod 8 Grasp threaded section of plug and insert poppet end into shell mouth 9 Install anti extrusion ring inside shell Fold anti ex trusion ring to enable insertion into shell Place anti extrusion ring on plug and poppet assembly with its steel collar toward shell mouth 10 Withdraw threaded end of plug through shell mouth Refer to Figure 3 21 11 Pull plug until...

Page 360: ...nnector in order to prevent gas leak age NOTE If leakage is still present replacement of the small copper washer in the swivel connector may be necessary 3 Precharge bladder slowly to about 10 psi 69 kPa before completely tightening the valve stem nut With wrench on valve stem flats tighten valve stem nut 4 Proceed to inflate accumulator to 1400 50 psi 9653 345 kPa pressure by slowly opening the p...

Page 361: ...ore troubleshooting brake circuit For Steering Circuit Test Procedure refer to Section L Hydraulic System FIGURE 4 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 ...

Page 362: ...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 waiting 90 seconds Confirm the steering pressure is released by...

Page 363: ...bucket for bleeding brakes f Volt ohm meter with leads and two 24 inch 61 mm 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 Brak...

Page 364: ...ss brake pedal and bleed air from bleeders located at each brake PARKING BRAKE NOTE Move one of the pressure measuring instruments from the BF or BR locations to the PK2 test port above the Park Brake Solenoid 8 Actuate brake lock Release parking brake with park brake switch Verify that Park Brake Status Light indicates parking brake is released Park Brake pressure should be 2500 100 psi 17 238 69...

Page 365: ...a sheet 21 Brake pressures should begin to rise Auto Apply when LAP1 reaches 2000 100 psi Close front brake accumulator bleed down valve Record on data sheet 22 Start engine to recharge hydraulic system Allow engine to run until low brake accumulator pres sure stabilizes at or above 3200 psi 22 064 kPa 23 Shut engine down Allow the steering accumula tor to bleed completely down Turn Key Switch on ...

Page 366: ...d bleed down both brake accumulators by opening the manual bleed down valves on the brake manifold 35 Outside the brake cabinet reconnect the hose that supplies oil from the rear brake accumula tor to the brake pedal in the cab 36 Install a jumper wire between circuits 33 and 33W at the brake warning timer Install another jumper wire between circuits 33W and 33T on the brake warning relay Both cir...

Page 367: ...LE One Brake Circuit is Dragging Obstruction 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 l...

Page 368: ...leaks Replace timer TROUBLE The Differential Pressure Warning Circuit is not Operating Low Brake Pressure lamp is burned out Electrical problem Differential pressure switch is defective or is improp erly adjusted Problem in brake valve assembly Brake warning relay defective Replace bulb Check wiring Check the switch and replace if necessary Check differential pressure switch adjustment Refer to Ta...

Page 369: ...in brake valve assembly Damage in brake valve assembly Remove disassemble clean reassemble or replace Repair or replace brake valve assembly TROUBLE Oil is Leaking Around the Pedal Base Defective seal on top of brake valve Replace the seal TROUBLE The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM Excessive internal leakage in a component Accumulator precharge too high or...

Page 370: ...J4 10 Brake Circuit Check Out Procedure J04031 NOTES ...

Page 371: ...STEP 9 _______________ Left outboard lining disc gap _______________ Left inboard lining disc gap _______________ Right outboard lining disc gap _______________ Right inboard lining disc gap Service Brake System Refer to appropriate Service Manual procedures and Bleed brakes Bleed park brakes STEP 11 _______________ Rear brake pressure when front brake pressure begins to rise STEP 12 _____________...

Page 372: ...TEP 21 _______________ Front brake pressure after auto apply occurs _______________ Rear brake pressure after auto apply occurs STEP 23 _______________ Front brake pressure after auto apply occurs _______________ Rear brake pressure after auto apply occurs Reapplications STEP 26 _______________ Number of applications prior to auto apply Differential Pressure Switch STEP 30 _______________ Rear bra...

Page 373: ...mbly 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 li...

Page 374: ...all 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 capscrews 6 Tighten capscrews 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 capscrews washers and nuts ...

Page 375: ...g 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 du...

Page 376: ...sh deterioration that can contribute to seal damage and fluid leakage NOTE In normal operation a very slow rate of wear should be experienced and will be noticeable by the slow disappearance of the hard chrome finish Minor nicks and scratches may be blended out by hand with 180 grit aluminum oxide or carborundum cloth then successively finer grades used until a surface comparable to the original s...

Page 377: ...of braking and possible cata strophic failure 1 To replace front linings remove front tire and rims refer to Wheel and Tire Installation Sec tion G 2 Remove end plates 7 or 8 Figure 5 3 from either end of caliper 3 Pry between lining and disc to force pistons to bottom in caliper housing 4 Remove lining from inboard and outboard sides of disc 5 Inspect dust seals Seals should be soft pli able and ...

Page 378: ...akes 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 plug ...

Page 379: ...ine 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 bra...

Page 380: ...J5 8 Rockwell Wheel Speed Front Disc Brakes J05019 NOTES ...

Page 381: ...rake Removal NOTE For electric wheels equipped with a two piece brake hub adapter 9 20 Figure 6 3 follow the instructions below For electric wheels equipped with a one piece wheel adapter 16 Figure 6 3A refer to page 4 NOTE The Park Brake caliper may be removed from either wheelmotor without disassembly of other brake components 1 Securely block wheels to prevent truck move ment 2 Remove rear whee...

Page 382: ... 20 ft lbs 287 27 N m torque 3 Install disc 19 with four equally spaced cap screws Tighten capscrews but do not tighten to final torque at this time 4 Measure and record distance from inner caliper mount surface to inside face of inner brake disc 19 Dimension A Figure 6 3 NOTE All measurements in the following references are inches unless otherwise stated 5 Subtract dimension A from 4 375 in 11 11...

Page 383: ... Install outboard disc 16 and bushings 14 Install capscrews and flatwashers 15 Tighten capscrews to standard torque 24 Remove studs and install outer caliper half 5 and secure in place with capscrews and flatwashers 4 Tighten capscrews to standard torque SHIM PACK CHART Shim Pack Required in 0 010 in Shim Qty 0 040 in Shim Qty 0 000 0 005 0 0 0 005 0 015 1 0 0 015 0 025 2 0 0 025 0 035 3 0 0 035 0...

Page 384: ... studs 4 Remove two remaining caliper mount capscrews and remove outer half of caliper 5 5 Support outer disc 12 and remove disc mount capscrews 11 and washers Slide disc from out board adapter 10 Shims 7 will be found between disc and adapter Remove bushing 8 and inner half of caliper 5 Remove park brake bracket 4 6 Remove capscrews and flatwashers 9 Remove adapter 10 7 Remove two center caliper ...

Page 385: ...r half 14 and two cap screws and flatwashers 13 13 Remove the two studs in the center and install two capscrews 13 and hardened flatwashers Tighten all capscrews 13 to standard torque 14 Install outer disc adapter 10 Install capscrews and flat washers 9 Tighten 12 point head cap screws 9 to standard torque 15 Install two 7 8 UNC 14 in studs in the two center caliper mounting capscrew holes for the...

Page 386: ...n 66 5 mm min Housing Bore I D 2 630 in 66 8 mm max 3 Replace parts if worn beyond above limits Piston Assembly Installation 1 Lubricate pistons seals and housing bores with clean C 3 hydraulic oil 2 Install piston O ring 7 Figure 6 7 into housing seal groove and push to bottom of groove Con sidering opening to housing bore as top 3 Install backup ring 16 into top of housing seal groove with conca...

Page 387: ...hreaded retaining ring 4 1 The piston subassembly can be inspected for required return spring force and built in clearance adjustment at the same time Use the set up on a spring checker as shown in Figure 6 8 2 Set up dial indicator between arbor of spring checker and table 3 Place sleeve A Figure 6 6 over return pin lower arbor and fully compress spring indicator pointer will stop moving 4 With s...

Page 388: ...ecial tools such as those illustrated in Figure 6 9 6 10 or tools that will perform equivalent functions Special tool as shown in Figure 6 9 calibrated spring pod need not be provided if a hydraulic press is available with a pressure gauge cali brated to read pounds of force exerted by the ram A typical hydraulic press with an effective ram area of 3 53 sq in 22 7 cm2 will exert a force of 400 lb ...

Page 389: ... combination on arbor press table drop in 3 dowel pins as indicated place spring pod tool on top of dowels apply force slowly to top of spring pod and again observe if grip slippage occurs within the pre scribed limits Grip Force Measurement To measure grip force of grip assemblies installed on return pin it is necessary to have available either a force calibrated hydraulic press or a calibrated s...

Page 390: ...er no circum stances should pin diameter be clamped in a vise or gripped with pliers In normal use surface of pin will show only a very slow rate of wear and both pins and grips will normally last through many brake lining changes and brake overhauls 5 Install grips on return pin as illustrated in Figure 6 13 Position grip and pilot pin assembly as shown to transfer grip assembly from pilot pin to...

Page 391: ...a sure greater than 200 lb 890 N It is recom mended that springs measuring a force of 180 lbs 800 N or less under these test conditions be replaced Disassembly of Piston Assembly To disassemble piston assembly for separate inspec tion of return spring 14 Figure 6 7 return pin and grip assembly 6 proceed as follows 1 Remove O ring 2 Figure 6 7 and return pin washer 3 from return pin 2 Remove lockwi...

Page 392: ... to Caliper Piston Installation BENCH TEST The purpose of this test is to verify that overhaul of the calipers was performed satisfactorily If any leakage occurs during this test the caliper assembly must be rebuilt A hydraulic supply with sufficient volume and pressure capacity to extend piston assemblies will be necessary A gauge of 0 2000 psi 0 14 MPa should be placed in the output line of the ...

Page 393: ...ing to Installation instructions this Section BRAKE LINING Replacement Inspect brakes periodically for wear Linings must be replaced when lining material has been worn to a mini mum of 0 31 in 7 8 mm Use of linings beyond this wear limit will result in a decrease of braking action and possible damage to disc When replacing linings never mix new and used linings in an assembly 1 To change linings r...

Page 394: ...ing and lining retaining plates clean before installation of new linings If a petroleum base cleaning fluid is used such as diesel fuel use sparingly on dust shields and wipe dry after cleaning 4 Inspect discs for wear Figure 6 18 Place a straight edge across face of disc and measure from straight edge to worn face It is recom mended that the disc be replaced when this mea surement is 0 06 in 1 52...

Page 395: ...gs slide freely between retainer plates 7 Check brakes for operation Linings should be free after release with minimum of 0 03 in 0 76 mm disc to lining clearance If clearance not present each piston must be pried completely into caliper housings 8 After installing new brake pads and before releasing truck to production the brakes must be burnished Refer to Conditioning Burnishing Procedure FIGURE...

Page 396: ... brakes until the recommended brake disc surface 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 bra...

Page 397: ...the event of an emergency c 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 or exceed 600 F 316 C NOTE The Override Switch on the instrument panel must be depressed and held by the operator in order to propel the truck with the br...

Page 398: ...way from brake assembly and into a container to catch excess oil 4 With engine at idle make partial brake application 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 reservoir level as bleeding takes place maintain c...

Page 399: ...PER Removal The park brake caliper may be removed from wheel without disassembling other brake components 1 Securely block truck to prevent movement Do not loosen or disconnect any hydraulic brake line or component until engine is stopped key switch is Off and drain valves on brake accu mulators are opened and steering accumulators are bled down Hydraulic fluid escaping under pressure can have suf...

Page 400: ...front and rear to prevent truck from moving 2 Loosen clamp capscrew 3 Figure 7 2 which secures the yoke to the housing 3 Loosen the jam nut 17 4 Loosen adjusting bolt 16 until the bolt does not contact the spring retainer 15 5 Tighten clamp capscrew 3 finger tight until no gap exists between yoke 1 and housing 2 but yoke must be free to slide on housing 6 Be sure the yoke is positioned inside hous...

Page 401: ...eler gauge Clearance should be 0 025 in 0 060 in 0 635 mm 1 524 mm for both inboard and outboard lin ings NOTE If another source of hydraulic power such as porta power is used for this check install a gauge in line and use 2200 2500 psi 10 3 MPa 17 2 MPa pressure for adjustment Exceeding MAXIMUM pressure of 3000 psi 20 7 MPa may rupture seals in park brake caliper and cause leakage 16 If the linin...

Page 402: ... releasing the lining 5 from pistons 9 Remove seal and backup ring 6 7 from housing and discard these parts Cleaning and Inspection Petroleum base cleaning solvents are flammable DO NOT USE NEAR OPEN FLAME 1 Clean all metal parts of brake assembly in cleaning solvent 2 Inspect all metal parts for breaks or cracks Replace all cracked parts 3 Measure pistons and housing bores Replace the parts if th...

Page 403: ...lubricate seals 6 12 Figure 7 2 with clean hydraulic oil as used in brake circuit Lubricate cylinder walls with Dow Corning 4 or equivalent 2 Install lubricated seals and backup ring 12 13 in housing 3 Install lubricated seals and backup ring 6 7 on pistons 4 Attach lining 5 to pistons with screws 14 Refer to Lining Replacement Procedure 5 Install piston in housing 6 Lubricate spring washers 9 wit...

Page 404: ... brake disc with service brakes to clean and heat rear discs to between 350 F 500 F 177 C 260 C 2 Park on hot disc 3 to 5 minutes to clean and heat parking brake linings NOTE Parking capabilities can be tested by parking loaded truck Do NOT exceed rated GVW shown on Grade Speed decal in cab on steepest hauling grade in mine not to exceed 15 grade If parking brake does not hold on grade allow vehic...

Page 405: ...ERING CIRCUIT OPERATION L4 1 COMPONENT DESCRIPTION L4 2 Steering Control Unit L4 2 Flow Amplifier L4 2 Bleed Down Manifold L4 12 Accumulators L4 13 Steering Circuit Filter L4 13 Steering Brake Pump L4 13 STEERING CIRCUIT COMPONENT REPAIR L5 1 BLEED DOWN MANIFOLD L5 1 ACCUMULATOR L5 2 Steering Accumulator Charging Procedure L5 6 FLOW AMPLIFIER L5 7 STEERING CONTROL UNIT L5 12 STEERING CYLINDER L5 1...

Page 406: ... 2 Spool Section L8 4 HOIST PILOT VALVE L8 7 BODY UP LIMIT SOLENOID L8 10 PILOT OPERATED CHECK VALVE L8 10 HOIST CYLINDERS L8 10 COUNTERBALANCE VALVE MANIFOLD L8 18 DISABLED TRUCK DUMPING PROCEDURE L8 19 HYDRAULIC CHECKOUT PROCEDURE L10 1 STEERING AND BRAKE PUMP L10 1 BLEED DOWN MANIFOLD L10 2 SHOCK SUCTION VALVES L10 3 LEAKAGE TESTS L10 4 TROUBLESHOOTING CHART L10 6 Steering Circuit L10 6 Steerin...

Page 407: ...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 238 gal 901 l 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 408: ...differential switch When restriction is excessive the switch will turn on an indicator lamp inside the cab to notify the operator that filter service is required BLEEDDOWN MANIFOLD The bleeddown manifold 6 Figure 2 2 receives oil from the steering brake pump and directs it to the steering accumulators 9 brake system and to the flow amplifier 7 for steering circuit components STEERING SYSTEM ACCUMU...

Page 409: ...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 410: ...L2 4 Hydraulic System L02027 NOTES ...

Page 411: ...rain 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 ...

Page 412: ...ering pump 13 Move pump to a clean work area for disassem bly Installation NOTE The following procedure assumes the steering pump is already in position on the truck 1 Install O ring 16 Figure 3 2 to steering pump 11 Install coupler 9 to hoist pump If removed coupler has a snap ring remove the snap ring and dispose The hoist pump weighs approximately 282 lbs 128 kg The hoist and steering pump toge...

Page 413: ...ition plate 8 and O ring 4 Remove capscrews 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 lightl...

Page 414: ... 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 plate 7 Remove both pressure plates 18 15 Remove outboard shaft seal 2 snap ring 21 and inboard shaft seal 20 NOTE To aid in shaft seal removal place the flange on two small wooden blocks refer to Figure 3 5 16 Use a pun...

Page 415: ...g 10 Bearing Plate 11 O Ring 12 Thru Studs 13 Steel Rings 14 Backup Ring 15 O Ring Retainer 16 Dowel 17 Isolation Plate 18 Pressure Plate 19 Plug 20 Seal 21 Snap Ring FIGURE 3 4 HOIST PUMP DISASSEMBLY FRONT SECTION 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 416: ... discard 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 ma...

Page 417: ...s 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 the snap ring opening is over the weep hole 10 8 Install the Outboard seal metal face out until it just contacts the snap ring 9 Lubricate the thru stud threads 14 Figure 3 9 with hydraulic oil Thread...

Page 418: ...Coat the inside of the gear plate and the gears with clean hydraulic oil NOTE To ensure the gear pump is correctly timed during reassembly place a mark on the end of the input shaft to indicate the location of the valley between any two gear teeth Refer to Figure 3 12 which illustrates gear pump timing 14 With the extension end of the drive gear facing toward the shaft seals install the drive gear...

Page 419: ...tion of the steel rings backup ring O ring retainer isola tion plate and pressure plate 20 Lubricate I D of bearings 18 Figure 3 14 Install O rings 8 9 and dowel 25 if removed Install gear plate 10 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 to...

Page 420: ...on on bearing plate 15 Install the assembled bearing plate and transition plate 15 16 to the connector plate 11 and secure in place with nuts 20 Tighten nuts to standard torque 26 IInstall coupling 19 27 Lubricate the thru stud threads and install two opposite stud nuts and hardened washers Tighten nuts to 240 to 250 ft lbs 325 to 339 N m torque FIGURE 3 14 HOIST PUMP REASSEMBLY 1 Drive Gear Rear ...

Page 421: ...shaft turns properly install the remaining hardened washers and nuts Tighten nuts to 240 to 250 ft lbs 325 to 339 N m torque 31 Install a new O ring on steering pump flange and install steering pump to the transition plate 16 Figure 3 14 Install capscrews and tighten to standard torque 32 Install companion flange on pump driveshaft If necessary heat to 400 to 500 F 204 to 260 C to ease installatio...

Page 422: ... 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 Removal 1 Turn keyswitch Off and allow at least 90 sec onds for the steering accumulator to bleed down Be prepared to contain approximately 238 gal 901 L of hydraulic oil If the oil is to ...

Page 423: ... lockwashers 4 securing cover to the hydraulic tank Remove and discard gasket 5 Remove capscrews and lockwashers securing suction strainers Remove suction strainers Inspect and Clean NOTE Inspect the strainers thoroughly for metallic particles and varnish build up if oil has been overheated The quantity and size of any particles may be an indication of excessive wear of components in the hydraulic...

Page 424: ...tion before actual bypass occurs The switch contacts close at 35 psi 241 kPa to actu ate a warning lamp on the overhead display panel Actual filter bypass occurs at 50 psi 345 kPa NOTE When the engine is initially started and the hydraulic oil is cold the warning lamp may actuate Allow the hydraulic system oil to reach operating temperature before using the warning lamp as an indicator to change t...

Page 425: ...Take 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 ...

Page 426: ...L3 16 Hydraulic Component Repair 7 02 L03026 NOTES ...

Page 427: ... circuit pressure The top side of the piston is pre charged to 1400 psi 9 653 kPa 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 accumulators also act as a reservoir for pressurized hydraulic oil to be used during an emergency situa tion should the hydraulic steering oil supply mal function fo...

Page 428: ...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 429: ...L04037 Steering Circuit L4 3 FIGURE 4 2 FLOW AMPLIFIER ...

Page 430: ...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 500 psi 3 447 kPa the spool moves compressing its spring and closes off...

Page 431: ...L04037 Steering Circuit L4 5 FIGURE 4 3 FLOW AMPLIFIER No Steer ...

Page 432: ... 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 433: ...L04037 Steering Circuit L4 7 FIGURE 4 4 FLOW AMPLIFIER Steering Left ...

Page 434: ... 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 to...

Page 435: ...L04037 Steering Circuit L4 9 FIGURE 4 5 FLOW AMPLIFIER Steering Right ...

Page 436: ...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 2900 psi 19 995 kPa 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 437: ...L04037 Steering Circuit L4 11 FIGURE 4 6 FLOW AMPLIFIER No Steer External Shock Load ...

Page 438: ... not individu ally rebuildable and are factory preset Refer to Steering Circuit Check Out Procedure for relief valve setting Each time the keyswitch 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 ch...

Page 439: ...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 1100 psi 7 584 kPa nitrogen precharge in the accumula tors because there...

Page 440: ...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 441: ...L04037 Steering Circuit L4 15 FIGURE 4 9 CUT AWAY VIEW OF STEERING PUMP ...

Page 442: ...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 443: ...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 444: ...L4 18 Steering Circuit L04037 NOTES ...

Page 445: ... 10 5 Clean exterior of manifold before removing any components Installation 1 Install bleed down manifold Secure in place with capscrews Tighten capscrews to standard 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 Start th...

Page 446: ... small hex nut 4 Figure 5 2 three com plete turns Remove valve cap 1 Depress the valve stem until all nitrogen pressure has been relieved 4 Disconnect electrical leads at the pressure switch located on top of the accumulator 5 Disconnect and plug the hydraulic line 3 Figure 5 4 at the bottom of the accumulator 6 Connect a lifting device to the top section of the accumulator and take up slack The a...

Page 447: ...5 5 on hydraulic port assembly Using a spanner wrench remove locking ring 10 from the hydraulic port assembly Use an adjustable wrench on the flats located on the port assem bly to prevent port assembly from rotating 3 Remove spacer 9 then push the hydraulic port assembly into the shell prior to Step 4 4 Insert hand into the accumulator shell and remove the O Ring backup 8 O Ring 7 and metal backu...

Page 448: ...e 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 all gas completely exhausted from bladder collapse bladder and fold longitudinally in a compact roll 4 Insert the bladder pull rod into the valve stem opening and out through the shell fluid port Attach the bladder pull rod to ...

Page 449: ...ll squeeze the O ring into position Use appropri ate wrench on flats on port assembly to insure the unit does not turn 18 Install bleeder plug 12 into the hydraulic port assembly 19 Precharge accumulator to 100 120 psi 690 827 kPa Refer to Steering Accumulator Charging Procedure for details After precharg ing install plastic cover over hydraulic port to prevent contamination Do not use a screw in ...

Page 450: ...ys set precharge to 100 120 psi 690 827 kPa before handling removing or installing accumulators NOTE If one accumulator is low on nitrogen it is recommended that both accumulators be checked charged at the same time 1 With engine shut down and key switch in the Off position allow at least 90 seconds for the accumulator to bleed down Turn the steering wheel to be certain no oil remains in accumula ...

Page 451: ...lbs 40 N m torque 10 Operate truck and check steering for normal operation FLOW AMPLIFIER Removal Relieve pressure before disconnecting hydraulic and other lines Tighten all connections before applying pressure Hydraulic fluid escaping 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...

Page 452: ...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 required 8 Remove capscrews 1 3 using a 10 mm and 13 mm hex head allen wrench Remove lock washers 2 4 Remove end cover 5 9 Remove O rings 6 7 8 and ...

Page 453: ...L05026 Steering Component Repair L5 9 FIGURE 5 7 FLOW AMPLIFIER VALVE ...

Page 454: ...hould O ring 2 Figure 5 9 spring 9 or orifice screw 11 require replacement otherwise replace the amplifier spool assembly as a complete unit For complete disassembly refer to steps 12 13 12 Remove retainer ring 7 Figure 5 9 remove pin 5 Remove plug 10 and spring 9 Remove retaining ring 6 and pin 4 and remove inner spool 8 13 Unthread check valve 1 and remove Remove O ring 2 Remove orifice screw 11...

Page 455: ... 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 valve spool 43 and spring 42 Install spring 55 8 Install spring control 31 springs 32 33 and spring stop 34 9 Lubricate O rings 6 7 8 with molycote grease and position on cover 5 Install end cover ...

Page 456: ...enever the steering control unit is removed for service the steering column shaft should be inspected for excessive wear 1 Thoroughly clean splines on steering column shaft and inspect for damage or excessive wear 2 Using an outside micrometer or dial caliper measure the outside diameter of the male splines on the steering column shaft Minimum diameter 0 950 in 24 13 mm 3 If splines are worn more ...

Page 457: ...screws and washers Remove capscrew with rolled pin 3 Figure 5 11 Mark hole location of capscrew with rolled pin on end cover to facilitate reassembly 4 Remove end cover 4 and O ring 2 Figure 5 12 5 Remove outer gear of gear wheel set 1 and O ring between gear set and distribution plate 6 Lift inner gear off cardan shaft 7 Remove cardan shaft 11 Figure 5 18 distribu tion plate 15 and O ring 14 8 Re...

Page 458: ... the sleeve These must be opposite each other on assembly so that the holes are partly visible through the slots in the spool refer to Figure 5 14 1 To install the neutral position springs place a screwdriver in the spool slot as shown in Figure 5 15 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 i...

Page 459: ...e 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 17 NOTE Cross pin must remain horizontal when spool and sleeve are pushed into bore to prevent pin from dropping out of spool FIGURE 5 14 NEUTRAL POSITION SPRING INSTALLATION FIGURE ...

Page 460: ...ing 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 Capscrews with Pin 23 Capscrews ...

Page 461: ...ardan 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 m...

Page 462: ...owly 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 comp...

Page 463: ... 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 syste...

Page 464: ...stallation 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 21 is factory preset to actuate at 35 psid 241 kPa When activated the switch will illuminate the amber Hydraulic Oil Filter warning lamp located on the overhead display in the operator s ...

Page 465: ... 3 Disconnect the suction and discharge lines at the steering pump 5 Figure 5 22 Disconnect and cap pump case drain line from fitting at top of pump housing Plug all lines to prevent oil contamination The steering pump weighs approximately 250 lbs 113 kgs Use a suitable lifting device capable of handling the load safely 4 Support the steering pump 5 and the rear sec tion of the hoist pump 3 Remove...

Page 466: ... capscrews at the pump to bleed any trapped air Tighten hose connection cap screws to standard torque NOTE If trapped air is not bled from steering pump possible pump damage and no output may result 13 If required top off the oil level in the hydraulic tank to the level of the upper sight glass 14 In the hydraulic brake cabinet open both brake accumulator needle valves completely to allow the stee...

Page 467: ...capscrew into the threaded end of the control link pin 16 8 Using a brass rod and hammer tap on end opposite the capscrew to remove control link pin 16 Maximum volume stop gland 14 Figure 5 23 MUST be removed BEFORE further disassembly of control piston 9 Without disturbing jam nut 16 Figure 5 23 unscrew gland 14 and remove stroke adjuster as a complete assembly Valve Plate Group NOTE Valve plate ...

Page 468: ...gs 24 can be removed by using a very short screwdriver or back hammer to pry them loose or continue to the next step for fur ther disassembly which will make their removal easier Driveshaft Group 27 Remove bearing retaining ring 3 Figure 5 23 Use a mallet on the tail shaft and tap driveshaft 1 out from the front of the pump housing 28 Remove seal retainer 21 from pump housing Use a mallet and tap ...

Page 469: ...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 470: ...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 471: ... and cra dle All shoes must be equal within 0 0001in 0 003 mm 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 24 PUMP REAR HOUSING 1 Plug 2 O Ring 3 Capscrew 4 O Ring 5 Plug 6 O Ring 7 Plug 8 Val...

Page 472: ...uc 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 Figure 5 26 22 Loosen jam nut 4 Separate stem 1 from gland 3 Remove and discard O ring 2 23 Inspect parts for damage or excessive wear 24 Install new O ring on stem a...

Page 473: ... assembly through the front of the pump housing A mallet will be required to install the driveshaft through shaft seal 2 15 Once the driveshaft assembly is fully seated within the pump housing install snap ring 3 Rotating Group 16 Mating surfaces should be greased Place cylin der assembly on clean table with the valve plate side down 17 During disassembly shoe retainer springs were referenced to i...

Page 474: ... the pump housing 36 Assemble one control link retainer ring 14 Fig ure 5 24 and one control link washer 15 onto the threaded hole side of the control link pin 16 Then thread a 1 4 in 20 UNC capscrew into pin to ease holding 37 Carefully maneuver valve plate assembly sup ported by overhead crane over driveshaft and into pump housing so slot on control piston 11 engages control link 17 38 With hole...

Page 475: ... new O ring 6 in side of com pensator block as shown in Figure 5 25 Install 0 032 in 0 813 mm diameter orifice 10 plug 7 and O ring 6 in top of block 10 Install remaining plugs with new O rings 11 Install unloader module 29 on compensator block with new O rings 25 and socket head capscrews 31 Tighten capscrews to 87 in lbs 9 8 N m torque 12 Install plugs 9 23 Figure 5 23 and O rings 10 15 in pump ...

Page 476: ...L5 32 Steering Component Repair L05026 NOTES ...

Page 477: ...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 sole noid prevents the hoist cylinders from extending to maximum physical limit A counterbalance valve in the overcenter manifold 12 prevents abrupt cylin der extension due to material...

Page 478: ...ear of the hoist pump Hoist pump output is directed to two remote mounted high pressure filters Maximum hoist pump output pressure is 2500 psi 17 2 MPa 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 permits...

Page 479: ...re vents flow from the high pressure core to the low pressure core The spool section of the hoist valve consists of the following components Two pilot ports Two main spools Two work ports Check poppets The pilot ports are located in the top spool section cover These ports provide connections for pilot lines from the hoist pilot valve Each pilot port has a corre sponding work port The work ports pr...

Page 480: ...lot port on the hoist valve is closed The hoist pilot valve raise port is opened to return to tank PILOT OPERATED CHECK VALVE The Pilot Operated Check Valve 7 Figure 7 4 is opened by power down pilot pressure to allow oil in the raise port to bypass the hoist up limit solenoid for initial power down operation while the solenoid is activated by the hoist limit switch COUNTERBALANCE VALVE MANIFOLD T...

Page 481: ...7027 Hoist Circuit L7 5 The following pages describe hoist circuit operation in the float power up hold and power down positions Refer to Figures 7 6 through 7 10 FIGURE 7 5 COUNTERBALANCE VALVE SCHEMATIC ...

Page 482: ... 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 2500 psi 17 2 MPa 2 Flow Control Valve 3 Low Pressure Relief Valve 75 psi 517 kPa 4 Counterbalance Valve 5 Rod End Work...

Page 483: ...L07027 Hoist Circuit L7 7 FIGURE 7 6 FLOAT POSITION ...

Page 484: ...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 75 psi 517 kPa causes this valve to open allowing the oil to flow out Port 10 to the tank The counterbal...

Page 485: ...L07027 Hoist Circuit L7 9 FIGURE 7 7 POWER UP ...

Page 486: ...o 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 2500 psi 17 2 MPa 2 Flow Control Valve 3 Low Pressure Relief Valve 75 psi 517 kPa 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 487: ...L07027 Hoist Circuit L7 11 FIGURE 7 8 HOLD POSITION ...

Page 488: ...e 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 75 psi 517 kPa to open the Low Pressure Relief 3 and exit the Hoist Valve through Port 10 to the tank As the body desce...

Page 489: ...L07027 Hoist Circuit L7 13 FIGURE 7 9 POWER DOWN ...

Page 490: ...sure 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 75 psi 517 kPa in the Low Pressure Passage causes oil to flow to the rod end of the cylinders 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 themselves and close the...

Page 491: ...L07027 Hoist Circuit L7 15 FIGURE 7 10 FLOAT POSITION ...

Page 492: ...L7 16 Hoist Circuit L07027 NOTES ...

Page 493: ...e 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 sep arator plate 8 Figure 8 1 located to the rear Secure in place with capscrews nuts and lock washers Tighten capscrews to sta...

Page 494: ...ench should be used to tighten the nuts in the pattern as shown in Figure 8 4 The tie rods should be tightened evenly to 160 ft lbs 217 N m torque in the following sequence a Tighten nuts evenly to 20 ft lbs 27 N m torque in order 1 4 2 3 b Tighten nuts evenly to 50 ft lbs 68 N m torque in order 1 4 2 3 c Tighten nuts evenly to 160 ft lbs 217 N m torque in order 1 4 2 3 INLET SECTION Disassembly 1...

Page 495: ...faces for nicks or excessive wear All seats must be sharp and free of nicks 3 Inspect all bores and surfaces of sliding parts for nicks scores or excessive wear 4 Inspect poppets in their respective bore for fit Poppets should move freely without binding through a complete revolution 5 Inspect fit and movement between sleeve and low pressure relief valve FIGURE 8 5 INLET SECTION DISASSEMBLY 1 Caps...

Page 496: ...ure 8 2 to accomplish spool section 3 disassembly 1 Match mark or identify each part when removed in respect to its location or respect to its mating bore to aid reassembly 2 Remove capscrews and remove spool section cover 2 Figure 8 2 Remove and discard O rings 4 5 Figure 8 8 3 Remove poppet 1 Figure 8 7 remove and dis card O ring 3 NOTE The poppet 1 is equipped with a small steel ball Do not mis...

Page 497: ...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 498: ...threads of spool end 6 Install spool end 6 and tighten to 25 ft lbs 34 N m torque Install poppet 5 Apply Dri loc 204 to the threads of plug 4 Install plug 4 and tighten to 15 ft lbs 20 N m 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 499: ...ions securely 3 Place hoist control lever in spring centered position Adjust pilot valve spool until center line 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 Thread sleeve 6 upward until contact is made with valve body Move flange 3 into position and se...

Page 500: ... 19 spring 4 and spacer 5 7 Remove relief valve 2 Figure 8 13 from the spool housing 1 8 Match mark the inlet and outlet housings in rela tionship to the spool housing to insure correct location during reassembly 9 Remove nuts 8 and 10 and remove tie rods 9 Separate the valve housings Remove O ring 11 Remove the poppet check and spring from the spool housing which are located on the outlet housing...

Page 501: ...ighten tie rod nuts to the torques shown in Figure 8 15 6 Install a new O ring 27 Figure 8 12 and wiper 26 Install seal retainer 25 7 Install spacer 5 spring seats 19 and spring 4 Thread detent pin 3 into spool 14 Slight pressure will be required to compress the detent spring Tighten detent pin 84 96 in lbs 9 11 N m torque Install spring 20 Carefully install spool into spool housing 8 Apply grease...

Page 502: ... 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 capscrew 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 cylinder to frame to prevent movement during n...

Page 503: ...t 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 capscrews Tighten capscrews to 220 ft lbs 298 N m torque Bend locking plate tabs over capscrew flats 3 Align the top hoist cylinder bearing eye with the bore of the upper mounting bracket Refer to Figure 8 16 4 Align retaining capscrew hole in ...

Page 504: ...L8 12 Hoist Circuit Component Repair L08031 FIGURE 8 18 HOIST CYLINDER ...

Page 505: ...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 12 5 in 318 mm in diameter 0 38 in 10 mm thick with a 0 56 in 14 mm hole in the center Align the disc over the second 2 and first 3 stage cylinders...

Page 506: ...ously been tack welded a Check the quill for tightness by using special tool SS1143 Figure 8 19 and applying a tightening torque of 1000 ft lb 1356 N m b If the quill moves remove quill clean threads in cover assembly and quill and reinstall using the procedure in Quill Instal lation 5 When a cylinder assembly is dismantled the capscrews 7 Figure 8 18 should be checked carefully for distress and i...

Page 507: ...ads 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 1000 ft lbs 1356 N m 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 t...

Page 508: ...eat 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 ...

Page 509: ... oil and lower the rod into the housing NOTE A cushion ring 24 can be added to hoist cylinders even if one was not removed during disassembly 9 Rotate housing 180 to position the cover end at the top Remove retainer installed in Step 6 Install bearings 17 and seal 16 on the rod bearing retainer 6 10 Thread two guide bolts 4 in 100 mm long in the end of the rod 1 Install seal 8 on the end of the ro...

Page 510: ...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 511: ...the hoist control lever to power up and then release it to place the hoist pilot valve in the HOLD position leave in this position during entire procedure 4 Start the engine on the good truck place the hoist control in the power down position and increase engine RPM to high idle to dump the disabled truck If the body of the disabled truck fails to raise increase the good truck power down relief pr...

Page 512: ...L8 20 Hoist Circuit Component Repair L08031 NOTES ...

Page 513: ...en The shut off valves are open when the handles are in line with the hose NOTE Serious pump damage will result if all shut off valves are not completely open when the engine is started 4 If the pump has just been installed on the machine and prior to starting the engine bleed air from inside pump to make sure the steering pump crankcase is full of oil To Bleed Air From Pump a With the engine Off ...

Page 514: ... 345 kPa Tighten jam nut Note The critical pressure adjustment is the unloader valve reload pressure The pressure at which it unloads is not adjustable separately but will follow the reload pressure adjustment Leakage Check To check for worn piston pump measurement of the leakage can be made from the case drain while the pump is under pressure 1 Disconnect steering pump drain line from the hydraul...

Page 515: ...ief pres sure a Remove steering relief valve external plug using an 8 mm metric allen wrench Refer to Figure 10 3 b Gently bottom out the steering relief valve using a 5 mm metric allen wrench Refer to Figure 10 3 for relief valve location 4 Check flow amplifier shock suction valve pres sure Pressure check can be accomplished by steering away from steering cylinder stops then steering into stop an...

Page 516: ...eakage is 50 in 3 820 ml per minute If leakage is excessive replace flow amplifier f Shut down engine turn keyswitch Off and wait 90 seconds for the steering accumulator to bleed down g Remove test equipment and reconnect all hoses to their proper location Bleeddown Manifold 3 Disconnect hoist pilot valve return line 15 Fig ure 10 4 Plug the port on bleeddown manifold Hydraulic tank oil level is a...

Page 517: ...Relief Valve 500 psi 6 Flow Amplifier 7 Feedback Pressure to Unloader Valve 8 Check Valve 9 Relief Valve 4000 psi 10 Bleeddown Manifold Valve Assembly 11 Tank Return Line 12 Supply From Filter 13 Check Valve Piloted 14 Supply to Flow Amplifier 15 Hoist Pilot Valve Return to Tank 16 Brake System Supply 17 Return From Flow Amplifier FIGURE 10 4 BLEEDDOWN MANIFOLD ...

Page 518: ...orrect 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 ...

Page 519: ...tion 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 o...

Page 520: ...ace 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 Cont...

Page 521: ...egular 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...

Page 522: ...rifice 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 Repl...

Page 523: ...L10016 05 03 Hydraulic Check out Procedure L10 11 FIGURE 10 5 FLOW AMPLIFIER VALVE ...

Page 524: ...ver in power up position and hold until body is in the full raised position Pressure at both hoist pumps should be 2500 100 psi 17 237 690 kPa NOTE Each hoist pump section supplies oil to a separate inlet section on the hoist valve Each inlet section on the hoist valve contains a power up relief valve If the either relief pressure is not within specifications adjust or replace the respective relie...

Page 525: ...relief pressure is not within speci fications 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 components cabinet located behind the c...

Page 526: ...d by the counterbalance 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 3000 psi 20 7 MPa or above stop hoisting immediately Pressure is adjusted too ...

Page 527: ... 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 th...

Page 528: ...n the 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 rep...

Page 529: ... other 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...

Page 530: ...ake cabinet behind cab 11 Restart engine and run at 1000 RPM while per forming the following a Steer truck full left then full right repeat four times b Steer full left keeping pressure against the steering wheel and hold for 10 seconds c Steer full right keeping pressure against the steering wheel and hold for 10 seconds 12 Increase engine speed to full throttle and steer full left and full right...

Page 531: ... 1 Fuel Receiver M5 2 ENGINE COOLANT HEATER M07001 M7 1 Heating Element M7 1 Thermostat M7 2 SPECIAL TOOL GROUP M08005 M8 1 HEATER AIR CONDITIONING SYSTEM M09010 M9 1 Environmental Impact M9 1 General Information M9 2 Principles of Refrigeration M9 2 Air Conditioner System Components M9 4 Electrical Circuit M9 6 System Servicing M9 8 Service Tools and Equipment M9 11 Manifold Gauge Set M9 13 Syste...

Page 532: ...NOTES M1 2 Index M01047 ...

Page 533: ...ng either actuator will activate fire con trol system Inspection and Maintenance It is imperative that the fire control system is inspected at least every six months To insure that it will operate effectively 1 Check the system for general appearance me chanical damage and corrosion 2 Inspect each chemical tank fill cap gasket for damage and replace if necessary Examine cap for nicks burrs cross t...

Page 534: ... toward ex tinguisher 5 Fill tank with dry chemical to not more than three inches 76mm from thebottom ofthefill opening 6 Inspect fill opening threads and gasket If neces sary clean threads 7 Install the fill cap and tighten the cap hand tight 8 Remove the cartridge guard from the dry chemical tank and remove the cartridge 9 Insure that the cartridge puncture pin is fully re tracted 10 Weigh thene...

Page 535: ...accumu lators have bled down 1 Install 0 2000 psi 0 14 MPa gauge in tee where motor supply line connects to line routed to relief valve 2 Remove line from tee to motor and plug 3 Install cap on tee 4 Loosen jam nut on circuit relief and back out relief adjusting screw 5 Start engine and slowly increase engine speed to high idle while observing gauge There is no directional control valve in this ci...

Page 536: ...STEM 1 Air Filter Assembly 2 Mounting Hardware 3 Scavenge Tubing Elbow 4 Relief Valve 5 Hydraulic Motor 6 Blower Discharge 7 Evacuation Blower 8 Electrical Control Cabinet M4 2 Alternator and Wheelmotor Cooling Air Filter System M04002 12 89 ...

Page 537: ...wear plate face 4 2 Install wear plate 4 on rear cover bronze side toward gears 3 Position center section on rear cover wear plate 4 Install idler and drive gears 6 7 5 Install front wear plate 9 bronze against gears Install seal retainer 3 and seal gland 2 90191 FIGURE 4 2 HYDRAULIC PUMP 1 Rear Cover 2 Seal 3 Seal Retainer 4 Rear Wear Plate 5 Notch 6 Driver Gear 7 Drive Gear 8 Center Section 9 Fr...

Page 538: ...s Tighten outlet split flange to standard torque 5 With suction hose loose temporarily pressurize the hydraulic tank with 15 psi 103 kPa regulated air pressure Be sure oil is present at pump Tighten suction line split flange capscrews to standard torque BLOWER DRIVE MOTOR Before removing hydraulic lines from motor be sure steering accumulators are completely bled down Turn steering wheel to check ...

Page 539: ...traight up off gear journals 6 Remove O ring 16 pressure balance O ring 11 and back up ring 12 7 Remove pressure plate 17 Remove O rings 10 from journal bores of pressure plate 8 Lift drive gear 1 and idler gear 6 straight up out of gear plate 9 Tap edges of gear plate 9 with mallet or plastic hammer to loosen If gear plate does not move by this method lift the plates up off work bench slightly an...

Page 540: ...embly 1 Using an arbor press press the new seal 3 Figure 4 4 into flange bore a Center the seal over the seal bore with metal face of the seal facing out b Make sure the seal is started and pressed straight into the bore c Place a socket wrench having an O D just slightly smaller than seal bore against seal d Press against socket and press seal in until seal has just cleared snap ring groove in se...

Page 541: ...ten set screw of flex cou pling to 65 ft lbs 88 N m torque 2 Install motor mounting capscrews tighten to standard torque 3 Connect all hoses tighten split flange capscrews to standard torque BLOWER BEARING REPAIR Removal 1 Remove blower inlet and outlet hoses 2 Loosen setscrew in flex coupling 3 Figure 4 3 on blower wheel shaft 3 Remove all nuts washers and capscrews securing housing halves Remove...

Page 542: ...move nuts from first two taper head capscrews Repeat Step 3 Tighten flex coupling setscrews to 65 in lbs 7 35 N m torque 5 Slide blower wheel onto key and shaft Tighten both setscrews to 65 in lbs 7 35 N m torque 6 Install inlet half of blower housing and tighten nuts to standard torque 7 Rotate shaft by hand to insure wheel rotates freely 8 Install inlet duct hose and clamp 9 Install outlet hose ...

Page 543: ...rom tank breather valve or tank does not completely fill check breather valve to see that float balls are in place and outlet screen is clean If valve is operating properly the problem will be with the fuel supply system FIGURE 5 1 FUEL TANK BREATHER RECEIVER INSTALLATION 1 Fuel Tank 2 Breather Valve 3 Fuel Receiver 4 Fuel Level Gauge NOTE This Illustration Represents a Typical Installation Fuel t...

Page 544: ...rts If valve body or springs are damaged replace complete breather valve 2 Install in order tapered spring one steel ball one cork ball and one hollow aluminum ball 3 Engage three coils of spring on small end of valve stem with hollow aluminum ball 4 Install valve into housing 5 Place steel ball 8 on top of valve Install spring 7 6 Place cover 6 over spring Screw on large nut 5 7 Install screen an...

Page 545: ...ve to see that float balls are in place and outlet screen is clean If valve is operating properly the problem will be with the fuel supply system FIGURE 5 3 LEFT SIDE FILL 1 Hydraulic Tank 3 Frame Rails 5 Filler Cap 7 Refueling Box 2 Filler Hose 4 Fuel Tank 6 Receiver Assembly 8 Capscrew 9 Tapped Bar NOTE This Illustration Represents a Typical Installation Installation may vary depending on truck ...

Page 546: ...NOTES M5 4 Wiggins Quick Fill Fuel System M05002 10 96 ...

Page 547: ...sen three capscrews 7 Figure 5 1 and re move vent housing 1 3 Remove filter 3 4 Compress the spring 12 Figure 5 1 and remove the cotter pin 17 5 Remove the retaining washer 16 spring and balls 13 14 and 15 Inspection 1 Inspect filter and clean or replace as required 2 Clean all parts thoroughly and inspect for damage Assembly 1 Assemble using new O ring seals 2 Install filter 3 and housing 1 3 Ins...

Page 548: ...es not fill completely check breather to see that the balls are in place and the filter is clean 91493 FIGURE 5 2 FUEL TANK BREATHER AND RECEIVER INSTALLATION 1 Breather Valve 2 Fuel Tank 3 Fuel Receiver 4 Fuel Level Gauge NOTE This Illustration Represents a Typical Installation Fuel tank may vary in size shape and location depending on truck model M5 2 Buckeye Quick Fill Fuel System M05003 5 90 ...

Page 549: ...tions 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 termi nals and check for operating voltage 220 to 230 volts while coolant temperature is below 120 F 48 C If correct voltage is present the heating element ...

Page 550: ...ot 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 with two setscrews 2 Connect the electrical leads 3 Move cover into position and secure in place with ...

Page 551: ...g Kit Suspension Accumulator Nitrogen Charging PART NO DESCRIPTION USE TY2930 Roll Out Assembly Power Module Removal Installation PART NO DESCRIPTION USE TG1106 Eye Bolt 75 10 UNC Misc lifting requirements WA4826 Eye Bolt 1 25 7 UNC M08005 7 02 Special Tools M8 1 ...

Page 552: ...E TZ3535 Offset Box End Wrench 1 1 2 Miscellaneous PART NO DESCRIPTION USE TZ2734 3 4 Female Adapter Torque Wrench Extension PART NO DESCRIPTION USE TZ2733 Tubular Handle Use with TZ3535 TZ2734 M8 2 Special Tools M08005 7 02 ...

Page 553: ...nstallation Tool Installation of Front Wheel Bearing Face Seals PART NO DESCRIPTION USE TZ0992 Alignment Sleeve Rear Suspension And Anti sway Bar Installation TY4576 Alignment Sleeve Steering Linkage Assembly M08005 7 02 Special Tools M8 3 ...

Page 554: ...5 766 PART NO DESCRIPTION USE ED8860 w Adapter Plate Engine Turn over Tool for MTU DDC 4000 Series Engine To Rotate Engine Crankshaft NOTE To use the MTU engine turn over tool for the MTU DDC 4000 Series Engine it must be used with the locally made Adapter Plate as shown here Remove screen cover plate on the bottom of the engine flywheel housing at the 5 or 7 o clock position Install assembly and ...

Page 555: ...o separate front wheel spindle from suspension piston KC7091 Pusher Capscrews 1 12 x 7 in Use for 830E AFE 32 ONLY WA0365 Hardened Flat Washers 1 12 in KC7095 Pusher Capscrews 1 25 x 8 in Use for 830E AFE 50 ONLY WA0366 Hardened Flat Washers 1 25 in M08005 7 02 Special Tools M8 5 ...

Page 556: ...NOTES M8 6 Special Tools M08005 7 02 ...

Page 557: ...ting factor of the Ozone depletion Consequently legislative bodies in more than 130 countries have mandated that the production and distribution of R 12 refrigerant be discontinued after 1995 Therefore a more environmentally friendly hydro flouro carbon 1 Blower Switch 2 Thermostatic Switch 3 Battery Supply 4 Circuit Breaker 5 Blower 6 Temperature Sensor 7 Evaporator 8 Expansion Valve 9 Suction Li...

Page 558: ...cted in the con denser evaporator or air filters decreases the system s cooling capacity The compressor condenser evaporator units hoses and fittings must be installed clean and tight and be capable of withstanding the strain and abuse they are subjected to on off highway vehicles Equipment downtime costs are high enough to encourage service areas to perform preventative maintenance at regular int...

Page 559: ...e and temperature changes The compressor refrigerant pump takes in low pres sure heat laden refrigerant gas through the suction valve low side and as its name indicates pressurizes the heat laden refrigerant and forces it through the dis charge valve high side on to the condenser Ambient air passing through the condenser removes heat from the circulating refrigerant resulting in the con version of...

Page 560: ...icle movement The radiator 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...

Page 561: ...n the evaporator NOTE It is important that the sensing bulb if present is tight against the output line and protected from ambient temperatures with insulation tape EVAPORATOR The evaporator cools and dehumidifies the air before it enters the cab Cooling a large area requires that large volumes of air be passed through the evaporator coil for heat exchange Therefore a blower becomes a vital part o...

Page 562: ...st thermostats have a positive OFF position as a means to turn the clutch OFF regardless of temperature The bellows type thermostat has a capillary tube con nected to it which is filled with refrigerant The capillary tube is attached to the bellows inside of the thermostat Expansion of the gases inside the capillary tube exerts pressure on the bellows which in turn closes the con tacts at a predet...

Page 563: ...ce temperature has a direct effect on pres sure if 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 disen gages the compressor clutch if system pressure rises above the 300 350 psi range After sys tem pr...

Page 564: ...transporting In addition technicians servicing AC systems must be certified they have been properly trained to service the sys tem Although accidental release of refrigerant is a remote possibility when proper procedures are fol lowed the following warnings must be observed when servicing AC systems Provide appropriate protection for your eyes gog gles or face shield when working around refriger a...

Page 565: ...compressor can be a result from not only a lack of oil but from too much oil also A lack of oil will cause excess friction and wear on moving parts Excessive oil can result in slugging the compressor This condition occurs when the compressor attempts to compress liquid oil as opposed to vaporized refriger ant Since liquid cannot be compressed damage to internal parts results Replacing Oil After Se...

Page 566: ...e wear or damage to air conditioning system components and poor cooling performance REFRIGERANT QUANTITY If not enough refrigerant is charged into the system cooling ability will be diminished If too much refrigerant is charged into the system the system will operate at higher pressures and in some cases may damage system components Exceeding the specified refriger ant charge will not provide bett...

Page 567: ...frigerant from an AC system prior to servicing Mixing different types of refrigerant will damage equipment Dedicate one recovery recycle station 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 ...

Page 568: ...ervice ports on 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 9 6 is used to c...

Page 569: ... side hoses The 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 refrigerant 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 incl...

Page 570: ...all the way turn them clockwise 2 Check the hose connections on the manifold for tightness 3 Locate the low and high side system service fit tings and remove their protective caps 4 Connect the two service hoses from the manifold to the correct service valves on the compressor as shown in Figure 9 8 High side to compressor discharge valve and low side to compressor suc tion side Do not open servic...

Page 571: ... and low sides The center hose also requires a valve The initial purging is best accomplished when con nected to recovery or recycle equipment With the center hose connected to the recovery station ser vice hoses connected to the high and low sides of the system we can begin the purging The manifold valves and service valves should be closed Activat ing the vacuum pump will now pull any air or moi...

Page 572: ...ting 1 Start engine and operate at 1200 to 1500 RPM 2 Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize 3 Place a thermometer in air conditioning vent clos est to evaporator 4 Evaluate the readings obtained from the gauges to see if they match the readings for the ambient temperature As preliminary steps to begin checkout of the system perform the follow...

Page 573: ...enough to find most leaks If the system is empty connect the manifold gauge set to the system and charge at least 3 5 lbs of refrigerant into the system Use extreme caution when leak testing a system while the engine is running In its natural state refrigerant is a harmless color less gas but when combined with an open flame it will generate toxic fumes phosgene gas which can cause serious injurie...

Page 574: ...hoses be sure to use the same type and ID hose you removed When hoses or fittings are shielded or clamped to prevent vibration damage be sure these are in position or secured Lines Always use two wrenches when disconnecting or con necting AC fittings attached to metal lines You are working with copper and aluminum tubing which can kink or break easily When grommets or clamps are used to prevent li...

Page 575: ...mpressor Clutch Clutch problems include electrical failure in the clutch coil or lead wire clutch pulley bearing failure worn or warped clutch plate or loss of clutch plate spring tem per Defective clutch assembly parts may be replaced or the whole assembly replaced If the clutch shows obvious signs of excessive heat damage replace the whole assembly The fast way to check electrical failure in the...

Page 576: ...tiple groove pulleys Use the proper tools to remove and replace clutch components Using the recommended tooling helps prevent damage to compressor components during maintenance Do not drive or pound on the clutch plate hub assembly or shaft Internal damage to the com pressor may result 1 Remove the belt guard from the front of the air conditioning compressor 2 Remove the drive belt from compressor...

Page 577: ...ompressor 5 Remove square key 1 Figure 9 13 from the key ways 6 Inspect the friction surface on the clutch hub and the friction surface on the pulley Scoring on the friction surfaces is normal DO NOT replace these components for this condition only Inspect the steel friction surface on the clutch and ensure that it is not damaged by excessive heat Inspect the other components near the clutch for d...

Page 578: ... should be as follows 68 F 20 C 12 0 37 ohms 239 F 115 C 16 1 0 62 ohms If the resistance of the coil is not within the specifica tions the clutch will not operate properly Remove the retaining ring and replace the coil PULLEY INSTALLATION 1 Place the pulley assembly into position on the compressor Use bearing installer 1 Figure 9 17 universal handle 2 and a hammer to lightly tap the pulley assemb...

Page 579: ...ion sur face Refer to Figure 9 19 NOTE The outer threads of installer J 9480 01 are left handed threads 5 IInstall locknut 4 Figure 9 10 and tighten the nut until it seats The gap should now measure 1 02 0 043 mm 0 040 0 017 in If the gap is not within the specification check for proper installa tion of the square key 10 Install the drive belt onto the compressor Ensure that the proper tension on ...

Page 580: ...t as per the manufacturer s instructions 7 Continue extraction until a vacuum exists in the AC system 8 If an abnormal amount of time elapses after the system reaches 0 psi and does not drop steadily into the vacuum range close the manifold valves and check the system pressure If it rises to 0 psi and stops there is a major leak 9 Check the system pressure after the recovery equipment stops After ...

Page 581: ... use the air conditioning compressor as a vac uum pump or the compressor will be damaged NOTE Lower the vacuum requirement one inch for every 1000 feet above sea level at your location 1 With the manifold gauge set still connected after discharging the system connect the center hose to the inlet fitting of the vacuum pump as shown in Figure 9 10 Then open the low side hand valves to maximum 2 Open...

Page 582: ...hen using refrigerant as a liquid never add more than two thirds of system requirements as a liquid Finish charg ing the system using gas The proper method for charging refrigerant into a R 134a system is to first recover all of the refrigerant from the system The charging refrigerant should then be weighed on a scale to ensure the proper amount is charged into the system Most recovery units inclu...

Page 583: ...r correct cooling sys tem operation Inspect the radiator hoses heater hoses clamps belts water pump ther mostat and radiator for condition or proper operation Radiator Shutters Inspect for correct operation and controls if equipped Fan and Shroud Check for proper operation of fan clutch Check installation of fan and shroud Heater Water Valve Check for malfunction or leaking System Ducts and Doors ...

Page 584: ...be extremely hot 6 Feel the hoses and components on the low side They should be cool to the touch Check connec tions near the expansion valve inlet side should be warm and cold cool on the outlet side 7 If these conditions are met the system is consid ered normal Shut down engine Remove gauges and install the caps on the service valves DIAGNOSIS OF GAUGE READINGS SYSTEM PERFORMANCE The following T...

Page 585: ...ressure sensing switch 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 refriger...

Page 586: ...leaks especially around the compressor shaft seal area When the leak is found recover refrigerant from the system and repair the leak Replace the receiver drier or accumulator because the desiccant may be saturated with moisture Check the compressor and replace any refrigerant oil lost due to leakage Evacuate and recharge the system with refrigerant using a scale Check AC operation and performance...

Page 587: ... carefully spray 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 expans...

Page 588: ...ng for a few minutes 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 sh...

Page 589: ...nt are found in the compressor flushing of the system will be required It will also be necessary to replace the receiver drier Always check the oil level in the compressor even if a new unit has been installed Rotary compressors have a limited oil reservoir Extra oil must be added for all truck installations Tighten all connections and evacuate the system Recharge the system with refrigerant using...

Page 590: ...nd there is adequate 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 AC 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 ...

Page 591: ...olts Check clutch alignment w crankshaft pulley within 0 06 in Perform manifold gauge check 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 damage 3 Receiver Drier Check inlet line from con denser should be hot to touch Replace if system is opened COMPONENT Maintenance...

Page 592: ...M9 36 Air Conditioning System 05 02 M09010 for HFC 134a Refrigerant NOTES ...

Page 593: ...This valve reduces the steering circuit pressure 3500 psi 24 132 kPa to 1500psi 10 342 kPa The pressure is further reduced to 75 psi 517 kPa by the pressure reducing valve 4 which supplies the shutter solenoid valve 5 to pressurize the head end of the shutter actuator cylin der 11 closing the shutters during engine warm up When the shutters are signalled to open the solenoid valve will be de energ...

Page 594: ...o energize relay K5 on relay board 6 to energize it and close the N O contacts to provide 24VDC from relay K3 to the shutter control solenoid when the key switch is ON and the shutter enable switch is closed After the coolant temperature has reached the proper operating temperature the ECM will open the ground circuit 563M and de energize relay K5 opening the N O contacts and removing 24VDC from t...

Page 595: ...iator Shutters M19 3 FIGURE 19 3 ELECTRICAL HOOKUP AND SCHEMATIC 1 Shutter Solenoid Valve 2 Shutter Enable Disable Switch 3 Relay K5 4 Relay Board 6 5 Relay K3 6 Electrical Cabinet 7 Junction Box Rear of Cabinet ...

Page 596: ...M19 4 Radiator Shutters M19002 NOTES ...

Page 597: ... 0 1 0 2 3 3 1 1 3 4 5 1 4 6 6 1 6 6 1 6 6 1 7 18 1 9 1 1 1 0 1 1 1 4 4 3 3 4 7 7 4 3 8 8 3 ...

Page 598: ... 3 3 4 1 1 6 6 6 6 6 0 0 2 2 0 1 0 0 3 3 7 3 6 6 7 7 8 1 1 4 2 4 1 1 51 1 3 1 1 1 1 ...

Page 599: ... 5 4 1 6 1 1 1 4 1 1 4 1 1 1 4 1 3 1 4 6 1 4 4 2 54 0 3 1 3 3 3 6 1 2 0 1 0 0 3 1 1 3 A ...

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Page 601: ... 1 B 0 C 8 D B 3 0 C 8 8 8 I 8 6 J 8 D I 8 8 D 0 8 8 K 8 8 8 8 3 6 B 0 C B C J 0 1 8 J L 0L 0 D D 1 ...

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Page 603: ...3 1 0 8 0 D 0 8 0 8 0 8 4 0 8 D D 0 0 0 8 0 8 0 8 8 0 0 8 8 8 8 8 8 8 0 L 0 0 L 1 8 0 0 0 L 8 8 4 D 8 8 8 0 0 N N 0 6 N 6 N 0 N N 6 N N 0 0 8 N ...

Page 604: ... 1 0 8 D 1 4 J D 7 1 L 8 6 0 8 0 8 3 1 3 N 8 3 1 0 N 3 1 ...

Page 605: ...6 8 L 0 D J J D J D 1 E F O F O F O F O 1 F O1 F O F O1 F O F O 1 D D 0 4 8 J D 0 6666 E P 1 Q P Q P Q P 1 Q L P Q P 1 Q L 3 P Q P 1 Q L 6 P Q P 1 Q D 8 1 0 0 8 5 D D 8 F 8 P 1 Q ...

Page 606: ... 1 8 F 8 1 P 1 Q 1 E P 1 Q P Q 0 8 0 8 8 8 8 D 0 D 8 0 D B C 8 0 D 0 O 8 0 0 8 D D 8 D F 1 D P 1 Q F D P 1 Q F 1 D P 1 Q F D P 1 Q F 0 D P 1 Q D 0 1 D 6 D D 1 D 8 D ...

Page 607: ...1 8 K 3 8 R N D RH D D N 8 D R R 4 RH D 8 0 B CD 0 8 RH 0 RH D 0 0 D H D H N 0 0 0 8 N 0 0 D R 8 0 8 8 H 0 8 8 H 0 8 B C RH 8 D R R D D 4 RH 8 0 B CD 0 8 RH 8 0 8 RH D 8 D 8 R R 0 R D E 8 N D 8 0 8 B C RH R R ...

Page 608: ... 8 N D 0 R R 8 N D RH 0 8 0 8 0 0 0 0 4 8 0 D 0 N D G 0 8 S 3N D 8 0 1 D 0 8 0 1 8 0 0 D 8 8 D 0 8 0 8 8 D 0 D 0 8 0 8 D 0 D 0 1 0 D D 8 0 ...

Page 609: ... 1 8 0 8 8 7 8 8 8 8 0 3N 0 0 0 8 4 1 8 D 8 0 8 0 1 8 1 4 D 3 1 4 D 8 D 8 T D 63 8 8 ...

Page 610: ...0 12 0 0J 0 L 0 3 D 8 D 8 D 8 4 D 6 0 0 RH 0 8 RH 0 1 1 8 D RH 0 8 1 8 D RH 0 1 1 8 8 1 0 0 1 0 0 0 8 8 0 8 5 0 0 D 8 0 8 8 0 8 G 0 0 D 8 0 0 0 0 0 0 0 0 0 0 8 0 0 0 0 0 0 8 8 8 1 E ...

Page 611: ... 3 4 0 D 8 8 2 0 8 N 0 8 0 1 0 0 0 1 0 0 1 0 2 R R 2 3 0 D 2 8 0 0 8 2 D 323 4 0 0 23 0 D 0 N 2 3 8 0 ND 8 52 3 0 8 2 0 8 8 2 8 4 1 D 0 0 ...

Page 612: ... 2 R R R 0 8 2 8 4 D 8 8 0 8 8 8 8 8 3 6 0 8 8 8 0 8 0 0 8 G 8 D D 0 D 8 8 8 8 0 7 23 1 U 1 V U V 1 U 1 V 3 U V 6 8 V 8 8 U 8 8 8 0 3 0 0 0 1 D 3 D ...

Page 613: ...3 8 8 0 8 8 8 E F 1 0 F 0 1 F 1 F H D 0 8 0 0 D 0 0 D D 0 8 0 1 0 8 0 0 8 E F 1 F F 9 F 0 F 0 F B C 8 D H 8 8 8 D D 2 H 1 8 ...

Page 614: ... 1 1 0 0 D 0 8 8 0 0 H 0 D D D D 8 D D 0 8 8 0 0 8 8 D E D 8 0 8 ...

Page 615: ...6 D 0 P Q D 0 8 D 0 8 8 D D E D D 2 D E 8 O E E 8 O F 0 0 F 0 0 F 8 F 8 F 8 8 8 D 8 8 F 8 8 8 F 1 7 8 0 ...

Page 616: ... 8 8 D 1 G J 4 D 0 F 6 0 1 1 0 0 4 D 8 8 D 1 8 8 D 8 D 0 6 E 0 8 8 8 E 0 8 8 8 ...

Page 617: ... 0 D 0 8 L 0 B 0 C B C 8 0 D 8 3 0 0 8 0 0 D 0 8 0 0 0 8 0 0 1 0 0 D 0 8 0 2 2 2 0 D 8 0 8 2 2 0 D 8 ...

Page 618: ... 0 8 0 0 0 8 0 D D 0 0 8 D 0 8 0 0 8 D 1 0 D 0 0 8 8 0 0 8 D 1 0 D 4 0 0 0 D P Q 0 8 0 0 D 4 0 0 0 D P Q 8 8 ...

Page 619: ... 7 0 D D D D 0 0 9 0 D D 0 8 0J D 0 0 0 0 0 0 0 4 D 0 0 D 0 0 3 D 3 0 H 0 2 0 0 8 0 D 6 0 ...

Page 620: ...6 D P Q P Q D 8 0 3 T D E 0 3 0 P Q T D P Q T D 8 8 E E E 8 0 3 T D T D E 0 3 0 P Q T D P Q T D P Q E P Q E 8 T T D E E T T E B E C E B E C D 6 E 21 1 2 2 1 2 2 2 1 2 7 2 172 5 7 5 A 7 5 7 5 B 7 5 7 9 2 9 ...

Page 621: ... 8 8 P Q D 0 8 D 0 3 T D E E 9 2 2 1 2 7 2 17 2 5 7 5 A 7 5 7 5 B 7 5 7 9 2 21 1 21 2 2 9 ...

Page 622: ... E H D D D D D D D D ...

Page 623: ...3 1 0 H H T 0 D P Q D 0 3 T D E E 9 P Q 1 7 8 7 8 8 8 P Q H 8 7 H F P 7Q F PK Q 8 7 7 0 1 8 D 7 ...

Page 624: ... D E F 0 F F F F F F 4 F 0 F F F F 1 F 1 F 1 F F 1 F F 1 F F 1 F F F F I F I F F F F F 1 0 F 0 F 8 0 F F 8 D3 E 8 8 1 F 8 E 8 8 L 0 8 D E F F F F F F 8 0 0 ...

Page 625: ...6 8 4 2 D A K 0 8 0 0 D P Q 0 H D H D P Q D H 8 0 ...

Page 626: ... D 0 P Q 8 8 D P Q D PH Q 8 0 ...

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Page 628: ... 2 2 0 4 5 1 1 4 4 1 1 3 3 3 3 7 4 3 1 3 2 2 3 23 0 8 9 4 A 8 9 4 4 4 4 4 0 2 4 4 B 4 4 4 ...

Page 629: ... 4 4 4 ...

Page 630: ...7 0 1 C 2 70 70D 4 0 4 C 2 4 8 9 ...

Page 631: ...0 4 4 8 5 E 9 ...

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Page 633: ...A 2 4 8 4 4 3 5 F 4 0 4 C 2 4 ...

Page 634: ... 3 0 5 3 6 3 ...

Page 635: ...I 4 F 4 4 4 ...

Page 636: ...7 0 7 7 7 C 2 I1 2 7 C 2 7 1 7 I ...

Page 637: ...7 4 0 7 7 7 C 2 I1 2 7 C 2 7 J 7 ...

Page 638: ...7 5 6 0 7 7 7 C 2 I1 2 7 C 2 7 J 7 ...

Page 639: ...7 7 8 0 7 7 7 C 2 I1 2 7 C 2 7 J 7 ...

Page 640: ...77 9 0 I1 0 0 C 2 7 ...

Page 641: ...70 5 4 0 K 4 ...

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Page 649: ... D D 0 4 D 4D 0 E F G G H G 9 0 G G 2 G G D D E 2 3 G G D D I 4 4 4 5 3 4 6 5 G G D D I ...

Page 650: ...2 4 4 5 3 4 6 5 D D D D D D D D D 7 D 7 2 1 3 A 1 2 3 7 2 6 E D D 7 D J D D D 6 0 6 0 D D 6 0 D D D 9 0 D D 0 D E D 4 0 D D 0 D E D 7 0 D D 0 D E D 0 D 2 E 1 2 I 3 1 3 0 C 2 7 2 7 8 5 62 4 62 6 ...

Page 651: ...2 8 5 6 6 6 22 8 5 6 4 6 2 8 5 6 6 6 2 2 D D 2 D 4 4 D K G 0 G 0 G 7 G 7 2 0 9 6 D D L 8 9 9 7 19 39 9 9 1 2 9 739 92 4 D D D M6 5 N 6 6 2 ...

Page 652: ... 2 67 D D 5 4 M6 5 N 2 M6 5 N DI D 5 2 6 OI M6 P 4 I ...

Page 653: ... A 0 A E 0 7 0 7 7 7 9 4 7 6 0 6 E E 7 0 ...

Page 654: ...0 1 0 9 2 4 7 7 7 E 7 0 4 9 4J0 4 4 E7 9 J 47 4 E 4 E7 E 7 0 7 09 49 6E E 2 2 ...

Page 655: ...nup Extend oil change intervals The normal supply system capacity of oil carried in the reserve tank is roughly equivalant to the volume in the engine In the process of continuous adjustment of the engine oil level there is a constant circulation 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 usua...

Page 656: ...ivates Pump 2 which returns oil from the 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 continu ously adjusted at the control point by alternating 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 M...

Page 657: ...ed push pull POWER ON switch that powers the fill sys tem The 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 pressure s...

Page 658: ...gnal 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 2 Every 500 Hours a Change all engine and system filters if appli cable b More system failures result from bad electrical connections than all other causes combined Check electrical system connections for tight ness corrosion and physical dama...

Page 659: ...erify by loosening the hose at pump 1 outlet to verify that oil is coming through pump 1 is marked by a groove 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 re...

Page 660: ...ne Oil Pressure Switch 3 Engine Subframe 4 15 Amp Circuit Breaker 5 Power Supply 6 Auxillary Box FIGURE 31 4 SYSTEM SCHEMATIC FIGURE 31 5 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 661: ...ent N2 12 Glass Replacement N2 13 Adhesive Bonded Windows N2 13 Windshield and Rear Glass N2 14 CAB COMPONENTS N3 1 Windshield Wiper N3 1 Windshield Washer N3 3 OPERATOR COMFORT N4 1 OPERATOR SEAT N4 1 Adjustment N4 1 HEATER AIR CONDITIONER COMPARTMENT AND CONTROLS N4 2 Heater Components N4 3 Filter N4 4 OPERATOR CONTROLS AND EQUIPMENT N5 1 STEERING WHEEL AND CONTROLS N5 2 Steering Column N5 2 PED...

Page 662: ...N1 2 Index N01031 INSTRUMENT PANEL AND INDICATOR LIGHTS N5 10 Control Symbols N5 10 INSTRUMENT PANEL N5 11 Panel Gauges Indicators and Controls N5 12 OVERHEAD STATUS WARNING INDICATOR LIGHTS N5 16 ...

Page 663: ...ring 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 modification or repairs are required contact the servicing Komatsu Distributor...

Page 664: ...al 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 venting air condi tioning system refrigerants into the atmosphere An approved recovery re...

Page 665: ... tighten securely Install clamps if removed during cab removal 4 Remove caps from hydraulic hoses and tubes and reinstall Reinstall hose clamps as required 5 Install heater hoses and clamps on fittings on underside of cab Connect other end of hose to fittings at shutoff valves on engine Open heater shutoff valves Connect air cleaner restriction indicator hoses 6 Remove caps and reinstall air condi...

Page 666: ...cab 2 Align door hinges with cab and install capscrews securing door to cab 3 Attach the travel limiting strap with the bolt and clip removed previously 4 Reconnect door harness to receptacle mounted in the cab floor 5 Verify proper operation of power window and door latch adjustment 6 Install door panel Door Adjustment If adjustment is necessary to insure tight closure of door loosen striker bolt...

Page 667: ...ner of the cab door Then press firmly inward on the lower corner of the door Press in one or two times then remove the wood block and check seal compression again Seal compression should be equal all the way around the door If seal is still loose at the bottom repeat procedure again until seal compression is uniform all the way around Step B If the door bucks back when trying to close it the strik...

Page 668: ...disengage the window regulator roller Figure 2 7 from the track on the bottom of the glass Slide the panel away from the cab to disengage the other top roller and lower roller from its tracks Place the panel out of the way after removal a Lift door glass and support at the top of the frame b Remove 2 screws Figure 2 8 holding the roller track to the bottom of the door glass 3 Remove capscrew and n...

Page 669: ...ounting screws support the panel to prevent the assembly from dropping Remove 15 mounting screws 5 NOTE Remove panel screws across the top last 6 Carefully lower the door panel a few inches Fig ure 2 7 Hold glass at top to prevent it from dropping Slide the door panel toward the cab to disengage the window regulator roller from the track on the bottom of the glass Then slide the panel away from th...

Page 670: ...indow channels It is necessary to pull the rubber felt insert 2 Figure 2 10 out of the channel in order to be able to remove the screws 9 Remove the trim material covering the screws holding the window frame to the door Remove screws 1 Figure 2 11 holding window frame to the door Note Screws along the bottom of window frame may be shorter than along the top and sides FIGURE 2 8 FIGURE 2 9 1 Suppor...

Page 671: ...the new window glass into the window frame glass channels Move the glass to the top of the frame 13 Lift window frame holding glass at the top of the frame and lower the assembly into the door Be sure the one channel 5 Figure 2 14 which is next to the door latch passes to the inside of the latch assembly 4 14 Lower glass in frame and support it as seen in Figure 2 9 15 Reinstall window frame screw...

Page 672: ...ulator away from cab just far enough to allow the rollers to enter their tracks Then with the rollers in the tracks slide the panel toward the cab Move the panel just far enough to allow the upper regulator roller to go into the track on the bottom of the glass 21 Lift door panel regulator and glass up to align screw holes in the panel with holes in door frame Install screws that retain panel to d...

Page 673: ...teps 20 23 to complete replacement Replace Door Handle or Latch Assembly The cab doors are equipped with serviceable latch handle assemblies inner and outer If they become inoperative they should be replaced by a new assembly The outer latch handle assembly on each door is furnished with a key operated lock to enable the operator to lock the truck cab while the truck is parked unattended 1 Follow ...

Page 674: ... Pull seal loose all the way around the opening 1 Figures 2 16 2 17 2 Inspect cab opening lip for damage dirt or oil Repair or clean cab opening as necessary Remove dirt old sealant etc Be certain perime ter of opening is clean and free of burrs etc Installation 1 Install the seal material around the door opening in the cab Start at the bottom center of the cab opening and work the seal lip over t...

Page 675: ...lass goggles when working with glass 1 Using chosen cut out tool slice into existing urethane adhesive and remove window 2 Carefully clean and remove all broken glass chips from any remaining window adhesive The surface should be smooth and even Use only clean water NOTE Removal of all old adhesive is not required just enough to provide an even bedding base 3 Using a long knife cut remaining ureth...

Page 676: ...low all the adhesive manufac turer s instructions for use including full allow ances for proper curing time The curing time may be as long as 48 hours 24 hours for some adhesives then double it before a truck can be driven 11 Remove tape or prop from glass after the cure time has expired WINDSHIELD REAR GLASS Two people are required to remove and install the windshield or rear glass One person ins...

Page 677: ...ial NOTE The ends of the weatherstrip material need to be square cut to assure a proper fit c Lift both ends so that they meet squarely then while holding ends together force them back over the lip of the opening 2 Lubricate the groove of the weatherstrip where the glass is to be seated a Lower the glass into the groove along the bottom of the opening b Two people should be used for glass installa...

Page 678: ...N2 16 Truck Cab 04 03 N02014 NOTES ...

Page 679: ...2 Remove the motor assembly Installation 1 Place wiper motor 1 Figure 3 1 into position on plate 2 2 Install three capscrews 3 with washers Tighten capscrews to 71 79 in lbs 8 9 Nm torque 3 Align the motor output shaft with the wiper link age Install nut 4 and while holding the linkage stationary tighten nut to 16 18 ft lbs 22 24 Nm torque 4 Reconnect the wiper motor harness connector 5 Verify the...

Page 680: ...he wiper compartment Installation 1 Place the linkage into position in the wiper com partment 2 Install pillow blocks 3 Figure 3 4 Install cap screws 2 with washers and tighten capscrews 3 Install nut 6 Figure 3 2 with washer 5 on each wiper shaft and tighten finger tight Tighten the nuts to 160 177 in lbs 18 20 Nm torque Do not overtighten The threads on the shafts are easily stripped when improp...

Page 681: ...ob When the switch is acti vated washing solution is pumped through the outlet hose 3 and fed to a jet located in each of the wind shield 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 ...

Page 682: ...N3 4 Cab Components N03018 NOTES ...

Page 683: ...en release Adjust each pillow for desired support 8 Seat Suspension Move rocker switch 8 up to increase ride stiffness and down to decrease ride stiffness 9 Horizontal Adjustment Lift control lever 9 and hold Bend knees to move seat to a com fortable position release control lever to lock adjustment 10 Seat Height Lift lever 12 and hold to adjust the height of the seat Release lever to lock adjust...

Page 684: ...ator to provide cooled air through the outlet vents All heater and air conditioner controls are mounted on a pod on the face of the enclosure Refer to Fig ure 4 2 for the following Defroster Switch 1 This is a 2 position toggle switch down is OFF Up provides air flow through the defroster vents Heat Vent Control Switch 2 This is a 2 position toggle switch down is OFF Up provides heated air flow to...

Page 685: ... on the face of the enclosure HEATER COMPONENTS Figures 4 3 and 4 4 illustrate both the heater system and air conditioning system parts contained in the cab mounted enclosure Refer to Section M for additional information regarding air conditioning system compo nents maintenance and repair CIRCUIT BREAKERS Before attempting to troubleshoot the electrical circuit in the heater enclosure turn key swi...

Page 686: ...TUATORS Two 2 rotary actuators 8 Figure 4 4 are installed inside the heater housing and are used to actuate the flappers for the following Defroster outlet Bi level or floor outlets A failure to switch one of the above modes of opera tion may be caused by a faulty actuator Test Visually inspect the flappers 11 or 43 and linkage for the function being diagnosed Make certain the flapper is not bindi...

Page 687: ...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 Knob 34 Toggle Switch 3 pos 35 Overlay 36 Plate Control 37 Potentiometer 38 Block Junction 39 Thermostat 40 Hose 41 Switch Blower 42 Screw 43 Discharge Flapper 44 Toggle Switch 2 pos 45 Bracket Flapper 46 Heater Core 47 Relay 12V 48 Circuit Br...

Page 688: ...N4 6 Operator Comfort N04023 NOTES ...

Page 689: ... Pedal 5 Heater Air Conditioner Vents 6 Heater Air Conditioner Controls 7 Instrument Panel 8 Grade Speed Chart 9 Radio Speakers 10 Warning Alarm Buzzer 11 Radio AM FM Stereo Cassette 12 Warning Lights Dimmer Control 13 Warning Status Indicator Lights 14 Air Cleaner Vacuum Gauges 15 Windshield Wipers FIGURE 5 1 CAB INTERIOR OPERATOR CONTROLS ...

Page 690: ...ther high or low headlight beams Move the lever upward to signal a turn to the right An indicator in the top center of the instru ment panel will illuminate to indicate turn direction selected Refer to INSTRUMENT PANEL INDICATOR LIGHTS Move the lever downward to signal a turn to the left Moving the lever toward the steering wheel changes the Headlight beam When high beams are selected the indicato...

Page 691: ...en cap screws 12 If brackets are not quite parallel then install flat washers as needed between brackets and mounting surface to eliminate any gaps Tighten capscrews 12 to standard torque 4 After capscrews 4 12 are tightened to stan dard torque remove nuts 13 and flatwashers 5 that were holding the steering column to the two brackets Do not remove capscrews 10 from the brackets 5 Lubricate the mal...

Page 692: ... brakes as the hydraulic brake valve is actu ated A slight increase in pedal effort will be felt Note that use of the service brakes also ensures maximum dynamic retarding has been applied Completely depressing the pedal causes full applica tion of both dynamic retarding and the service brakes DYNAMIC RETARDING PEDAL The Dynamic Retarder Pedal 3 Figure 5 4 is a foot operated pedal which allows the...

Page 693: ...over head panel WARNING ALARM BUZZER This alarm 10 Figure 5 1 will sound when activated by any one of several truck functions Refer to In strument Panel and Indicator Lights for a detailed description of functions and indicators that will acti vate this alarm CAB RADIO This panel will normally contain an AM FM Stereo ra dio 11 Figure 5 1 Refer to Section 6 Optional Equipment for a more complete de...

Page 694: ...ntrols the FORWARD NEUTRAL REVERSE motion of the truck When the Selector Switch handle is positioned to the center it is in the N position and is in NEUTRAL The handle must be in neutral to start the engine The truck should be stopped before the selector han dle is moved to a drive position 1 Center Console 2 F N R Selector Switch 3 Hoist Control Lever 4 Ash Tray 5 Cigar Lighter 6 L H Window Switc...

Page 695: ...ing smoking materials DO NOT use for flammable materials such as paper wrappers Be certain that all fire ash is extinguished LIGHTER The lighter 5 Figure 5 5 may be used for lighting ci gars cigarettes Always use CAUTION with smok ing materials This socket may also be used for a 12 VDC power supply WINDOW SWITCHES The window switches 6 7 Figure 5 5 are 3 posi tion switches The center position is O...

Page 696: ...lt when indicated by the red warning light Refer to Indicator Lights RETARD SPEED CONTROL RSC SWITCH The Retard Speed Control Switch 11 turns the sys tem On or Off Push the Retard Speed Control Switch knob IN to turn OFF Pul the Retard Speed Control knob OUT to turn the system ON Then the system is ON an amber indicator light on the overhead panel is illuminated Refer to Indicators Lights for loca...

Page 697: ...to Section E for additional information MODULAR MINING PORT CONECTOR This connector 15 Figure 5 5 location is used if the optional Modular Mining System is installed on the truck UNUSED CONNECTOR This connector 18 Figure 5 5 location is not used for this model truck KOMATSU ENGINE QUANTUM CONNECTOR This connector 17 Figure 5 5 is for use by qualified personnel to access engine diagnostic informati...

Page 698: ...lone or with another symbol This symbol identifies the Off position of a switch or control This symbol may be used alone or with another symbol This symbol identifies the On position of a switch or control This symbol identifies the Pushed In position of a push pull switch or control This symbol identifies the Pulled Out position of a push pull switch or control This symbol when it appears on an i...

Page 699: ...ght s 7 Vent s Cab Air Conditioner Heater 8 Engine Starting Aid Switch Optional 9 Rotating Beacon Light Switch Optional 10 Heated Mirror Switch Optional 11 Blank Not Used In This Application 12 Wheel Brake Lock Switch 13 Parking Brake Switch 14 Digital Tachometer 15 Right Turn Signal Indicator Light 16 High Beam Headlight Indicator Light 17 Left Turn Signal Indicator Light 18 Digital Speedometer a...

Page 700: ...o return to the ON position 3 Turn the key switch to the OFF position When the delay system has been activated the 5 Minute Idle Delay amber lamp on the overhead display will illuminate indicating the shutdown timing sequence has started The engine will then continue to idle for approximately 5 minutes and then shut down automatically providing the key switch is OFF The Engine Shutdown Timer DOES ...

Page 701: ... SWITCH OPTIONAL If truck is equipped with the OPTIONAL Heated Mirror it will be activated by this rocker type switch when it is pressed toward the ON position 11 Figure 5 7 BLANK Not Used In This Application Reserved for future options 12 Figure 5 7 WHEEL BRAKE LOCK CONTROL The Wheel Brake Lock should be used with the engine running for dumping and loading operations only The brake lock switch ac...

Page 702: ...ring col umn is moved upward Moving the lever to its center position will turn the indicator OFF 16 Figure 5 7 HIGH BEAM INDICATOR The high beam indicator when lit indicates that the truck headlights are on High beam To switch headlights to High beam push the turn indicator lever away from the steering wheel For Low beam pull the lever toward the steering wheel 17 Figure 5 7 LEFT TURN SIGNAL INDIC...

Page 703: ...SHER The windshield wiper control switch is a four position rotary switch with intermittent wiper delay and wash feature OFF is the detent position when the knob is rotated fully counterclockwise against the stop The intermittent wiper position is located between OFF and the first detent position when rotating the knob clockwise Rotate the knob clockwise to the first detent position for slow speed...

Page 704: ...44L C3 Body Up Yellow 12MD6 63L D3 Dynamic Retarding Yellow 12MD 44DL E3 Stop Engine Red 12M 509MA A4 Blank For Future Use Yellow 12MD SP2 B4 Back up Lights Yellow 12MD 47L C4 5 Minute Idle Timer Yellow 12MD 23L1 D4 Retard Speed Control Yellow 12MD 31R E4 Check Engine Yellow 12MD7 419 A5 Blank For Future Use Red 12MD 528A B5 Wheel Motor Tempera ture Red 12FD1 722L C5 Blower OFF Red 12FDZ 32B D5 Bl...

Page 705: ...warning horn will turn on if steering system hydraulic pressure drops below 2100 psi 14 7 MPa If the light illuminates momentarily while turning the steering wheel at low truck speed and low engine RPM this may be considered normal and truck operation may continue If the light illuminates at higher truck speed and high engine RPM DO NOT OPERATE TRUCK If the low steering warning light continues to ...

Page 706: ...oss Refer to Section L for hydraulic tank filling procedure system troubleshooting and repair procedures B2 Low Automatic Lubrication Pressure This amber light will illuminate if the automatic lubrication sys tem fails to reach 2 200 PSI at the junction block located on the rear axle housing within one minute after the Lube Timer indicates a cycle of grease To turn the light off turn key switch of...

Page 707: ...namic retarding function of the truck is operating E3 Stop Engine The RED engine monitor warn ing light will illuminate if a seri ous engine malfunction is detected in the electronic engine control system Electric propulsion to the wheel motors will be discontinued and maximum engine speed will be reduced to 1250 RPM Dynamic retarding will still be available to slow the truck If this lamp illumina...

Page 708: ...Not currently used Reserved for future use or options B5 High Wheel Motor Temperature optional When this light is illuminated and the alarm sounds high wheel motor temperature is indicated The operator must stop the truck place the Selector Switch in NEU TRAL and raise engine RPM to high idle for several minutes to cool the wheel motors If the indicator does not turn off investigate the cause and ...

Page 709: ...w the operator to test the indicator lamps prior to starting the engine Any lamp bulbs which do not illuminate should be replaced before operating the truck Lamp Test To test the lamps and the warning horn 1 Turn the key switch to the RUN position 2 Press the bottom of the rocker switch for the check position 3 All lamps should illuminate unless they relate to optional equipment not installed on t...

Page 710: ...N5 22 Operator Controls N05056 NOTES ...

Page 711: ...UR Lubrication and Maintenance Checks P2 7 250 HOUR Lubrication and Maintenance Checks P2 8 500 HOUR Lubrication and Maintenance Checks P2 10 1000 HOUR Lubrication and Maintenance Checks P2 11 2500 HOUR Lubrication and Maintenance Checks P2 12 5000 HOUR Lubrication and Maintenance Checks P2 13 10 000 HOUR Lubrication and Maintenance Checks P2 13 AUTOMATIC LUBRICATION SYSTEM P3 1 GENERAL DESCRIPTIO...

Page 712: ...P1 2 Index P01028 NOTES ...

Page 713: ...ion intervals is normally adjustable For adjustments to these devices consult the Automatic Lubrication System later in this section of the manual HYDRAULIC TANK SERVICE There are two sight gauges on the side of the hydraulic tank With engine stopped keyswitch OFF hydraulic system bled down and body down oil should be visible in the top sight gauge If hydraulic oil is not visible in the top sight ...

Page 714: ...e oil The engine oil level must still be checked every shift using the dipstick If engine oil level is not correct check for proper opera tion of reserve oil system Never add oil to 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 ...

Page 715: ...P02039 Lubrication and Service P2 3 ...

Page 716: ...mmenda tions Lube key A and the following checks Intake exhaust piping check for security CENTINEL Check reservoir oil level Eliminator Filter Check operating indicator Fuel Filters Fuel Separators Drain water from bottom of each filter housing NOTE If truck is equipped with a reserve engine oil tank the oil should be visible in the center middle sight gauge If not add oil to reserve tank until oi...

Page 717: ...d 550 ft lbs 746 N m torque This requirement is prescribed for both front and rear wheels 8 CAB AIR FILTER NOT SHOWN Under nor mal operating conditions clean every 250 hours In extremely dusty conditions service as frequently as required Clean filter element with mild soap and water rinse completely clean and air dry with maximum 40 psi 275 kPa air pres sure Reinstall filter 9 AUTOMATIC LUBE SYSTE...

Page 718: ...ial 50 100 and 250 hours of operation then at each 500 hours of operation thereafter 3 FAN DRIVE ASSEMBLY Check fan mounting capscrew torque Refer to the engine manufac turer s maintenance manual for torque specifi cation These checks are required only after the initial hours of operation such as the commissioning of a new truck or after a new or rebuilt component instal lation Truck Serial Number...

Page 719: ...he initial 50 100 and 250 hours of operation then at each 500 hours of operation thereafter These checks are required only after the initial hours of operation such as the commissioning of a new truck or after a new or rebuilt component instal lation Truck Serial Number_________________________ Site Unit Number ___________________________ Date _______________Hour Meter ____________ Name of Service...

Page 720: ...p to tighten filter elements c If truck is equipped with a Reserve Engine Oil Tank change the reserve tank oil filter d Check fan belt tension Refer to engine manufacturer s Operation and Maintenance Manual for specific fan belt adjustment instructions e Eliminator Filter Check pressure drop 2 FUEL FILTERS Change the fuel filters fuel separators Refer to engine manufacturer s Operation and Mainten...

Page 721: ...operating conditions clean every 250 hours In extremely dusty conditions service as frequently as required Clean filter element with mild soap and water rinse completely clean and air dry with maximum of 40 psi 275 kPa Reinstall filter 9 HYDRAULIC SYSTEM FILTERS Replace filter elements after the initial 50 100 and 250 hours of operation then at each 500 hours of operation thereafter Check oil leve...

Page 722: ...ction J PARKING BRAKE MAINTENANCE and perform the recom mended inspection 8 RESERVE ENGINE OIL SYSTEM OPTIONAL a Check electrical system connections for tightness corrosion and physical damage Check battery oil pressure switch junction boxes remote control fill box and circuit breakers b Examine all electrical cables over their entire length for possible damage c Examine all hoses including those ...

Page 723: ... manufac turer s manual for recommended additives 3 FUEL TANK Remove breather and clean in solvent Dry with air pressure and reinstall 4 OPERATOR S SEAT Apply grease to slide rails Use Lube Key D 5 AUTOMATIC BRAKE APPLICATION Check that brakes are automatically applied when hydraulic brake pressure decreases below specified limit Refer to Section J Brake Checkout Procedure 6 FRONT ENGINE MOUNT TRU...

Page 724: ... Specification Chart 1 FRONT WHEELS Drain oil and refill to proper level Lube key E 2 MOTORIZED WHEELS Drain and replace gear oil Refer to G E Motorized Wheel Service Maintenance Manual for lubrication specifica tions Lube Key C Truck Serial Number _________________________ Site Unit Number____________________________ Date ______________ Hour Meter ____________ Name of Service Person _____________...

Page 725: ...ure washer or high pressure air to clean tubes high pressure causes pre cleaner tubes to distort 10 000 HOURS LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10 250 500 1 000 2 500 5 000 hour Lubrication and Maintenance Checks should also be carried out at this time NOTE Lube Key references are to the Lubrication Specification Chart 1 WHEEL MOTORS Clean the area around the grease ports to...

Page 726: ...P2 14 Lubrication and Service P02039 NOTES ...

Page 727: ...vious stroke 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 ...

Page 728: ...ly From Pump 9 R H Suspension Bottom Bearing 10 R H Hoist Cylinder Top Bearing 11 R H Hoist Cylinder Bottom Bearing 12 Rear Axle Pivot Pin 13 L H Anti Sway Bar Bearing 14 R H Anti Sway Bar Bearing 15 Truck Frame 16 Vent Hose 17 Manual Override Knob 18 Pressure Switch N O 2500 psi 17 237 kPa 19 Grease Pump 20 Vent Valve 21 Filter 22 Grease Supply to Injectors 23 Injector 24 Pressure Switch N O 2000...

Page 729: ... motor The flow control valve has been factory adjusted and the setting should not be disturbed Solenoid Valve 5 Figure 3 1 The solenoid valve when energized allows oil to flow to the hydraulic motor Vent Valve 7 Figure 3 1 With the vent valve closed the pump continues to operate until maximum grease pressure is achieved As this occurs the vent valve opens and allows the grease pressure to drop to...

Page 730: ...and to the vent valve 11 and the normally open pressure switch 9 5 During this period the injectors will meter the appropriate amount of grease to each lubrica tion point 6 When grease pressure reaches the pressure switch 4 Figure 3 4 setting the switch con tacts will close and energize relay RB6 K1 12 removing power from the hydraulic motor pump solenoid 5 and the the pump will stop The relay wil...

Page 731: ...stem Pressureª warning lamp on the overhead display After RB6 K2 energizes it will ground the coil of RB6 K6 and allow it to energize 4 Once RB6 K6 is energized it will latch and remain latched as long as the key switch is On Also RB6 K2 will remain energized and the Low Lube Pressure Warning light will remain on to notify the operator a problem exists and the system requires service 5 The warning...

Page 732: ...3 through the outlet port 7 to the bearing STAGE 3 As the injector piston 2 completes its stroke it pushes the slide valve 5 past the passage 4 cutting off further admission of lubricant 6 to the passage 4 and measuring chamber 1 The injector piston 2 and slide valve 5 remain in this position until lubricant pressure in the supply line 6 is vented STAGE 4 After venting the injector spring expands ...

Page 733: ...upply line remove the main supply line 2 Figure 3 1 at the pump outlet port and connect an external grease sup ply to the line 3 Remove plugs from each injector group in sequence right front left front and rear axle 4 Using the external grease source pump grease until grease appears at the group of injectors and re install the pipe plug Repeat for remain ing injector groups 5 Remove the caps from ...

Page 734: ...djustment 1 With the truck engine running actuate the man ual override 2 Figure 3 6 to start the hydraulic motor and grease pump 2 Loosen the locknut on the pressure control 1 Figure 3 6 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 sett...

Page 735: ...e is attained by turning the adjust ing screw 1 fully counterclockwise until the indicating pin 8 just touches the adjusting screw At the maximum delivery point about 0 38 inch 9 7 mm adjusting screw threads should be showing Decrease the delivered lubricant amount by turning the adjusting screw clockwise to limit injector piston travel If only half the lubricant is needed turn the adjusting screw...

Page 736: ...tart the first cycle will be approximately double the nominal setting All subsequent cycles should be within the selected time tolerance 4 Voltage checks at the timer should be accom plished if the above checks do not identify the problem a Insure timer ground connection is clean and tight b Using a Volt Ohm meter read the voltage between positive and negative posts on the solid state timer with t...

Page 737: ... the check seat housing 28 from the reciprocating tube 21 Note There is a 3 8 in allen head socket in the throat of the check seat housing to facilitate removal 12 Unscrew the wrist pin anchor 14 from the recip rocating tube 21 and pull the plunger assem bly 9 through 20 from the tube 13 Using a 0 50 in 13 mm diameter wooden or plastic rod push the cup seal 22 and the pump cylinder 24 from the rec...

Page 738: ...Ball 20 Plunger 21 Reciprocating Tube 22 Cup Seal 23 O Ring 24 Cylinder 25 Ball Cage 26 Steel Ball 27 O Ring 28 Check Seat 29 Screw 30 Housing Cover 31 Cover Gasket 32 Gauge 33 Screw 34 Valve Cartridge 35 Solenoid Valve 36 Connector 37 Manifold 38 Press Reducing Valve 39 Flow Control Valve 40 O Ring 41 Gasket 42 Hydraulic Motor 43 Washer 44 Screw 45 Pipe Plug 46 Pump Housing 47 Backup Ring 48 O Ri...

Page 739: ...age 25 ball 26 O ring 27 and check seat 28 into reciprocating tube 21 Tighten check seat housing to 20 25 ft lbs 27 1 33 9 N m torque 8 Assemble crank rod assembly to pump with bushings 13 and button head screws 12 Tighten screws to 100 110 in lbs 11 3 12 4 N m torque 9 Place pump subassembly parts 1 through 28 into pump housing 46 10 Install new O ring 54 backup washer 53 and O ring 52 and bronze...

Page 740: ...bsequent timer cycles should be as specified TROUBLE Pump Will Not Prime Low lubricant supply Dirt in reservoir pump inlet clogged filter clogged TROUBLE 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 Re...

Page 741: ...ressure switch Refer to Pressure Control Valve Adjustment Replace grease with a lower viscosity lubricant Remove inspect and clean if necessary Inspect seal ing surfaces between checks Replace if rough or pit ted Repair lubricant supply line Check oil pressure and flow to motor TROUBLE 24VDC Timer Not Operating Timer BAT connection is not on grounded member Timer BAT connection not on circuit cont...

Page 742: ...ise may be generated into vehicle electrical system which may cause timer to turn on at random inter vals independent of timer setting If this occurs a 250 to 1 000 MFD capacitor rated 150 to 350 VDC should be added across BAT and BAT terminals to suppress this noise and improve timer performance TROUBLE Timer Turns On At Intervals Faster Than Allowable Tolerances Of Settings Timer out of adjustme...

Page 743: ...equired 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 on each Injector This will indicate if there are any frozen or plugged bearings and will help flush the bearings of co...

Page 744: ...P3 18 Automatic Lubrication System P03022 NOTES ...

Page 745: ... 0 0 1 2 0 0 3 3 0 0 1 2 0 4 5 6 7 6 4 ...

Page 746: ...8 9 9 8 9 9 9 9 2 8 3 1 1 3 3 9 9 9 0 3 4 6 7 6 4 5 ...

Page 747: ... 8 9 9 8 9 5 9 9 5 2 9 9 8 3 8 9 9 8 9 9 9 5 2 9 9 8 3 3 9 A4 0 9 9 9 9 9 3 9 9 9 9 9 4 5 6 7 6 4 ...

Page 748: ... 1 9 B 9 3 9 B 3 0 0 0 B 2 1 A 9 B 3 46 2 46 B 3 3 6 5 B 3 46 3 6 B 4 6 7 6 4 5 ...

Page 749: ...tion Indicator B3 5 Body Sling Cable B3 4 Body Up Switch D3 7 Brake Accumulators J3 15 Brake Circuit J2 1 Bleeding Procedures Front J5 7 Rear J6 18 Parking J7 6 Checkout Procedure J4 1 Troubleshooting J4 7 Brakes Front J5 1 Brake Pad Conditioning Front Brakes J5 6 Rear Brakes J6 16 Parking Brake J7 6 Brake Parking J7 1 Brakes Rear J6 1 Brake Valve J3 1 Test and Adjustment J3 10 C Cab N2 1 Door Rep...

Page 750: ... Grids Retarding E2 62 Grille Hood B2 1 H Heater Air Conditioner N4 2 RotaryActuators N4 5 Water Control Valve N4 4 Hoist Circuit Operation L7 1 Hoist Cylinder Limit Switch D3 7 Hoist Pilot Valve L8 7 Hoist Cylinders L8 10 Hoist Relief Valve L10 12 Hoist Valve L8 1 Hub Wheel G3 1 HYDRAIR II Suspensions Front H2 1 Rear H3 1 Oil and Nitrogen Specifications H4 8 Hydraulic Hoist Pump L3 1 Schematic R1...

Page 751: ...on System E2 41 Pump Hoist System L3 1 Pump Steering Brake System L4 13 L5 21 R Radiator C3 2 Rear Axle G4 1 Rear HYDRAIR II Suspension H3 1 Rear Tire and Rim G2 3 Retarding Grids E2 62 Retarder Pedal Electronic E2 62 Rims G2 5 Rock Ejector B3 5 Reserve Engine Oil System M31 1 S Safety Rules A3 1 Software Propulsion Control System E2 22 Statistical Data E2 48 Seat Operator N4 1 Service Capacities ...

Page 752: ...alves Bleeddown Solenoid L4 12 Brake J3 1 Flow Amplifier L4 2 L5 7 Hoist L8 1 Hoist Pilot L8 7 Adjustment Procedure Power Down L10 13 Hoist Relief L10 12 Adjustment Procedure L10 12 Counterbalance L7 4 Service L8 18 Adjustment Procedure L10 14 Steering Control Unit L5 12 Unloader L10 2 Adjustment Procedure L10 2 W Warnings and Cautions A4 1 Weights Truck A2 4 Wheel Bearing Adjustment Front Tire Re...

Page 753: ...lement 7 step Retarding XS1408 Drive System Monitoring Control CIrcuits XS1409 Two Digit Display Circuits XS1410 G E Digital Inputs Auto Lube Circuits XS1411 Rear Tail Lights Dimmer Control XS1412 5 Minute Idle Spare Circuits XS1413 Windows Radio Gauge Circuits XS1414 Contactor Feedback Circuits XS1415 Contactor Coil Circuits XS1416 Machine Control Circuits XS1417 Accelerator Retard Pedal Circuits...

Page 754: ...R1 2 System Schematics R01060 NOTES ...

Page 755: ......

Page 756: ...Electrical Schematic HH354 Jun 03 Hydrauiic Schematic Brake System 830E Effective with A30650 UP ...

Page 757: ...Electrical Schematic Payload Meter III 730E A30212 and UP 830E A30650 and UP Sheet 1 of 1 NOTE FIELD RETROFITS DO NOT HAVE CONNECTOR P268 HE481 June 03 ...

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