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Komatsu 930E-2, Shop Manual

The Komatsu 930E-2 Shop Manual is essential for those seeking to understand and maintain this powerful mining truck. Download this comprehensive manual for free from manualshive.com, providing detailed instructions, diagrams, and maintenance tips to ensure optimal performance and longevity of this remarkable product.

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System Operation

Normal Operation:

1. During truck operation, the lubrication cycle timer

(1, Figure 3-4) will energize the system at a preset
time interval.

2. The timer provides 24 VDC through the normally

closed  relay,  RB7K5  (4)  used  to  energize  the
pump  solenoid  valve  (5),  allowing  hydraulic  oil
provided by the truck steering pump circuit to flow
to the pump motor and initiate a pumping cycle.

3. The hydraulic oil pressure from the steering circuit

is reduced to 325 to 350 psi (2 240 to 2 413 kPa)
by  the  pressure  reducing  valve  (4,  Figure  3-3)
before entering the motor. In addition, the amount
of oil supplied to the pump is limited by the flow
control  valve  (6).  Pump  pressure  can  be  read
using the gauge (5) mounted on the manifold.

4.  With  oil  flowing  into  the  hydraulic  motor,  the

grease pump will operate, pumping grease from
the reservoir to the injectors (13), through a check
valve (10) and to the vent valve (11).  

5.  During  this  period,  the  injectors  will  meter  the

appropriate amount of grease to each lubrication
point.

6.  When  grease  pressure  reaches  the  pressure

switch (3, Figure 3-4) setting, the switch contacts
will close and energize the relay RB7K5, remov-
ing  power  from  the  hydraulic  motor/pump  sole-
noid  and  the  the  pump  will  stop.  The  relay  will
remain  energized  until  grease  pressure  drops
and the pressure switch opens again or until the
timer turns off.

7.  After  the  pump  solenoid  valve  is  de-energized,

hydraulic pressure in the manifold drops and the
vent valve will open, releasing grease pressure in
the lines to the injector banks. When this occurs,
the injectors are then able to recharge for the next
lubrication cycle.

8. The system will remain at rest until the lubrication

cycle  timer  turns  on  and  initiates  a  new  grease
cycle. 

FIGURE 3-3. HYDRAULIC SCHEMATIC

1. Hydraulic Oil Return
2. Hydraulic Oil Supply
3. Pump Solenoid Valve
4. Pressure Reducing Valve

5. Motor Pressure Gauge
6. Flow Control Valve
7. Hydraulic Motor
8. Grease Pump

  9. Pressure Switch (N.O.)
10. Check Valve
11. Vent Valve
12. Orifice
13. Injector Bank

P3- 4

Automatic Lubrication System

P03018 4/00

Summary of Contents for 930E-2

Page 1: ......

Page 2: ......

Page 3: ...n the latest revision CALIFORNIA Proposition 65 Warning Diesel engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer birth defects or other reproductive harm Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read and understand this manual before operating...

Page 4: ...NOTES ...

Page 5: ...such as 100 ft lbs 135 N m torque All torque specifications have 10 tolerance unless otherwise specified A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number Product Identification Number vehicle serial number and Maximum G V W Gross Vehicle Weight rating The KOMATSU Truck Model designation consists of th...

Page 6: ...oper 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 damage to the equipment This ALERT symbol is used with the signal words CAUTION DANGER and WARNING in this man ual to alert the reader to hazards arising from improper operating and maintenance practices A 2 In...

Page 7: ...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 A00017 03 01 Introduction A 3 ...

Page 8: ...KOMATSU MODEL 930E Dump Truck A 4 Introduction A00017 03 01 ...

Page 9: ... GENERAL INFORMATION INDEX TRUCK COMPONENT DESCRIPTION SPECIFICATIONS A2 1 GENERAL SAFETY AND TRUCK OPERATION A3 1 WARNINGS AND CAUTIONS A4 1 CHARTS AND TABLES A5 1 STORAGE PROCEDURES A7 1 A01001 2 94 Index A1 1 ...

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

Page 11: ...le ride for the operator and dampens shock loads to the chassis during loading and operation Operator s Cab The Operator s Cab has been engineered for operator comfort and to allow for efficient and safe operation of the truck The cab provides for wide visibility with an integral 4 post ROPS FOPS stucture and an ad vanced analog operator envirnment It includes a tinted safety glass windshield and ...

Page 12: ...930E MAJOR COMPONENTS A2 2 Major Component Description A02055 ...

Page 13: ... 220 Ampere Hour Capacity With Disconnect Switch Alternator 24 Volt 240 Ampere Output Lighting 24 Volt Starters 2 24 Volt SERVICE CAPACITIES U S Gallons Liters Crankcase Includes lube oil filters QSK60 C 74 280 Cooling System 157 594 Fuel 1200 4542 Hydraulic System 350 1325 Wheel Motor Gear Box 20 Wheel 76 Wheel HYDRAULIC SYSTEM Hoist Brake Cooling Pump Tandem Gear Output 270 GPM 1022 l min 1900 R...

Page 14: ...Tread Tubeless Rims patented Phase II New Generation rims WEIGHT DISTRIBUTION EMPTY Pounds Kilograms Front Axle 49 3 219 913 99 751 Rear Axle 50 7 226 121 102 567 Total 50 Fuel 446 034 202 318 LOADED Front Axle 33 9 372 727 169 069 Rear Axle 66 1 727 273 329 891 Total 1 100 000 498 960 Not to exceed 1 100 000 lbs 498 957 kg including options fuel and payload Weights in excess of this amount requir...

Page 15: ...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 not wear oily clothes because they are flammable Wear a hard hat safety g...

Page 16: ... any control levers when getting on or off the machine Always maintain three point contact with the handholds and steps to ensure that you support yourself When bringing tools to the operator s compartment always pass them by hand or pull them up by rope If there is any oil grease or mud on the handholds or steps wipe it off immediately Always keep these parts clean Repair any damage and tighten a...

Page 17: ...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 necessary PREVENTION OF INJURY BY WORK EQUIPMENT Never ent...

Page 18: ...the ROPS always consult the authorized regional Komatsu Mining Systems Inc distributor Even if the ROPS is installed it cannot show its full effect if the operator does not fasten the seat belt properly Always fasten the seat belt when operating PRECAUTIONS FOR ATTACHMENTS When installing and using optional equipment read the instruction manual for the attachment and the information related to att...

Page 19: ...termine the travel roads in the worksite and maintain them so that it is always safe for the machines to travel If travel through wet areas is necessary check the depth and flow of water before crossing the shallow parts NEVER be in water which is in excess of the permissible water depth FIRE PREVENTION Thoroughly remove wood chips leaves paper and other flammable things accumulated in the engine ...

Page 20: ... 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 worklights and taillights are in proper working order Check that the machine is equipped with the head lamps and working lamps needed for the operating conditions OPERATING THE MACHINE WHEN STARTING ENGINE NEVER ...

Page 21: ... 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 operating the machine or work equipment do as follows Sound the horn to warn people in the area For machines equipped...

Page 22: ...rting 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 place or any other place where there are height limits alw...

Page 23: ... 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 pedestrians and other vehicles Be sure that the machine fla...

Page 24: ... 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 wear safety glasses or goggles when starting the machine...

Page 25: ...en carrying out inspection or maintenance always stop the machine on firm flat ground lower the dump body then stop the engine If the engine must be run during service such as when cleaning the radiator always move the shift control lever to the Neutral N position and set the parking brake lever to the PARKING position Always carry out the work with two people One person should sit on the operator...

Page 26: ...der the machine if the machine is poorly supported KEEP THE MACHINE CLEAN Spilled oil or grease or scattered tools or broken pieces are dangerous because they may cause you to slip or trip Always keep your machine clean and tidy If water gets into the electrical system there is danger that the machine may not move or may move unexpectedly Do not use water or steam to clean the sensors connectors o...

Page 27: ...re 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 oil or carry out maintenance or inspection before comp...

Page 28: ...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 rivers etc Always put oil drained from your machine in conta...

Page 29: ...losions 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 replacement of the wheel or tire is not used the wheel or tire may ...

Page 30: ..._______________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ ...

Page 31: ...p MUST BE ATTACHED AS NEAR AS POSSIBLE to the weld area Always avoid lay ing welding cables over or near the vehicle elec trical harnesses Welding voltage could be induced into the electrical harness and possibly cause damage to components Never allow weld ing current to pass through ball bearings roller bearings suspensions or hydraulic cylinders 9 If truck is to be towed for any reason use a rig...

Page 32: ...counter clockwise to Off position for normal shutdown of engine If engine does not shutdown with keyswitch use Engine Shutdown Switch on operator cab center console and hold this switch down until engine stops 4 With keyswitch Off and engine stopped wait at least 90 seconds Insure steering circuit is com pletely bled down by turning steering wheel back and forth several times No front wheel moveme...

Page 33: ...are Always inspect power cable insula tion prior to servicing the cables and prior to returning the truck to service Discard cables with broken insulation 10 Power cables and wiring harnesses must be protected from weld spatter and heat Always fasten the welding machine ground lead to the piece being welded the grounding clamp MUST BE ATTACHED AS NEAR AS POSSIBLE to the weld area Always avoid layi...

Page 34: ... sequence and are repeated from the same point and in the same direction 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 HIGH VOLTAGE MAY...

Page 35: ...START HERE Walk Around Inspection A03017 General Safety and Operating Instructions A3 21 ...

Page 36: ...greasing and any 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 be tween 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 nu...

Page 37: ...et inspect for leaks Before latching doors turn work lights off if used 31 Clean cab windows and mirrors clean out cab floor as necessary Insure steering wheel con trols and pedals are free of any oil grease or mud 32 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 ...

Page 38: ...tion 2 Operate each of the truck s brake circuits at least twice prior to operating and moving the truck These circuits include individual activation from the operator s cab of the service brake parking brake and brake lock With the engine running and with the hydraulic circuit fully charged acti vate each circuit individually If any application or release of any brake circuit appears sluggish or ...

Page 39: ...el at all times 6 Do not allow engine to run at Idle for extended periods of time 7 Check parking brake 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 brak...

Page 40: ...NOT hold a stationary truck on an incline use the Parking Brake or Wheel Lock brake for this purpose Dynamic Retarding is available in Neutral only when truck speed is above 3 mph 4 8 kph When dynamic retarding is in operation the engine RPM will automatically go to an advance RPM retard speed setting usually 900 1000 RPM NOTE The exact engine speed in retarding may vary due to the temperature of ...

Page 41: ...ruck move ment start Be sure to completely release the foot operated retarder service brake pedal As truck speed increases above 3 5 MPH 5 8 KPH the Propulsion System Control PSC will drop propulsion if the retarder is still applied Releasing and reapplying dynamic retarding dur ing a hill start operation will result in loss of propulsion PASSING 1 Do not pass another truck on a hill or blind curv...

Page 42: ...as cleared body 6 Reduce engine RPM as last stage of hoist cylinder begins to extend and let engine go to low idle as last stage reaches half extension 7 Release hoist lever as last stage of hoist cylinder reaches full extension 8 After material being dumped clears body lower body to frame To Lower Body When dumping over a berm or into a crusher 9 Move hoist lever forward to down position and rele...

Page 43: ...body returned to frame move Selector Switch to Forward release Brake Lock and leave dump area carefully TOWING Prior to towing a truck many factors must be carefully considered Serious personal injury and or significant property damage may result if important safety prac tices procedures and preparation for moving heavy equipment are not observed Do not tow the truck any faster than 5 MPH 8 kph At...

Page 44: ...e the REST indicator light in the overhead panel is illuminated 3 With engine cooled down turn keyswitch counter clockwise to Off position for normal shutdown of engine If engine does not shutdown with keyswitch use Engine Shutdown Switch on operator cab center console and hold this switch down until engine stops 4 With keyswitch Off and engine stopped wait at least 90 seconds Insure steering circ...

Page 45: ... by the keyswitch The en gine will not shutdown if the keyswitch is not turned OFF using this procedure b When the Engine Shut down Timer has been activated the Timer De lay indicator light in the overhead display panel will illuminate to indicate that the shutdown timing sequence has been started The engine will continue to run at Idle RPM for approximately 5 minutes to allow for proper engine co...

Page 46: ...NOTES A3 32 General Safety and Operating Instructions A03017 ...

Page 47: ...ucture and Falling Object Protective Structure meets various SAE per formance requirements WARNING Do not make modifications to this structure or attempt to repair damage without written approval from the Manufacturer Unauthorized repairs will void certification A warning instruction is applied below the Parking Brake and the Rear Wheel Brake Lock switches which are located to the right of the ste...

Page 48: ...nimizes dan ger of sparks near the batteries Sulfuric acid is corrosive and toxic Use proper safety gear goggles rubber gloves and rubber apron when handling and servicing batteries Get proper medical help immediately if required This plate is placed on both battery boxes and near the battery disconnect switches to indicate that the battery system 24VDC is a NEGATIVE GROUND system These decals are...

Page 49: ...ecals are mounted on the side of each of the accumulators both steering and brake to alert technicians to discharge all gas and hydraulic pressure and to read the maintenance service manual prior to performing any service This Danger plate is attached to all four suspensions The plate contains instructions for releasing internal pressure before disconnecting any hardware Serious injury can occur i...

Page 50: ...tment by a physician familiar with this injury is not received immediately A wheel motor oil level decal is attached to the gear cover on both electric wheel motors This decal stresses the fact that the truck must be on a level surface and parked for 20 minutes prior to checking the oil level This is necessary in order to get an accurate reading A decal plate is located on the frame near the left ...

Page 51: ...h 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 pos sibly cause damage to components A High Voltage Danger Plate is attached to the door of the rear hatch cover HIGH VOLTAGE may be present Only authorized personnel should access this r...

Page 52: ...n the rear wall On the front of the control box which is mounted on the right side of the main control cabinet On the outside of the left control cabinet wall that faces the right side of the operator cab See also Information decal above When any of these indicator lights are ON High Voltage is present throughout the pro pulsion and retarding system Extreme care should be exercised This decal is p...

Page 53: ... be lifted in a specific manner and from specific points in order to safely move or lift any of these structures If any of these decals are damaged or defaced so that it is no longer legible it should be replaced immedi ately Maintenance personnel must follow these lifting instructions A04039 Warnings and Cautions A4 7 ...

Page 54: ...r contains information which will identify the original manufacturing bill of mate rial for this unit The complete truck serial number will be re quired for the proper ordering of many service parts and or warranty consideration The Lubrication Chart is mounted on the right hand side of the radiator grille structure Refer to the Lubrication and Service section in this manual for more complete lubr...

Page 55: ...steners 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 A5 2 on the threads and seats unless specified otherwise NOTE Always be sure threads of fasteners and tapped holes are free of burrs or other imperf...

Page 56: ... meteric Class 10 9 finished hexagon head capscrews and Class 10 nuts Capscrews threads and seats SHALL NOT be lubricated when assembled These specifications are based on all capscrews nuts and hardened washers being phosphate and oil coated NOTE If zinc plated hardware is used each piece must be lubricated with a Rust Preventive Grease or Lithium base grease to achieve the same clamping forces pr...

Page 57: ...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 TUBE SIZE 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 0 750 1 062 12 48 5 14 0 875 1 188 1...

Page 58: ...2 59 12 72 12 86 13 00 13 14 13 28 13 42 13 55 13 69 See NOTE on page A5 5 TABLE X PRESSURE CONVERSIONS Pounds sq in psi To kilopascals kPa Formula psi x 6 895 kPa PSI 0 1 2 3 4 5 6 7 8 9 0 kPa 6 895 13 79 20 68 27 58 34 47 41 37 48 26 55 16 62 05 10 68 95 75 84 82 74 89 63 96 53 103 42 110 32 117 21 124 1 131 0 20 137 9 144 8 151 7 158 6 165 5 172 4 179 3 186 2 193 1 200 0 30 206 8 213 7 220 6 22...

Page 59: ... 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 13 55 131 46 50 58 68 155 311 10 50 122 48 55 67 6...

Page 60: ... 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 in in 3 0 061 liters l cu in in 3 61 ...

Page 61: ...ppropriate actions taken when re storing a long term idle vehicle These instructions are not intended to be all inclusive but are furnished to provide the minimum guide lines The final aim should always be to provide the operator with a safe fully productive vehicle that he can rely on SHORT TERM IDLE PERIODS There will be periods when a vehicle may be idle from 30 60 days but must be ready for us...

Page 62: ...temperature anticipated Refer to Section P Fluid Specifications and Charts for the proper anti freeze and conditioner concentrations After refilling the system always operate the engine until the thermostats open to circulate the solution through the cooling system NOTE NEVER store a vehicle with a dry cooling sys tem 10 New hydraulic filters should be installed and the hydraulic tank fully servic...

Page 63: ...ly drained chemically flushed and refilled with a conditioned water antifreeze solution suitable for the lowest temperature anticipated Refer to Fluid Specifi cations in Section P Lubrication and Service of the Komatsu service manual for the proper anti freeze and conditioner concentrations After refill ing thesystem alwaysoperatetheengineuntil the thermostats open to circulatethesolution through ...

Page 64: ...checkout Make a thorough check of all hose and line con nections for leakage when the engine is running 18 Before moving the vehicle cycle all hydraulic con trols and steering to verify proper operation Verify proper operation of service brakes emergency braking system and parking brake Check ALL system instruments to insure that all systems are operational 19 When all systems are operational and ...

Page 65: ...ing tire deflation to protect against any foreign object being projected into the eyes 3 Inspect tires thoroughly for tread and side wall condition weathering cuts and cracks a Any tire suspected of being unserviceable should be dismounted and thoroughly in spected inside and out before being inflated Do not mixrim partsof different rim manufacturers Rim parts may resemble those of a different man...

Page 66: ...as left in the tanks it must be removed Do not attempt to use old diesel fuel a With tanks empty remove inspection plates and thoroughly check interior of tanks clean if necessary to remove sediment and contamina tion If fuel was contaminated lines should be disconnected and blown clear b Check all fuel lines for deterioration or damage Replace lines as necessary c Replace inspection covers use ne...

Page 67: ...ions All pivot points must be free of any binding 11 Check battery charging alternator for corrosion or deterioration Alternator rotor must be free with no binding or roughness Inspect install and properly tension the alternator drive belts 12 Check security of steering cylinder ball joints link and hydraulic connections 13 Examine Hydrair suspensions for signs of dam age a Discharge nitrogen from...

Page 68: ...s and windows are open and ventilation is adequate 2 Turn key switch On Warning lights for low brake and steering pressure should illuminate and the horn should sound If it does not check all com ponents in the circuit and correct the discrepancy before continuing 3 Turn key switch to start position to crank engine release switch when engine fires Watch engine oil pressure gauge if pressure does n...

Page 69: ...se 4 Cycle hoist controls and steering several times to remove trapped air Complete steering cycles in both directions to verify steering response smoothness and reliability Check seals and lines for leaks 5 When satisfied that all discrepancies have been corrected the vehicle is ready for a road test This test should be done only by a capable and expe rienced operator and should be accomplished i...

Page 70: ...ter this run 4 Check the air cleaner and service it if necessary 5 If freezing weather is expected during the storage period add an ethylene glycol base antifreeze solution in accordance with the manufacturer s recommendations 6 Clean the entire exterior of the engine except the electrical system with fuel oil and dry it with compressed air To prevent possible personal injury wearadequate eye prot...

Page 71: ... Drain the engine cooling system 15 Drain the preservative oil from the engine crank case Reinstall and tighten the drain plug 16 Remove and clean the batteries and battery cables with baking soda water solution and rinse them with fresh water Do not allow the soda solution to enter the battery Add distilled water to the electro lyte if necessary and fully charge the battery Store the battery in a...

Page 72: ...oil 6 Fill the fuel tank with the engine manufacturer s specified fuel 7 Close all of the drain cocks and fill the engine cooling system with clean soft water and a rust inhibitor If the engine is to be exposed to freezing temperatures fill the cooling system with an eth ylene glycol base antifreeze solution refer to cool ant specifications in Lubrication and Service Section P 8 Install and connec...

Page 73: ...to achieve the best possible equipment life and the lowest operating cost when the equipment is returned to service NOTE Local conditions and or experience may re quire ADDITIONAL procedures and or additional stor age precautions Placing Equipment Into Storage Perform the following instructions when preparing General Electric equipment for storage Therearethree main equipment categories to conside...

Page 74: ...the hubcap will accommodate the electrical cord for the heat source in the Motorized Wheels These heat sources are to be energized continu ously 11 Seal compartment doors with a weatherproof tape to prevent entry of rain snow and dirt allow breathing When Storing A Truck That Is Not Operational When a truck which is not fully operational is being stored for a period of any length perform the follo...

Page 75: ...rized Wheels control compartments and the alternator 4 Fill with recommended oil Refer to the Motorized Wheel Service Manual for the type and amount oil to be used This oil should be drained and new oil should be added after 500 hours of operation 5 Clean all Motorized Wheel grease fittings in the axle box Insure that all grease lines are com pletely full of grease Then add the recommended amount ...

Page 76: ...y the Motorized Wheel gear case has been filled with new oil the dirt seals have been completely purged with new grease and the system completely checked the truck can be placed into service It is recommended however that the truck be driven unloaded at a low speed 10 mph for the first hour of operation A7 16 Storage Procedures A07003 ...

Page 77: ... B2 4 Center Deck B2 4 DUMP BODY B3 1 Removal B3 1 Installation B3 2 BODY PADS B3 3 BODY GUIDE B3 4 HOIST LIMIT SWITCH B3 4 BODY UP SWITCH B3 4 BODY UP RETENTION CABLE B3 4 ROCK EJECTORS B3 5 FUEL TANK B4 1 Removal B4 2 Installation B4 2 Repair B4 2 Cleaning B4 2 VENT B4 3 FUEL GAUGE SENDER B4 3 Removal B4 3 Installation B4 3 B01016 03 01 Index B1 1 ...

Page 78: ...NOTES B1 2 Index B01016 ...

Page 79: ...nician should inspect the truck and verify the propulsion system does not have dangerous voltage levels present be fore repairs are started After the truck is parked in position for the repairs the truck must be shut down properly to ensure the safety of those working in the areas of the deck electrical cabinet and retarding grids The following procedures will ensure the electrical system is prope...

Page 80: ...e to the ladder and lift structure off truck 3 Disconnect wiring harnesses and remove cable clamps as necessary to allow hood removal 4 Attach lifting device to the hood and grille assem bly 1 Figure 2 2 5 Remove all side mounting capscrews and lock washers 2 6 Verify all harnesses cables hoses etc are re moved 7 Lift hood and grille assembly from truck and move to work area Installation 1 Movehoo...

Page 81: ...er repairs are required refer to applicable G E publication for serv ice and maintenance procedures 5 Disconnect electrical harness at connector 7 Figure 2 3 Inspect underside of deck and if nec essary remove any hoses or cables that remain Light harness and clamps do not require re moval 6 Install lifting device at eyes at each corner of the deck and take up slack Do not attach lifting device to ...

Page 82: ...ctions on discharging the air conditioning system prior to disconnecting any air conditioning lines 4 Install lifting device to lift eyes at each corner of the deck and take up slack Do not attach lifting device to the hand rail structure 5 Remove deck mounting hardware at frame sup port and front upright 6 Verify all wiring harnesses cables or hoses have been removed Carefully raise deck and remo...

Page 83: ... take up the slack as shown in Figure 3 1 2 Remove mud flaps and rock ejectors from both sides of the body Remove electrical cables lubri cation 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 3 2 from each of the upper hoist cylinder mounting eyes With adequate means of ...

Page 84: ...e slack as shown in Figure 3 1 Lower body over the truck frame and align body pivots to frame pivot holes 2 Install shims 9 Figure 3 3 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 ...

Page 85: ...f shims as removed in step 3 5 Install the mounting hardware and torque to 65 ft lbs 88 1 N m 6 Remove blocks from frame and lower body onto the frame Adjustment 1 Vehicle must be parked on a flat level surface for inspection 2 All pads except the rear pad on each side should contact the frame with approximately equal com pression of the rubber 3 A gap of approximately 0 06 in 1 5 mm is re quired ...

Page 86: ... 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 in the up position raise the body to it s maximum height Refer to Figure 3 6 2 Remove the cable 3 from its stored position on the body and install between the Rear Body Ear 1 and the Axle Housing Ear 4 3 Secure the cable clev...

Page 87: ... from the wheel spacer ring 3 Refer to Figure 3 7 NOTE With Rock Ejector Arm 1 Figure 3 8 hanging vertical as shown in Figure 3 7 there must be NO GAP at Stop Block 3 Figure 3 8 3 If the arm 1 becomes bent it must be removed and straightened 4 The wear plates 2 must be replaced if severely worn 5 Inspect the mounting brackets 4 Figure 3 8 pins 2 and stops 3 at each shift change for wear and or dam...

Page 88: ...NOTES B3 6 Dump Body B03013 03 01 ...

Page 89: ... 14 Wire Harness 20 Wire Harness 3 Mounting Cap 9 Fuel Gauge Sender 15 Tank Mount Bracket 21 Capscrews L W s 4 Lifting Brackets 10 Drain Cock 16 Capscrew F W L W 22 Capscrews L W s 5 Breather 11 Fuel Supply Connector 17 Flat Washer 23 Refueling Cap 6 Filler Cap 12 Capscrews L W s 18 Rubber Dampener 24 Wiggins Receiver Assy B04015 Fuel Tank B4 1 ...

Page 90: ...four capscrews lockwashers and flat washers 16 flat washers 17 and rubber dam peners 18 in the lower mounts and tighten the 4 x 0 750 UNC x 6 00 G8 lower mounting bolts to 310 31 ft lbs 420 42 N m torque 4 Tighten the trunnion mount capscrews 2 to 459 45 ft lbs 622 62 N m torque 5 Connect hoses removed during removal proce dure Install wire harness and clamps Open the in line shut off valves if eq...

Page 91: ...k fill systems and servicing of the Tank Vent Valve FUEL GAUGE SENDER A fuel gauge sending unit 9 Figure 4 1 mounted on the side of the tank provides an electrical signal to operate the fuel gauge on the instrument panel Removal 1 Drain fuel below level of gauge sender 2 Disconnect wire from terminal 3 Loosen the small screws holding the fuel gauge sender unit and carefully remove Installation 1 I...

Page 92: ...NOTES B4 4 Fuel Tank B04015 ...

Page 93: ... C3 4 POWER TRAIN C4 ALTERNATOR REMOVAL PROCEDURE C4 1 Removal C4 1 ENGINE ALTERNATOR MATING C4 3 Joining Alternator and Engine C4 5 ENGINE C4 6 Removal C4 6 Installation C4 6 AIR FILTRATION SYSTEM C5 AIR CLEANERS C5 1 Filter Element Replacement C5 2 Main Filter Element Cleaning C5 3 Precleaner Section C5 4 Cleaning Precleaner Tubes C5 4 Air Intake Troubleshooting C5 5 C01021 03 01 Index C1 1 ...

Page 94: ...NOTES C1 2 Index C01021 03 01 ...

Page 95: ...m In the event of a propulsion system malfunction a qualified technician should inspect the truck and verify the propulsion system does not have dangerous voltage levels present before repairs are started After the truck is parked in position for the repairs the truck must be shut down properly to ensure the safety of those working in the areas of the deck electrical cabinet and retarding grids Th...

Page 96: ...t entrance of foreign material 4 Remove engine air inake duct support rods 9 Figure 2 3 Remove any hoses or electrical ca bles attached to center deck structure 5 Attach overhead hoist to center deck structure Remove deck mounting hardware lift deck from truck and move to storage area 6 Disconnect the air cleaner restriction indicator nylon tubes at ports on inlet ducts 7 Loosen clamps 5 on hump h...

Page 97: ...Cleaner Assemblies 2 Left Rear Intake Duct 3 Left Front Intake Duct 4 Hump Hose 5 T Bolt Clamp 6 T Bolt Clamp 7 Reducer Elbow 8 T Bolt Clamp 9 Duct Support Rod 10 Right Front Intake Duct 11 Right Rear Intake Duct C02017 03 01 Power Module C2 3 ...

Page 98: ...engine installation Coolant capacity is approximately 195 gal 738 l 13 Disconnect and remove piping 6 Figure 2 5 from engine water pump and radiator routed to the brake system cooling heat exchanger 7 14 Remove upper radiator support rod 11 at each side of radiator 15 Remove capscrews and washers at vertical and diagonal ladder mounting pads Lift ladders from truck and move to storage area 16 Refe...

Page 99: ...frame support bracket 3 at rear of subframe 3 Check engine and alternator to make sure all cables wires hoses tubing and linkages have been disconnected Lift power module only at the lifting points on subframe and engine alternator cradle structure Refer to Figure 2 5 and 2 7 FIGURE 2 5 POWER MODULE REMOVAL INSTALLATION 1 Alternator 2 Rear Power Module Lift Eye 3 Rear Frame Sub frame Mount 4 Engin...

Page 100: ...n front of electri cal cabinet for the lifting device to be attached to the engine alternator cradle structure 2 Figure 2 5 and front subframe lifting points 9 Place stands or block under front of subframe and lower hoist until front of subframe is supported Install safety chain to prevent subframe from rolling 7 Attach lifting device 1 Figure 2 7 to hoist and attach to engine alternator cradle st...

Page 101: ...ame roller to prevent rolling 10 Lower hoist to allow subframe to rest on stands and rollers Remove lifting device 11 Attach hoist to front lifting eyes on subframe 12 Remove the small blocks behind the subframe rollers remove safety chain and slowly roll the power module into position over the main frame mounts Lower hoist until front subframe mounts are aligned and seated on the front main frame...

Page 102: ...water pump and radiator 7 Inspect alternator wheel motor cooling duct gas kets and replace if damaged Install Alternator inlet transistion structure 8 Figure 2 2 and wheel motor duct transition structure 5 8 Connect the hydraulic pump drive shaft compan ion flange 4 Figure 2 1 to the alternator 5 Tighten capscrews to standard torque Install driveshaft guard 2 9 Connect all remaining electrical oil...

Page 103: ... re cycle station The system is charged with HFC 134A refrigerant a Remove refrigerant hose clamps and remove the receiver drier 7 Figure 3 1 mounted on rear left side of the radiator shroud Discon nect wiring from low pressure switch b Remove clamp and disconnect inlet and outlet hoses 4 5 Figure 3 2 at the condenser Remove mounting capscrews 3 and remove condenser c Cap all hoses to prevent cont...

Page 104: ...h hoist to lift radiator and take up slack NOTE The radiator and shroud assembly weigh ap proximately 5 730 Lbs 2 600 Kg 10 Remove the upper radiator side support rods 4 Figure 3 1 Remove lower support rods 5 11 Remove nuts lockwashers flat washers and cap screws 2 Figure 3 5 from power module sub frame 3 at the lower radiator mounts 12 Verify all hoses and wiring harnesses have been removed Lift ...

Page 105: ...s 2 Figure 3 5 at lower radiator mounting brackets to standard torque 8 Install the fan guard using capscrews and wash ers removed during disassembly 9 Install upper radiator hoses and lines between radiator and engine seat hoses fully and tighten clamps securely 10 Install lower radiator hoses and lines between radiator and engine seat hoses fully and tighten clamps If outlet elbows 2 4 Figure 3 ...

Page 106: ...aches normal operating temperature Engine coolant must always be visible in the sight gauge before truck operation COOLANT SYSTEM TROUBLESHOOTING If abnormal coolant temperatures are experienced perform the following visual inspections and tests 1 Check coolant level and thoroughly inspect sys tem for leaks a Check for proper coolant antifreeze mixture b Follow engine manufacturer s recommenda tio...

Page 107: ...device that can handle the load safely 1 Attach hoist with two lifting chains to the two alternator lifting eyes 8 Figure 4 1 2 Block under rear of engine a Loosen cradle adjustments setscrews 3 Fig ure 4 2 b Loosen engine cradle capscrews 5 Figure 4 1 FIGURE 4 1 ENGINE AND ALTERNATOR 1 Alternator 2 Capscrews Lockwashers 3 Cradle 4 Flywheel Housing 5 Capscrews 6 Engine 7 Sub Frame 8 Alternator Lif...

Page 108: ... of the capscrews at all locations Be sure all the capcrew threads are completely disen gaged from the alternator housing 1 5 Take up slack in hoist and remove capscrews and lockwashers 2 Figure 4 1 securing the alterna tor to the cradle structures 6 Keep alternator as level as possible and move away from engine 7 Note shim location and quantity Retain shims for possible use during reinstallation ...

Page 109: ...e Runout Flywheel Housing 0 25 mm Max Eccentricity of Flywheel Coupling Assy 0 18 mm Max Axial Runout of Flywheel Face Coupling Assy 0 25 mm MEASURING PROCEDURE 1 Thoroughly clean the alternator housing mounting surface rotor drive adapter mounting surface and flywheel housing adapter mounting surfaces 2 With magnetic base mounted on the front of the engine and the dial indicator on the front of t...

Page 110: ... 4 4 d Carefully measure Dimension A Do not move alternator rotor at four 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 Measurement A Step 4 f a If C is greater than A subtract C A B B Shim pack thickn...

Page 111: ...adle structure mounting cap screws 5 Figure 4 1 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 ...

Page 112: ... Service Complete instructions covering the disassembly as sembly and maintenance of the engine and its compo nents can be found in the engine manufacturer s service manual Installation 1 Align engine to subframe and install front mount ing capscrews and lockwashers 5 Figure 4 7 Align and install rear engine mounting capscrews and lockwashers 2 through cradle structure but do not tighten at this t...

Page 113: ...tem The function of the safety filter is to increase overall reliability and engine protec tion The truck engine must be shut down before serv icing the air cleaner assemblies or opening the engine air intake system Never start the engine with the filter elements re moved Engine operation with elements removed can cause serious engine damage General Service Information Inspect and empty dust colle...

Page 114: ...ndary filter element indicator nut 7 If solid red area is showing safety filter replacement is required If center is green safety element does not require service Have a new safety secondary filter element on hand before removing old one Do not keep intake system open to the atmosphere any longer than absolutely necessary 5 If indicator indicates safety filter replacement is required remove indica...

Page 115: ...gged with carbon soot oil and or dust the com plete washing procedure will produce the best results 1 Wash elements with water and detergent as fol lows a Soak the element in a solution of detergent and water for at least 15 minutes Rotate element back and forth in the solution to loosen dirt deposits DO NOTsoak elements for morethan 24 hours b Rinse element with a stream of fresh water in the opp...

Page 116: ...s and remove dust collector cup Use a light to inspect the tubes all tubes should be clear and the light should be visible Clean the tubes as follows if clogging is evident Cleaning Precleaner Tubes Both the main and safety elements must be in stalled in the air cleaner while Steps 1 and 2 are being accomplished to prevent any possibility of dirt being forced into the engine intake area 1 Dust can...

Page 117: ...sembly and install all mount ing hardware removed 9 With a serviceablegasket install dust collector cup assembly on precleaner section and secure with mounting clamps AIR INTAKE TROUBLESHOOTING To insure maximum engine protection be sure that all connections between air cleaners and engine intake are tight and positively sealed If air leaks are sus pected check the following 1 All intake lines tub...

Page 118: ...NOTES C5 6 Air Filtration System C05013 5 98 ...

Page 119: ... A I D System D3 3 ELECTRICAL INTERFACE CABINET D3 6 TRUCK CONTROL INTERFACE PANEL TCI D3 6 Diode Board DB1 D3 8 Diode Testing D3 8 Relay Boards D3 9 Service D3 9 Body Up switch D3 13 Hoist Limit Switch D3 14 Circuit Breaker Chart D3 15 NOTE Electrical system wiring hookup and electrical schematics are located in Section R of this Manual DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNI...

Page 120: ...ing grids The following procedures will ensure the electrical system is properly discharged before repairs are started TRUCK SHUTDOWN PROCEDURE 1 Reduce the engine speed to idle Place the selector switch in NEUTRAL and apply the parking brake Be certain the Parking Brake Applied indicator lamp in the overhead panel is illumi nated 2 Place the drive system in the REST mode by turning the Rest switc...

Page 121: ...um battery life use only dis tilled water or water recommended by the battery manufacturer After adding water in freezing weather operate the engine for at least 30minutes to thoroughly mix the electrolyte DO NOT SMOKE or allow flame around a dead battery or during the recharging operation The expelled gas from a dead cell is extremely explo sive Excessive consumption of water indicates leakage or...

Page 122: ...more than two weeks the batteries should be removed and placed in a cool dry place where they may be checked periodically and charged when necessary Remember all lead acid batteries dischargeslowly 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 ...

Page 123: ...x 4 is located near the right corner of the front bumper This box contains the battery disconnect switches and other components listed below System Battery Starter Disconnect Relay TheSystem Battery Starter Disconnect Relay 7 Figure 2 2 isolates the engine cranking circuit when the starter is actuated from the system battery circuits to ensure the high current demand in the starter circuit does no...

Page 124: ...ernal batteries are used they should be of the same type 8D as the batteries installed on the truck Two pairs of batteries should be used Each pair should be connected in series to provide 24VDC with one pair connected to the top receptacle and the other pair connected to the bottom receptacle on the truck NOTE If both the truck cranking batteries and the system batteriesare discharged the system ...

Page 125: ...er a If the circuit breaker has opened check circuits and repair cause b Reset circuit breaker 2 Check other applicable circuit breakers to deter mine if one or more has opened Refer to Circuit Breaker Chart in the following Section for a list of circuit breakers and the circuits involved a If the circuit breaker has opened check circuits and repair cause b Reset circuit breaker 3 Check battery vo...

Page 126: ...NOTES D2 6 24VDC Electric Supply System D02018 ...

Page 127: ...series with the lamp reduces voltagesupplied to thelamp thereby reducing the lamp intensity When the service brakes are applied and the stop lights are activated current flows from the stop light relay through a diode bypassing the resistor and applies 24 VDC to the lamp filament RD1 controls the left lamp and RD2 controls the right lamp No adjustments are available or necessary 5 MINUTE IDLE TIME...

Page 128: ...4 Terminal Board TB12 5 Terminal Board TB11 6 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 D3 2 24VDC System Components D03019 04 01 ...

Page 129: ...RNING BUZZER BWB The brake warning buzzer 11 provides an audible alarm for the operator if a malfunction occurs in the hydraulic service brake system Refer to Section J for additional operational details ALARM INDICATING DEVICE AID SYSTEM The Alarm Indicating Device 16 Figure 3 1 used on Haulpak trucks is a device which is connected in the electrical accessories circuits to provide the operator wi...

Page 130: ...igh Temperature Light through terminal D8 R14 can adjust the temperature resistance at which the circuit is activated NOTE Some electronic engine controls monitor cool ant temperature If the engine controls monitor the circuit a 2KΩ resistor is installed to replace the tem perature sensor and disable the AID system circuit The Latch Circuit monitors the accumulator precharge pressure switches When...

Page 131: ... by connecting it to the 12M circuit In addition some of the indicator light circuits are routed through a dimmer module to allow the operator to vary the inten sity of the lamps These lamps are fed by circuits 12FD flashing and 12MD steady When an indicator circuit is not activated there is no ground circuit for the bulb When the Indicator detect ing switch activates the circuit it grounds the la...

Page 132: ...nt test point for measuring battery voltage during troubleshooting procedures TRUCK CONTROL INTERFACE PANEL The Truck Control Interface Panel TCI 6 Figure 3 3 is the main interface between truck systems and de vices and service personnel This panel is used in conjunction with the Diagnostic Information Display DID located in the operator s cab The TCI panel provides the following functions Communi...

Page 133: ...anel TCI 7 Relay Board RB7 Not Used 8 Cabinet Service Light 9 Barometric Pressure Transducer 10 Circuit Breaker Panel 11 Relay Board RB2 12 Relay Board RB3 13 Relay Board RB4 14 Relay Board RB5 15 Cable Entrance Panel 16 Diode Board DB1 17 24 VDC Terminal 18 Control Power Relay 19 12 VDC Terminal 20 Cabinet Left Wall 21 Cabinet Right Wall D03019 04 01 24VDC System Components D3 7 ...

Page 134: ...helock ing ears while pulling the connector off the board Note the connector key used to ensure correct polarity NOTE Some digital multimeters are designed to test diodes If this type is used follow the manufacturer s instructions for proper test 2 An analog ohmmeter can be used to test the diode as follows a Place the meter on the X100 scale b With the red meter lead on the banded end of the diod...

Page 135: ...e contacts inside the relay may not be closing or the contacts may be open preventing an electrical connection Swap relays and check again Replace defective relays Check the wiring and all of the connections be tween the relay board and the component for an open circuit Defective component Replace component Poor ground at the component Repair the ground connection Service To replace a relay NOTE T...

Page 136: ...ws Refer to Figure 3 3 for location Relay Board 1 Clearance Turn Signal Relay Board 2 Payload Meter Relay Board 3 Stop Retard Backup Lights Relay Board 4 Parking Brake Horn Body up Engine Cranking Relay Board 5 Head Lights Relay Board 6 Engine Functions Mid Full Load Signals to PSC Backup Lights Horn Refer to Circuit Breaker Chart for electrical circuit iden tification numbers FIGURE 3 6 TYPICAL R...

Page 137: ...relays 4 Relays Light Relay 1 Green K1 Light Relay 2 Amber K2 Light Relay 3 Red K3 Light Control Relay K4 Relay Board 3 RB3 1 Light Module Display card 1 Rev Light Green This light is ON whenever the selector switch is in the reverse position and the key switch is in the ON position 4 15 amp circuit breakers CB16 CB17 CB18 CB19 4 Relays Manual Back up Lights Relay K1 Stop Lights Relay K2 Retard Li...

Page 138: ...o control 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 pro tected by a circuit breaker coming into the relay which will supply the electrical power for the com ponent being controlled NC terminal is connected through the relay to the COM terminal w...

Page 139: ... assembly Adjustment Prior to adjusting the body up switch inspect body pads for wear or damage and replace pads if required The body must be resting on the frame in the normal body down position when adjustments are made 1 Loosen capscrews 2 Figure 3 8 and adjust prox imity switch bracket 3 to achieve an air gap dimension A between sensing area cross hatched area as marked on switch and actuator ...

Page 140: ...et to prevent further oil flow to the hoist cylinders The switch must be properly adjusted at all times Improper adjustment or loose mounting bolts may cause false signals or damage to the switch assembly Adjustment With body raised and hoist cylinders within 6 in 152 mm of maximum travel make the following adjust ment 1 Adjust limit switch to achieve an air gap dimen sion A of 0 50 to 0 56 in 12 ...

Page 141: ... Elect Interface Cabinet CB23 15 Low Beam Headlight L H 11DL RB5 Elect Interface Cabinet CB24 15 Low Beam Headlight R H 11DR RB5 Elect Interface Cabinet CB25 15 High Beam Headlight L H 11HL RB5 Elect Interface Cabinet CB26 15 High Beam Headlight R H 11HR RB5 Elect Interface Cabinet CB27 15 Headlight Switch 11D RB5 Elect Interface Cabinet CB28 15 Payload Meter 39J RB2 Elect Interface Cabinet CB29 1...

Page 142: ...NOTES D3 16 24VDC System Components D03019 04 01 ...

Page 143: ... Checks Battery Power On E3 7 Memory Backup Battery Replacement E3 10 TCI Programming E3 10 PSC Programming E3 11 Inverter Programming E3 11 Truck Control Interface TCI Checkout E3 12 Propulsion System Controller PSC Checkout E3 18 Load Testing E3 26 On Board Load Testing E3 30 PVM Optimum Load Curve Handshaking Troubleshooting E3 35 MISCELLANEOUS COMPONENT REPAIR E3 36 Troubleshooting Phase Modul...

Page 144: ... propulsion system does not have dangerous voltage levels present before repairs are started THE LINK VOLTAGE LIGHTS MUST NOT BE ILLUMINATED WHEN TEST OR RE PAIRS ARE INITIATED It requires approximately 5 minutes after the truck is shut down before the Link Voltage has dissipated AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR AND ITS CIRCUITS TO DE ENERGIZE Do not attemp...

Page 145: ...opulsion and 600 and 1500 volts during retarding The alternator field is supplied from a tertiary winding on the alternator and is controlled by a silicon control led rectifier SCR bridge A starting boost circuit in itially energizes the alternator from the truck batteries until the flux builds up enough to sustain excitation Cooling air for the Alternator only is supplied by an internal fan assem...

Page 146: ...FIGURE 2 1 PROPULSION SYSTEM DIAGRAM E2 2 Electrical Propulsion System Components E02014 3 01 ...

Page 147: ...r data software code etc Drive the operator cab status and warning lamps The PSC contains the following internal removable printed circuit boards and an external fiber optic board Brief descriptions of board functions are as follows 17FB127 Power Supply Supplies regulated 15VDC 15VDC and 5VDC for internal panel use and 15VDC external circuits 17FB147 System CPU Card Provides serial communications ...

Page 148: ...ls to activate many of the cab mounted warning lamps and gauges Con trols the park brake solenoid Processes front wheel speed signals for the PSC and speedometer The 17FL349 TCI Panel contains the following inter nal removable printed circuit boards 17FB127 Power Supply Supplies regulated 15VDC 15VDC and 5VDC from the filtered battery supply B input 17FB144 CPU Card Provides high speed RS422 seria...

Page 149: ...ay line may change to indicate what func tions are available by pressing the F1 through F5 keys In addition the DID panel can be used by to perform the self load test DID PANEL FAULT CODES The Tables on the following pages list the possible event codes which may be displayed on the DID panel when accessed Table I below describes restrictions to operation of the propulsion and retarding systems whe...

Page 150: ...04 alternator No Propel Temperature exceeds a limit for a sufficient time 05 left stator No Propel Temperature exceeds a limit for a sufficient time 06 left rotor No Propel Temperature exceeds a limit for a sufficient time 07 right stator No Propel Temperature exceeds a limit for a sufficient time 08 right rotor No Propel Temperature exceeds a limit for a sufficient time 09 chopper GTO No Propel T...

Page 151: ...retard lever 012 RETARD PEDAL BAD No propel Incorrect input from retard pedal N A 3 01 voltage too high No propel Incorrect input from retard pedal 02 voltage too low No propel Incorrect input from retard pedal 013 LINKV ABOVE MIDVOLT No power Incorrect link volts 014 SENSOR FAULT No propel Incorrect input from a sensor 01 alt field amps No propel Incorrect input from a sensor 02 link amps No prop...

Page 152: ...rial data received from TCI over period of time N A 3 01 message missing No propel No serial data received from TCI over period of time 02 bad tick No propel No serial data received from TCI over period of time 03 bad CRC No propel No serial data received from TCI over period of time 04 overflow No propel No serial data received from TCI over period of time 05 bad start bit No propel No serial dat...

Page 153: ...Y19 GRID BLOWER FAILURE No power A grid blower has failed 01 blower 1 stall No power A grid blower has failed 02 blower 2 stall No power A grid blower has failed 03 blower 1 open No power A grid blower has failed 04 blower 2 open No power A grid blower has failed 05 blower 1 2 delta too large No power A grid blower has failed 037 VOLTS 5 POS No propel 5V Power Supply out of limits 038 VOLTS 15 POS...

Page 154: ...ruck stopped No spin slide on M1 High output from sensor with all other wheel speeds zero 054 TACH RIGHT FRONT No spin slide on M2 Input from right front wheel sensor out of tolerance N A 3 01 zero output with truck moving No spin slide on M2 Zero output from sensor with rear wheels moving brake released 02 high output with truck stopped No spin slide on M2 High output from sensor with all other w...

Page 155: ... range 03 auxrpm feedback None Rpm feedback does not match rpm command 086 AUX BLOWER SYSTEM None Aux OK signal goes low while aux blower is being commanded to run 087 HP LOW None Horsepower adjust is at negative limit for 30 seconds N A 10 088 HP LIMIT No propel Horsepower limit exceeded while in propulsion N A 10 01 engine may stall None HP demand is above HP available 089 ENGINE SPEED DOES NOT ...

Page 156: ... None A limp mode request is received while truck is moving N A 10 01 inverter cutout None Inverter cutout switch is moved improperly truck is moving or not in NEUTRAL 095 BAD BRAM BATTERY None BRAM battery voltage low N A 3 096 UNEXPECTED PSC CPU RESET None PSC CPU reset without request 098 DATA STORE None PTU data store command N A 099 SOFTWARE EVENT None Software error N A 3 E2 12 Electrical Pr...

Page 157: ...m TIC No power Cam ISR not running 49 no peak samp TIC No power Peak sample ISR not running 101 201 INVERTER CPU CARD 01 Aup cmd not off No power Phase A up command not off 02 Adn cmd not off No power Phase A down command not off 03 Bup cmd not off No power Phase B up command not off 04 Bdn cmd not off No power Phase B down command not off 05 Cup cmd not off No power Phase C up command not off 06 ...

Page 158: ...ommand not off 03 chop 1 cmd not on No power Chopper 1 command not on 04 chop 2 cmd not on No power Chopper 2 command not on 05 volt scale A flt No power Scale A volts out of range 70 100 06 volt scale B flt No power Scale B volts out of range 70 100 07 link V scale flt No power Link V scale out of range 70 100 08 current scale A flt No power Scale A current out of range 70 100 09 current scale B ...

Page 159: ...power supply monitor 02 fo card disable No power Fiber optic card disabled 03 fo card enable No power Fiber optic card enabled and no dir 105 205 POWER SUPPLY CARD 01 P5V not ok No power 5 volt not in tolerance 02 P15V not ok No power 15 volt not in tolerance 03 N15V not ok No power 15 volt not in tolerance 06 P24V not ok No power 24 volt not in tolerance 07 N24V not ok No power 24 volt not in tol...

Page 160: ...oo low 13 A zero cur hi No power Phase A current out not zero 15 B zero cur hi No power Phase B current out not zero 17 A volt hi Adn No power Phase A volt too high while phase A down on 18 A volt lo Aup No power Phase A volt too low while phase A up on 19 A volt hi Bdn No power Phase A volt too high while phase B down on 20 A volt lo Bup No power Phase A volt too low while phase B up on 21 A volt...

Page 161: ...urrent when phase B up on 38 Bdn fault cur No power Phase B fault current when phase B down on 39 Cup fault cur No power Phase C fault current when phase C up on 40 Cdn fault cur No power Phase C fault current when phase C down on 48 A volt hi off No power Phase A voltage high with all GTOs off 49 A volt lo off No power Phase A voltage low with all GTOs off 50 B volt hi off No power Phase B voltag...

Page 162: ...wer Phase C positive current high unbalance 82 no current w run No power No current while running 114 214 INVERTER GENERAL 22 IA VCO lo No Propel Low frequency on IA channel 24 IB VCO lo No Propel Low frequency on IB channel 26 linkV VCO lo No Propel Low frequency on VCO link filter V channel 28 infilV VCO lo No Propel Low frequency on VCO in filter V channel 38 LinkV too lo No Propel Link voltage...

Page 163: ...ower VI test incomplete 116 216 INVERTER PHASE A A 01 alarm A No power Phase A GTO did not turn off 02 PTF A No power Overcurrent in phase A 03 IGBT_SAT_AP No power IGBT saturated 04 IGBT_SAT_AN No power IGBT saturated 117 217 INVERTER PHASE A 01 alarm AP No power Phase A pos GTO did not turn off 02 Aup fb not off No power Phase A up feedback not off 03 phase A modl pos No power Phase A positive m...

Page 164: ...t off with enable DC volts 121 221 INVERTER PHASE A CURR 01 I sensor ph A No power Phase A current sensor failed 02 IA zero not ok No power Current IA not zero at startup 03 IA not ok No power Phase A current too high 04 I snsr ph A open No power Phase A current sensor open 05 I snsr ph A short No power Phase A current sensor short 123 223 INVERTER PHASE A VOLTS 01 V sensor phase A No power Phase ...

Page 165: ...on 07 IGBT_PS_BN No Power IGBT protective shutoff 129 229 INVERTER PHASE B 02 Bdn temp short No Propel Phase B down thermistor short 03 Bdn temp open No Propel Phase B down thermistor open 04 Bdn temp warm No Propel Phase B down thermistor warm 05 Bdn temp hot No Propel Phase B down thermistor hot 06 Bdn fb not off S No Propel Phase B down not off with enable DC volts 130 230 INVERTER PHASE B CURR...

Page 166: ...istor hot 06 Cup fb not off S No propel Phase C up not off with enable DC volts 137 237 INVERTER PHASE C 01 alarm CN No power Phase C negative GTO did not turn off 02 Cdn fb not off No power Phase C down feedback not off 03 phase C modl neg No power Phase C negative module failed 04 hold CN No power Phase C positive and negative GTOs on negative turn on 05 Cdn fb not on No power Phase C down feedb...

Page 167: ...hermistor short 04 chopA temp open No power ChopA thermistor open 05 chopA temp warm No power ChopA thermistor warm 06 chopA temp hot No power ChopA thermistor hot 07 DB1 fb not off S No power Chopper 1 not off with DC volts 150 250 INVERTER CHOPPER 2 01 chop2 fb not off No power Chopper 2 feedback not off 02 chop2 fb not on No power Chopper 2 feedback not on 03 chopB temp short No power ChopB the...

Page 168: ...ENT RESTRICTION DETECTION INFORMATION EVENT NUMBER Limp Possible Lockout Limit 155 255 INVERTER 2ND LOAD 01 second load open No power Second load connection open 175 INV 1 GENERIC EVENT None Inverter shutdown with no event code E2 24 Electrical Propulsion System Components E02014 3 01 ...

Page 169: ...l CRC on BBRAM did not match expected value 602 DIGITAL I O CARD FAULT No propel Internal TCI self test detected a digital I O card problem 603 ANALOG I O CARD FAULT No propel Internal TCI self test detected an analog I O card problem 604 PSC FAULT No propel Lost RS422 communication with PSC 01 missing message No propel Lost RS422 communication with PSC 02 bad tick No propel Lost RS422 communicati...

Page 170: ...07 payload None Signal is outside the design range of valid values 08 ambts None Signal is outside the design range of valid values 09 hydbrktemp None Signal is outside the design range of valid values 10 motorpress None Signal is outside the design range of valid values 11 grade None Signal is outside the design range of valid values 12 cntrlbatt None Signal is outside the design range of valid v...

Page 171: ...t too low No propel Accelerator pedal signal below minimum limit 622 PARK BRAKE FAULT No propel Error in park brake operation has occurred 01 command response failure No propel Park brake command and feedback don t agree 02 set above maximum speed No propel Park brake set feedback received when truck is moving 623 HYDRAULIC BRAKE FLUID None Hydraulic brake oil temperature has exceeded limit N A 3 ...

Page 172: ...mit Voltage above maximum operational limit 631 AMBIENT TEMPERATURE No propel Ambient temperature signal outside operational limits N A 5 01 low No propel Voltage feedback below minimum operational limit 02 high No propel Voltage above maximum operational limit 632 TCI CONFIGURATION DATA No propel Problem with TCI configuration file N A 2 01 GE config file No propel Configuration file loaded impro...

Page 173: ...d due to low dc bus voltage 13 gate drive trip None IGBT protection circuit detected overload 14 no input voltage None Zero input voltage detected 637 AUX DC LINK HOT None Auxiliary inverter DC link energized while traction inverter DC link de energized N A 691 PSC COMM FAULT None A PSC communication error has occurred N A 10 01 missing message None A PSC communication error has occurred 02 bad ti...

Page 174: ... is to provide an environment for the verification of system functionality Test state will support a variety of activities including 1 Waiting for the engine to start if needed 2 Automatic testing on initial system startup or following rest state 3 Application of power to the DC link 4 Externally initiated testing to clear a fault set temporary variables or for maintenance pur poses NOTE The Test ...

Page 175: ...nctions performed while in Startup Shutdown state for the purpose of startup have been completed Transition from Test State to Ready State This transition will occur upon completion of any re quired testing if all of the following conditions are true 1 The TCI rest request is not active 2 There is sufficient voltage on the DC link Transition to Rest State This transition will occur automatically f...

Page 176: ...peed is below the set retard speed and acceleration is such that no retard effort is currently required to maintain this condition Transition from Propel State to Retard State The system will transition directly from Propel state to Retard state if at least one of the following conditions exists 1 Truck speed is such that retard is allowed and the retard pedal or lever is pressed such that a sig n...

Page 177: ...rence signal is 0 De Powering the Link The PSC software will attempt to de power the DC link i e command the system configuration defined be low if the system is in Test or Ready state and any of the following conditions are true 1 Event restrictions prohibit power on the DC link 2 The system is preparing to transition to Startup Shutdown state for the purpose of shut down i e all the non link rel...

Page 178: ...ge will be ade quate During retard the DC link voltage is not necessarily related to the three phase voltage since the motors will be powering the DC link and reverse biasing the rectification diodes In this case the control ensures that the minimum three phase voltage is maintained Desired DC Link Voltage The desired link voltage is controlled by the alternator during all powered states except re...

Page 179: ...total desired torque as possible is maintained Retard Torque Control The retard system converts braking torque from the wheel motors to energy dissipated in the resistor grid The requested retard torque is based on the following three sources Retard Foot Pedal or Lever The maximum short time retard torque at any speed hence the constant torque level will be scaled linearly by the retard foot pedal...

Page 180: ...e aux blower system status AUXOK indi cates the aux blower system is not okay a reset pulse will be sent Additional reset pulses will be sent at periodic intervals if the aux blower system does not respond EVENT PROCESSING The PSC contains very powerful troubleshooting soft ware The PSC software constantly monitors the AC drive System for any abnormalities events Automatic self tests are performed...

Page 181: ...tance is below the minimum allowable level event 71 logs and the truck is restricted to 10 MPH If test is not able to complete after numer ous attempts event 72 logs indicating a problem in the truck s ground detection circuit and truck speed is limited to 10 MPH Initiated Tests These tests are performed when requested by main tenance personnel the truck must be in test mode for these tests to run...

Page 182: ...ch containing 100 frames of real time snapshot data Snapshot data is defined as a collection of key data parameter values for a single point in time The purpose of each data pack is to show a little movie of what happened before and after a fault The time interval between snapshots is default to 50 ms but each data pack may be programmed via the DID or PTU from 10 ms to 1 sec In multiples of 10 ms...

Page 183: ...mit the background data PSC PTU Communications Processing This software function performs the processing neces sary for the PSC System CPU Card to communicate through an RS 232 serial link to the Portable Test Unit PTU Inverter Communications Processing This software function performs the processing neces sary for the System CPU Card to communicate with both Inverter CPU Cards The communications i...

Page 184: ...to 0 5 second Limp Home Mode The purpose of Limp Home mode is to address the situation where the truck has suffered a failure and is not able to continue normal operation but is still capa ble of limping getting either back to the maintenance area or at least out of the way of other trucks The intent is that limp mode will be used by maintenace personnel operating the truck at low speeds with the ...

Page 185: ... with the AXIND to filter the regulated DC voltage from the Auxiliary Phase Control Rectifier into a smooth DC supply suitable for use by the Auxiliary Power Inverter AXFU1 2 33 Auxiliary Power Rectifier Input Fuses 1 and 2 Provide overload protection for the Auxiliary Power Inverter Phase Control Rectifier AXIND 30 Auxiliary Power Filter Inductor Used with the AXCAP to filter the regulated DC vol...

Page 186: ...utput Chopper Module Resistor Grid circuits and traction Inverters CIF11 12 13 14 15 16 40 Inverter 1 Filter Capacitors Stores the Inverter 1 DC bus voltage to provide instantaneous power when the PM1 GTO Phase Modules first turn on CIF 21 22 23 24 25 26 41 Inverter 2 Filter Capacitors Stores the Inverter 2 DC bus voltage to provide instantaneous power when the PM2 GTO Phase Modules first turn on ...

Page 187: ...nt for FDP operation FIBER OPTIC ASSEMBLY 31 Fiber Optic Assembly Provides volatage and electrical noise isolation for control and feedback signals between the PSC and Phase Chopper Modules FP 39 Filter Panel 17FM460 Filters electrical noise on 3 phases of Alternator output GDFU1 2 1 Gate Driver Power Source Fuse 1 and 2 Provide overload protection for the Gate Drive Power Supply GDPC1 17 Gate Dri...

Page 188: ...t corner of electrical cabinet KEYSW Key Switch Connects battery voltage to CPR and control circuits when closed Located on instrument panel LDBXI 48 Load Box Current Sensing Module Monitors current during load box test LEDP 60 Light Emitting Diode Panel LED s indicate status of the following CPR Illuminated when CPR is energized SYS RUN Illuminated when the PSC power up sequence has completed suc...

Page 189: ...Grid Resistors Dissipate power from the DC link during retarding load box testing and Inverter Filter Capacitor discharge operations RP1 2 3 47 Retard Contactors 1 2 and 3 17CM55 When closed connects Grid Resistors to the DC link during retarding load box testing and Inverter Filter discharge operations RP1S 2S 3S 55 Suppression Modules Suppresses voltage spikes in coil circuit when RP contactors ...

Page 190: ...rges the Alternator field when the AFSE is first turned off VAM1 46 Voltage Attenuation Module 17FM702 Attenuates the three high voltage outputs applied to each phase winding of Traction Motor 1 to a level acceptable for use by the Analog I O card in the PSC VAM2 46 Voltage Attenuation Module 17FM702 Attenuates the three high voltage outputs applied to each phase winding of Traction Motor 2 to a l...

Page 191: ...FIGURE 2 3 ELECTRICAL CABINET FRONT VIEW E02014 3 01 Electrical Propulsion System Components E2 47 ...

Page 192: ...FIGURE 2 4 ELECTRICAL CABINET TOP VIEW E2 48 Electrical Propulsion System Components E02014 3 01 ...

Page 193: ...FIGURE 2 5 ELECTRICAL CABINET REAR FLOOR VIEW E02014 3 01 Electrical Propulsion System Components E2 49 ...

Page 194: ...2 6 CONTACTOR BOX Right Side Electrical Cabinet FIGURE 2 7 INFORMATION DISPLAY PANEL Left Front Corner of Electrical Cabinet FIGURE 2 8 RETARDING GRIDS E2 50 Electrical Propulsion System Components E02014 3 01 ...

Page 195: ...s from truck harness connector 2 Remove mounting capscrews lockwashers and nuts and remove pedal assembly Installation 1 Install pedal assembly using hardware removed in step 2 Removal Connect potentiometer to wiring harness 2 Calibrate pedal potentiometer per instructions in AC Drive System Checkout Procedure Setting Pedal Percentages Disassembly 1 Remove screws on cable clamps 1 Figure 2 9 and p...

Page 196: ...NOTES E2 52 Electrical Propulsion System Components E02014 3 01 ...

Page 197: ... have dan gerous voltage levels present before re pairs are started If weld repairs are required the welding ground electrode should be attached as close as possible to the area to be welded NEVER weld on the rear of the Electrical Control Cabinet or the retard grid exhaust air louvers Power cables and wiring harnesses should be protected from weld spatter and heat Prior to welding disconnect Engi...

Page 198: ...e energized during test and repair procedures turn the GF Cutout Switch 8 Figure 3 1 to the CUTOUT position by pulling the switch handle out before moving the switch AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR CIRCUITS TO DE ENERGIZE Do not attempt to perform Auxiliary Blower repairs until it has been verified the system is de ener gized by verifying the Blower Module...

Page 199: ...ry Capacitor Panel AXCAP 4 If these lights are off the blower system blower power cables and remainder of the control cabinet is safe to work on The normal de energi zation time is 10 to 15 minutes IF THE LINK VOLTAGE RED LIGHTS IN THE CON TROL CABINET INFORMATION DISPLAY PANEL AND OR CONTACTOR BOX AND OR THE BACK WALL OF THE OPERATOR CAB CONTINUE TO BE ILLUMINATED AFTER FOLLOWING THE ABOVE PROCED...

Page 200: ...receded by this symbol escape When a keyboard key must be pressed the key label is enclosed in braces PTU screen display information is shown in this type font and pre ceded by this symbol Note The following test procedures are applicable to Release 17 software Procedures required for later software versions may vary Contact the Komatsu distributor or factory representative for current soft ware v...

Page 201: ...abinet service light operator cab light passenger seat compartment service light hazard lights headlights ground level engine shutdown switch engine governor heater switch MTU 396 only in Electrical Interface Cabinet left and right side engine service lights 11T TB30 36Ω Engine governor heater switch in Electrical Interface Cabinet open MTU 396 engine only 11FR TB30 MTU 396 engine only 11HTR TB30 ...

Page 202: ...ve lead on a cabinet ground Resistance should be 2 megohms or greater 7 Place VOM positive lead on the DC plus link and the VOM negative lead on the DC negative link VOM must be on the Rx1 scale otherwise the link capacitors will start charging and an accurate reading will not be possible Resistance should be infinity 8 VOM positive lead on the DC negative bus and the VOM negative lead on the DC p...

Page 203: ...INK VOLTAGE IS DRAINED OFF before performing tests 1 Preparation for Power Supply Voltage Checks a Remove the 50 amp system fuse BATFU located on the bottom left wall in the left com partment of the control cabinet b If equipped with MTU 396 engine disconnect circuits 21SS and 21SR and insulate wire ter minals at the engine starter If equipped with Komatsu or MTU DDC 16V4000 engine dis connect cir...

Page 204: ...significantly low check battery circuits If voltage is slightly low install a battery charger 6 Check and record circuit 11B1 voltage to ground Read approximately 12V DC 7 Using a digital multimeter check polarity at the BATFU fuse holder With the leads on BATP positive lead and RTN negative lead meter should indicate BATP is positive 8 Turn the Key Switch ON 9 Check Circuit 712 to ground Voltage ...

Page 205: ... on the edge of the 17FB147 card in the PSC panel Connect the positive lead to the top screw 2 Figure 3 3 and the negative lead to the bottom screw 4 Verify approximately 3 5 volts 12 Connect a VOM across the screws securing the green plate on the edge of the 17FB144 card in the TCI panel Connect the positive lead to the top screw and the negative lead to the bottom screw Verify approximately 3 5 ...

Page 206: ...ERSON NEL must be present to program the TCI BE SURE TO VERIFY LINK VOLTAGE IS DIS CHARGED BEFORE PERFORMING THE FOLLOW ING PROCEDURES 1 Disconnect Circuits 21SS and 21SR and insulate from engine starter if equipped with MTU 396 engine If MTU DDC 16V4000 or Komatsu engine is installed disconnect and insulate 21B circuits at starter solenoids Apply park brake and brake lock a Connect the serial com...

Page 207: ...ighlight DOWNLOAD PSC PANEL Highlight DOWNLOAD PSC 3 Cycle keyswitch or CPS when requested on screen 4 Verify the Object Code and Configuration file shown on the screen for downloading is correct INVERTER PROGRAMMING NOTE At the present time GE or KMS PERSON NEL must be present to program the PSC BE SURE TO VERIFY LINK VOLTAGE IS DIS CHARGED AND ENGINE IS NOT RUNNING BE FORE PERFORMING THE FOLLOWI...

Page 208: ...d the center console in the cab on the driver side c ACNMENU enter Highlight PTU TCI PSC enter Type your name enter Type your password enter View Set the Date and Time in the PSC panel Cursor to Special Tasks enter Cursor to View Set Time enter Cursor to Day of Month Type day of month enter Arrow to desired month enter Cursor to year type year enter Cursor to hour type hour enter Cursor to minute ...

Page 209: ...ted on the PTU are similar to the examples below Note Actual values shown in illustrations will vary from those displayed on truck being serviced 2 Press enter to display TCI SERIAL LINK DATA screen shown below 3 Press enter to display TCI ANALOG INPUT CHANNELS screen below E03015 3 01 AC Drive System Electrical Checkout Procedure E3 13 Release 17 Software ...

Page 210: ...tch in NEUTRAL and apply park brake TABLE II TCI DIGITAL OUTPUT TESTS STEP DO NAME DESCRIPTION LOCATION FIG 3 4 1 RESTLT Rest Light B6 2 PSCNOTRDY Propel System Not Ready Light C6 3 REDUCELT Reduced Propulsion Level Light D6 4 LINKONLT Link ON light DID Panel Behind Operator s Seat 5 TEMPWARNLT Propulsion System Temperature Warning Light C5 6 NORETARDLT No Retard No Propel Light A5 7 NOPROPELLT No...

Page 211: ... will be 01 if the TCI is not communicat ing with the aux inverter FIGURE 3 4 STATUS WARNING LIGHTS Row Column Indicator Description Indicator Color A1 Spare B1 Low Steering Pressure Red C1 Low Accumulator Precharge Red D1 Spare E1 Low Brake Pressure Red A2 Low Hydraulic Tank Level Red B2 Autolube Low Pressure Amber C2 Circuit Breaker Tripped Amber D2 Hydraulic Oil Filter Restricted Amber E2 Low F...

Page 212: ...t to activate the function Refer to Table III below for instructions 4 Turn OFF and ON all circuit breakers on relay boards RB1 RB2 RB3 RB4 and RB5 in the Electrical Interface Cabinet Verify the Circuit Breaker Tripped lamp on the overhead display illuminates when each circuit breaker is turned off except as noted below Note To check CB19 on relay board 3 selector switch must be in REVERSE positio...

Page 213: ...tdown Switch Depress switch on console 9 DATASTORE Data Store Switch on front of console push to activate 10 BODYDWN Body Up Switch Activated when body is down 11 PRKBRKSW Park Brake Switch Highlighted with switch ON 12 PRKBRKFDBK Park Brake Feedback Signal Highlighted Jumper circuit 73S on Park Brake Pressure switch on brake manifold in brake cabinet to ground to remove highlight 13 ENGSTRTREQ En...

Page 214: ...icks up and RP1FB is highlighted 4 RP2 RP2 Contactor Verify RP2 picks up and RP2FB is highlighted 5 RP3 RP3 Contactor Verify RP3 picks up and RP3FB is highlighted 6 CPRL Control Power Relay With CPRL highlighted turn off CPS and verify that control power is not lost Turn CPS back on 7 AFSE Alternator Field Static Exciter With AFSE highlighted verify 24 volts to ground on the 25 terminal on the AFS...

Page 215: ...for 90 to 100 volts AC between the pins on the round connector on the top of Chopper Module 2 CM2 G X removed in step 3 Press escape escape 18 Turn OFF the Control Power Switch 19 Reconnect the round connectors to Inverter 2 20 Reconnect the round connector for Chopper Mod ule 2 21 Turn ON the Control Power Switch Cursor to Engine Stopped Tasks enter Cursor to Manual Test Mode enter Highlight GD2E...

Page 216: ...ff CPRL escape escape 7 Turn OFF Control Power Switch TABLE V PSC DIGITAL INPUT TEST STEP DI NAME DESCRIPTION DEVICE CHECKOUT 1 KEYSW Key Switch With the Key Switch and Control Power Switch ON digital inputs should be highlighted 2 CPSFB Control Power Switch Feedback 3 CNFB Panel Connectors Status 4 CNIFB CNI and CNENG Connector Status 5 CNXFB Auxiliary Blower Connector Status 6 INV1CO Inverter 1 ...

Page 217: ...onnect a jumper wire from the BATFU fuse located on the bottom left wall in the left compart ment to terminal A on LINKV 4 Connect a jumper wire from a cabinet ground to terminal C on LINKV 5 Measure voltage between terminals D and F Verify panel output is 0 12 volts battery volts divided by 200 6 With the PTU connected to the PSC enter the following c ACNMENU enter Highlight PTU TCI PSC enter Typ...

Page 218: ...e parameter value with the lever down typical value 8 75 volts Meter Calibration Procedure 1 Connect the serial communication cable from the PTU to the TCI port behind the center console on the passenger side 2 Turn ON the Key Switch and the Control Power Switch 3 On the PTU enter the following c ACNMENU enter Highlight PTU TCI PSC enter Type your name enter Type your password enter 4 Turn park br...

Page 219: ... the following information from the screen F Accelerator pedal Record the accel pedal voltage with pedal released typical value 1 61 Record the accel pedal voltage with pedal fully depressed typical value 8 53 G Retard Speed Pot Setting 13 Pull the retard speed control button UP Record value of RSC POT with knob fully counterclockwise typical value 10 75 Record value of RSC POT with knob fully clo...

Page 220: ... configuration filename enter Cursor to Q Quit enter Type Y Example To determine accelerator pedal percentages using above formula 1 Divide accelerator voltage with pedal released 1 61 volts step F by Pot Reference Voltage 10 86 volts step H Multiply result by 100 to obtain percentage value to enter for percent accel pedal travel off request on Change View Truck Specifics screen 2 Divide accelerat...

Page 221: ...wn on the screen for downloading are correct K Check Pedal Percentages On the PSC PTU cursor to Normal Operation enter Cursor to PSC Real Time Data enter 1 With the accelerator pedal released verify the following is displayed ACCEL_SEL 0 00 2 With the accelerator pedal fully applied verify the following is displayed ACCEL_SEL 1 00 3 With the retard pedal released and retard lever up verify the fol...

Page 222: ...ights must be OFF 1 Connect a voltmeter across resistor R1 located in the Contactor Box on the Electrical Cabinet a Connect the positive lead to BAT b Connect the negative lead to F101 2 Close the cabinet door 3 Turn Key Switch and Control Power Switch ON 4 Connect one serial communication cable from the PTU to the PSC port C ACNMENU enter Highlight PTU TCI PSC enter Type your name enter Type your...

Page 223: ...FIGURE 3 6 PSC REAL TIME DATA SCREEN FIGURE 3 7 TCI REAL TIME DATA SCREEN E03015 3 01 AC Drive System Electrical Checkout Procedure E3 27 Release 17 Software ...

Page 224: ... in the CUT OUT position down 3 Start the engine 4 Move the GF Cutout Switch to the NORMAL position 5 Move the Rest Switch to the OFF position 6 Check the rotation of the Aux Blower Make sure it is rotating counterclockwise as viewed from the driver side of the truck Verify the Link Voltage lights are ON Verify that the exhaust holes on the control cabinet are free of debris and air is flowing out...

Page 225: ...TU still connected to the PSC port and the PSC REAL TIME DATA screen displayed and the engine running compare the values dis played with the values shown on the sample screen in Figure 3 8 3 Verify AUXFB is about 1700 rpm and exhaust air is flowing from the rear exhaust ports of the control cabinet Inverter Link Voltage Check 1 On the PSC PTU Cursor to Normal Operations enter Cursor to View Set PS...

Page 226: ...with just control power on Refer to PVM Test at the end of this section for additional information 3 Turn brake lock ON 4 On the PSC PTU Cursor to Normal Operation enter Cursor to PSC Real Time Data enter 5 With the engine running place the Rest Switch in the OFF position 6 Verify the analog values and the functions high lighted on the PTU are similar to the screen shown in Figure 3 8 7 Place the ...

Page 227: ... of the screen This is a self test indication 3 Put the Selector Switch in NEUTRAL and depress the accelerator pedal RPM must be above 1300 RPM to pick up RP1 4 Compare the values on the Loadbox Screen to the values shown in Figure 3 10 FIGURE 3 9 TCI REAL TIME DATA SCREEN SAMPLE FIGURE 3 10 SELF LOAD TEST SCREEN RP1 PICKED UP E03015 3 01 AC Drive System Electrical Checkout Procedure E3 31 Release...

Page 228: ...mpare values displayed on the Loadbox Test Screen with the sample screen in Figure 3 11 8 Fully depress the accelerator pedal to pickup all three RP contactors 9 Compare the values on the loadbox screen with the values shown in the sample screen in Figure 3 12 10 Record the Loadbox Screen on the PTU as fol lows a While viewing the loadbox screen during full load Press the F2 key Arrow down to reco...

Page 229: ...ead the parasitic losses from the graph based on ambient temperature and altitude 2 Add the value on the graph to the delivered HP to GE and compare that to the 5 value at the rpm rated tolerance i e 2612 HP plus value from graph corrected HP Manual Offset HP Output Adjustment If necessary to troubleshoot HP problems use the following procedure 13 With loadbox initiated cursor to HP Offset enter C...

Page 230: ...R Komatsu SSDA16V160 2700 GHP ECS 8 Blade 78 dia 5 3 PW 798 RPM FIGURE 3 14 TOTAL PARASITIC LOSS AT FULL POWER DDEC 4000 2700 GHP ECS 8 Blade 78 dia 5 3 PW 836 RPM E3 34 AC Drive System Electrical Checkout Procedure 3 01 E03015 Release 17 Software ...

Page 231: ...908M is correct and the supply voltage 15SIM to the PVM is correct but output is incorrect replace the PVM module Trucks equipped with Komatsu engine 1 With the engine shut down keyswitch ON and control power ON measure voltage between 72E and 72R lead Voltage should be 5 0 volts a Jumper circuit 22FO to ground and verify volt age on 72E to 72R changes to 7 0VDC b If the voltage is 0VDC verify the...

Page 232: ...harness or NO voltage at all on the harness 8 If there is NO voltage troubleshoot the Gate Drive Power Converter GDPC or the harness 9 If there IS voltage reconnect the harness and disconnect the GTO Gate lead on the G termi nal 10 If there IS red light visible with the gate lead disconnected the GTO is shorted and the entire phase module or chopper module must be re placed 11 If there IS NOT red ...

Page 233: ... snubber base to prevent air leakage at the seams 3 Install a flat washer over each mounting hole between the base and the gasket 4 Install new inner and outer gaskets Using RTV 6708 seal the seam between the outer gasket and the two inner gaskets 5 Apply Loctite to the four mounting screws for the snubber resistors and install the resistors on the base 6 Install the snubber assembly in the truck ...

Page 234: ...teps replace the Controller Subcode 03 Description An overcurrent condition was detected during operation 1 Check Capacitor Bank and Controller connec tions 2 Verify the inductor connections match up and from the Auxiliary Inverter and to the Auxiliary Capacitor bank PH to IV and PH to IV 3 If a problem was found and corrected in step 1 or 2 restart and check operation again 4 If problem still exi...

Page 235: ...age was detected during operation 1 Check Capacitor Bank and Controller connec tions 2 Check DC Sense connection connector J13 to IV red wire and IV black wire 3 If problem still exists replace controller FIGURE 3 15 AUXILIARY BLOWER CONTROL COMPONENTS 1 Auxiliary Inductor AXIND 2 Snubber AUX SNUB 3 Auxiliary Inverter Controller AXINV 4 Blower Control System Warning LED s 5 Auxiliary Power Filter ...

Page 236: ...ay be damaged Subcode 11 Description An overcurrent condition exists due to a low DC bus voltage 1 Check the 3 phase input connections and fuses F1 and F2 2 Check Capacitor Bank and Controller connec tions 3 After performing checks in step 1 and 2 attempt to restart 4 If problem still exists replace the controller Subcode 12 Description A sustained overload exists due to low DC bus voltage 1 Check...

Page 237: ... 1 2 3 and DC output terminals PH PH A reading of less than 100 ohms indicates a shorted SCR Good SCR s will measure more than 100K ohms Replace at least the connected pair of SCR s if one is shorted preferably replace all 6 SCR s 7 Whenever it is determined that an Aux Inverter input SCR has failed both AC Input fuses must be replaced and the old ones discarded 8 Check pin and wire continuity bet...

Page 238: ...ify Snubber Panel components by measuring resis tance values between points shown in Table be low Refer to Figure 3 10 and 3 11 for test point locations 3 After all measurements have been made and repairs completed if needed reconnect wiring removed in step 1 Measuring Point Specified Value From To Minimum Maximum 1 C2 4 23 75 Ω 26 25 Ω 1 C1 4 23 75 Ω 26 25 Ω 2 C3 4 23 75 Ω 26 25 Ω 3 C2 2 0 Ω 0 Ω ...

Page 239: ...harness connectors All circuit test points listed in the Table should show continuity Note All 3 pins in connectors should show an open circuit to all other test points All IGBT s should be free of cracks or leaks 7 After all circuits have been tested reconnect all cables to their proper terminals Reconnect J1 J2 J3 J4 J7 and J8 8 Reinstall cover 2 and attach harness connector at CNX receptacle Co...

Page 240: ...NOTES E3 44 AC Drive System Electrical Checkout Procedure 3 01 E03015 Release 17 Software ...

Page 241: ...WHEEL HUB AND SPINDLE G3 1 Removal G3 1 Installation G3 4 Disassembly G3 5 Cleaning and Inspection G3 5 Assembly G3 7 Wheel Bearing Adjustment G3 7 Seal Assembly Gap Check G3 9 STEERING CYLINDERS AND TIE ROD G3 9 Removal G3 10 Installation G3 11 Bearing Replacement G3 11 TOE IN ADJUSTMENT G3 12 REAR AXLE HOUSING MOUNTING ATTACHMENT G4 Pivot Pin G4 1 Anti Sway Bar G4 4 REAR AXLE HOUSING G5 Rear Axl...

Page 242: ...NOTES G1 2 Index G01017 ...

Page 243: ...es on top of one another Avoid contact with oil grease and other petroleum products Before storing used tires clean thoroughly and inspect for damage Repair as necessary When a truck is placed in storage it should be blocked to remove the weight from the tires If a stored truck cannot be blocked check air pressure and inspect tires twice a month for proper inflation pressure DO NOT weld or apply h...

Page 244: ... ground and block up securely under frame 5 Inspect hydraulic brake lines for damage or leak ing fittings 6 Grip tire and wheel assembly with tire handler Remove nuts 11 securing wheel assembly 7 Care should be taken not to damage the inflation hose during tire removal Move wheel assembly away from wheel hub and into clean work area Do not attempt to disassemble wheel assembly until all air pressu...

Page 245: ...ts in a clockwise direction to the required 1715 100 ft lbs 2326 136 N m torque 3 Remove blocking etc and lower jack 4 Operate truck for one load and retighten wheel nuts to the specified torque REAR TIRES AND RIMS Removal 1 Park truck on level ground and block front wheels Position a jack under rear suspension mounting plates as shown in Figure 2 3 2 Raise rear axle housing of truck until tires c...

Page 246: ...ating flanges with lithium base grease Install and tighten nuts in the following sequence a Install six 6 nuts at the 12 O clock and six 6 nuts at the 6 O clock positions Tighten each nut to 1715 100 ft lbs 2326 136 N m torque b Install three 3 nuts directly below the 3 O clock and three 3 nuts directly above the 9 O clock positions Tighten these nuts to 1715 100 ft lbs 2326 136 N m torque c Insta...

Page 247: ...y above the 9 O clock positions Tighten these nuts to 1715 100 ft lbs 2326 136 N m torque c Install three 3 nuts directly above the 3 O clock and three 3 nuts directly below the 9 O clock positions Tighten these nuts to 1715 100 ft lbs 2326 136 N m torque d Install the remaining nuts and torque in a clockwise direction to 1715 100 ft lbs 2326 136 N m torque e Retorque all nuts in a clockwise direc...

Page 248: ... bead seat band 6 as possible 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 approximately 90 from the first application Continue this pro cedure until tire bead is free from rim 5 After bead is broken loose insert flat of tire tool in beading notch on lockring 8 Pry loc...

Page 249: ...ible without prying against the beads Any damage to tire bead will destroy air seal and cause air leaks at these points 5 Install outer flange 7 Figure 2 6 in position and install bead seat band 6 Push in on bead seat band to expose O ring groove in rim 6 Lubricate new O ring 9 with soap solution and install in groove of rim 7 Install lockring 8 and tap into place with lead hammer Lockring lug mus...

Page 250: ...NOTES G2 8 Tires and Rims G02015 ...

Page 251: ...tify the electrical department 5 Verify the steering accumulators have bled down by attempting to steer 6 Bleed down the brake accumulators using the manual bleed valves on the brake manifold 7 Open the battery disconnect switches Removal Refer to the Front Tire and Rim Removal instructions and remove front tire and rim assembly 1 Close hydraulic pump shut off valves 2 Disconnect speed sensor cabl...

Page 252: ...ws a Refer to Figure 3 5 spindle removal tool and remove the capscrews in the spindle arm des ignated by an an X b Remove the capscrews using a circular pattern in torque increments of 500 ft lbs 678 N m Do not attempt to remove each capscrew in one sequence 9 Run a tap 1 25 UNF in the threads after cap screws are removed 10 Using several 1 25 UNF x 8 00 long grade 8 capscrews and hardened flatwas...

Page 253: ...refully tap the spindle on the top surface NOTE In extreme cases it may be necessary to remove additional steering arm retaining capscrews and use additional pusher capscrews to apply more force 14 Lower wheel hub and spindle assembly away from suspension piston rod Use care during removal to prevent damage to suspension piston rod taper and tapered spindle bore 15 Move spindle and hub assembly to...

Page 254: ...ool group to position spacers and bearing during pin insertion Tighten pin retaining nut to 750 ft lbs 1017 N m torque 8 Install tie rod on steering arm using EH4638 alignment tool Tighten pin retaining nut to 750 ft lbs 1017 N m torque 9 Connect lubrication lines 10 Install brake system cooling hoses using new O rings in the flange fittings Install brake apply line Be certain drain plug 2 Figure ...

Page 255: ... damage to wheel studs and machined surfaces 10 Remove capscrews 14 and washers 15 secur ing seal carrier 37 sensor gear 35 and shims 36 to wheel hub 11 Remove capscrews 23 and hardened washers 24 securing brake assembly inner gear to wheel hub 12 Attach lifting eyes to brake assembly attach over head hoist and carefully lift off hub Refer to Sec tion J for brake assembly rebuild instructions 13 R...

Page 256: ...Assembly 31 Capscrew 32 Hardened Washer 33 Drain Plug 34 Socket Head Capscrew Temporary 35 Speed Sensor Gear 36 Shims 37 Seal Carrier 38 O ring 39 Bearing Retainer Pin 40 Bearing Retainer Pin 41 O ring 15 Washer 16 Speed Sensor 17 Sensor Bracket 18 Disc Brake Assembly 19 Brake Adaptor 20 Capscrew 21 Hardened Washer 22 O ring 23 Capscrew 24 Hardened Washer 25 O ring 26 Spindle 27 Bearing Spacer 28 ...

Page 257: ...the cap into the end of spindle 26 The tapped holes on the spindle cap must face the outside for disassembly purposes Wheel Bearing Adjustment 9 Install bearing retainer 13 onto the spindle with out any shims The thickness of the retainer is etched on the surface of the retainer This side should be facing outward Use 4 equally spaced capscrews in order to secure the retainer Two capscrews must be ...

Page 258: ...adapter 19 Place the assembly into position on the spindle 19 Install hardened flatwashers 32 and capscrews 31 Tighten capscrews to 1995 ft lbs 2705 N m torque Socket head capscrews 34 are installed to posi tion the seal carrier on the brake back plate after assembly and prior to installation on the Hub spin dle In the next step it may be necessary to loosen the socket head capscrews slightly to a...

Page 259: ...dimensions and divide the result by 3 to obtain the average gap width 29 If average gap width is not between the minimum and maximum allowable range loosen the seal retainer capscrews 4 Figure 3 6 and add shims 5 as required to reduce the gap or remove shims to increase the gap The quantity and thickness of shims at each of the six locations must be equal 30 Re tighten seal retainer capscrews to s...

Page 260: ... and retainers 10 from both ends of assembly 4 Remove pins 16 from each end of assembly and move assembly to clean work area The bearing spacers and the washers are secured by the pin Take measures to prevent components from falling during removal of pin Damage to the components and or personal injury may result FIGURE 3 8 STEERING CYLINDER AND TIE ROD INSTALLATION 1 Steering Cylinder 2 Tie Rod As...

Page 261: ...rs 10 and secure with locknut 9 Tighten to 750 ft lbs 1017 N m torque 3 Connect hydraulic and lubrication lines to their respective ports Operate steering and check for leaks and proper operation Bearing Replacement 1 Remove capscrews 2 Figure 3 9 and lockwash ers 3 Remove bearing retainer 4 2 Press bearing 1 out of bore in steering cylinder or tie rod end 3 Press new bearing into bore 4 Install b...

Page 262: ...re ments should be taken on a horizontal centerline at front and rear of tires Refer to Figure 3 10 3 Radial tires should have equal measurements zero toe in 4 Loosen clamp locknuts on tie rod and rotate tie rod as necessary to obtain correct toe in setting 5 When adjustment is complete tighten clamp locknuts 7 Figure 3 8 on tie rod to 310 ft lbs 420 N m torque 6 Remove blocks from rear wheels 930...

Page 263: ...f pin Remove pin 7 NOTE Placement of a pry bar or jack between mount ing structure and pivot eye may be necessary to push pivot eye down and away from mount structure Spac ers 8 and cover rings 9 will fall free Installation 1 Raise pivot eye 15 Figure 4 1 into position 2 Be certain spherical bearing inner race is aligned Install cover rings 9 and spacers 8 Install pin 7 3 Position lock plate 5 by ...

Page 264: ...ool to press spherical bearing 4 from bearing carrier 3 2 Inspect all parts and bearing for wear or damage Replace parts showing excessive wear or dam age Spherical bearing outer race O D 8 7500 8 7488 in 222 25 222 22 mm Bearing bore I D 5 9990 6 0000 in 152 37 152 40 mm 3 If bearing carrier 3 is damaged or worn refer to Pivot Eye Repair for repair procedure Assembly 1 Setup an appropriate tool t...

Page 265: ...arrier 3 Figure 4 2 into the bore of the pivot eye structure NOTE With parts to correct size the fit of the bearing carrier into the bore of the pivot eye structure may be 0 001 0 003 in 0 025 0 08 mm interference fit Freezing the bearing carrier will ease installation Lubrication groove in bearing carrier outer diame ter must align with lubrication fitting hole in pivot eye structure 2 Press bear...

Page 266: ...shing into other ear of bracket If necessary realign pin with retainer capscrew hole Install capscrew 9 and locknut 10 3 Repeat above procedure to install remaining pin spacers capscrew and locknut at opposite end of bar Start the pin into the bore of the axle housing mount from the rear of the truck 4 Attach lubrication lines Pump grease into bearing to verify line and system is operational 5 Rem...

Page 267: ... for GF switch location 4 Verify the LINK VOLTAGE lights are OFF If they remain on longer than 5 minutes after shutdown notify the electrical department 5 Verify the steering accumulators have bled down by attempting to steer 6 Bleed down the brake accumulators using the manual bleed valves on the brake manifold 7 Open the battery disconnect switches Front wheels must be securely blocked to preven...

Page 268: ...ousing 17 Remove automatic lube system hoses and clamps attached to housing Secure hoses to frame to prevent interference during axle housing removal 18 Remove rear suspensions Refer to Section H 19 Remove anti sway bar as described in this Sec tion 20 Remove pivot pin as described in this Section 21 Remove wheel motors as described in this Sec tion FIGURE 5 1 REAR AXLE HOUSING AND WHEEL MOTORS 1 ...

Page 269: ...ure earlier in this Section 3 Install anti sway bar Refer to installation proce dure earlier in this Section 4 Install rear suspensions as described in Section H 5 Connect auto lube system hoses and clamps 6 Route wheel motor cables 7 Figure 5 1 into housing and clamp in place Install cable grip mounting plate and cable grips 7 Install speed sensor harness 9 Figure 5 1 through housing Install cabl...

Page 270: ...connect switches Front wheels must be securely blocked to prevent movement as brakes will be released All electrical cables and hydraulic hoses should be marked prior to removal Close the shut off valves on the hydraulic pumps to reduce amount of oil loss from brake system Removal NOTE If suitable equipment is available to lift wheel motor assembly from the axle housing it is not neces sary to rem...

Page 271: ...motor power cables terminals cable grips and clamps Replace any cables or hardware that is damaged or worn All propulsion system power cables must be prop erly secured in their wood or other non ferrous cable cleats If clamps are cracked or broken re place them with new parts Inspect cable insula tion and replace entire cable if insulation is damaged Installation 1 Install two guide pins 180 apart...

Page 272: ...es 17 10 Install air duct 5 Close duct inspection covers and install duct tube in rear opening of axle hous ing 11 Open pump shut off valves 12 Check wheel motor oil level Check hydraulic tank oil level before and after engine start up and brake bleeding procedure Service as necessary 13 Bleed the brake apply line according to the instruc tions in Wet Disc Brake Assembly Brake Bleed ing Procedure ...

Page 273: ...embly H2 6 Assembly H2 7 REAR SUSPENSION H3 Removal H3 1 Installation H3 3 Disassembly H3 4 Assembly H3 4 OILING AND CHARGING PROCEDURES H4 GENERAL H4 1 EQUIPMENT LIST H4 1 FRONT SUSPENSION H4 2 Front Suspension Oiling H4 2 Front Suspension Nitrogen Charging H4 3 REAR SUSPENSION H4 4 Rear Suspension Oiling H4 4 Rear Suspension Nitrogen Charging H4 5 OIL AND NITROGEN SPECIFICATIONS H4 6 H01013 04 0...

Page 274: ...NOTES H1 2 Index H01013 04 01 ...

Page 275: ...eels and set parking brake Remove front wheel and tire according to Removal instruc tions in Section G Front Tire and Rim Remove front wheel hub and spindle as covered in Section G 2 Remove boot clamp and boot from around sus pension 3 Discharge nitrogen pressure from suspension by removing cap from charging valve 5 Figure 2 1 Turn the charging valve swivel nut small hex 2 Figure 2 2 counterclockw...

Page 276: ...s 9 11 Move suspension to a clean work area for disas sembly Installation Use the following procedure for preparing mounting surfaces and mounting hardware 1 The mounting surface of both the suspension and the frame must be clean and dry Use a cleaning agent that does not leave a film after evaporation such as trichlorethylene tetrachlorethylene ace tone or lacquer thinner When using a cleaning ag...

Page 277: ...fore installation inspect each capscrew for any defects and number of punch marks Replace cap screw and related hardware if two punch marks are evident do not reuse if any defect is suspected Hard ware 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 operated with the suspension mou...

Page 278: ...ned until the marked corner 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 ex ceed 4 RPM tightening speed Do not ham mer or jerk wrench during the tightening procedure e Loosen the top two corner capscrews 1 and the bottom outer four capscrews 8 the 4 bot tom capscrews with nuts 1 ...

Page 279: ...d away from the seal as shown in Figure 2 8 2 Install new O rings 22 and backup rings 23 in their appropriate grooves in the lower bearing retainer 18 Install new bearing 24 NOTE Backup rings must be positioned toward the flange of bearing retainer as shown in Figure 2 9 3 Install temporary guide bolts to ensure bolt hole alignment as bearing retainer is seated Lift lower bearing retainer 18 assem...

Page 280: ...balls 9 will fall free when the housing is rotated 4 Attach lifting device to the piston 7 and carefully lift out of housing 5 Remove capscrews and washers 20 21 Figure 2 8 Install pusher bolts and remove lower bear ing retainer 18 6 Remove and discard rod seal 28 step seal 27 and rod wiper 29 Remove and discard O rings 22 and backup rings 23 Remove lower bear ing 24 1 Housing 2 Cap Structure 3 Ca...

Page 281: ...n stop Tighten locknut one half turn further until hole for the roll pin 10 is in align ment Install roll pin 8 Attach a lifting device to top side of end cap assembly Lower assembly down on piston 7 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 9 Install upper bear...

Page 282: ...NOTES H2 8 Front Suspensions H02013 2 01 ...

Page 283: ...sembly Removal 1 Remove capscrews washers and metal shield 2 Figure 3 1 from the suspension 2 Remove charging valve cap 1 Figure 3 2 loosen small hex 4 on charging valve and turn counterclockwise three full turns to unseat valve seal Connect suspension charging kit Make certain only the swivel nut turns Turning the complete charging valve assembly may result in the valve assembly being forced out ...

Page 284: ...e top and bottom pins is identical 8 Remove pin retainer locknuts 3 Figure 3 3 and capscrews 2 at upper and lower pins 1 9 Install a puller and pull the lower mounting pin from the bore in the rear axle housing Remove both spacers 4 10 With the fork lift positioned under the suspension install a puller and remove upper mounting pin from the bore in the truck frame Remove pin and spacers 11 Clean t...

Page 285: ... drive the pin in through the spherical bearing Insert the re maining 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 343 ft lbs 465 N m torque 7 Lower the suspension housing until the lower mount bearing aligns with the bore in the rear axle housing and repeat the above procedure...

Page 286: ... parts NOTE If other repairs are necessary refer to your local Komatsu Distributor for repair information and instructions not covered in this manual Assembly Assembly must be accomplished in a clean dust free work area All parts must be completely clean dry and free of rust or scale Lubricate all interior parts and bores with fresh suspension oil See Oil Specifications under Oiling and Charging P...

Page 287: ...ring 5 Piston Rod 6 Bleeder Screw 7 Vent Plug 8 Shield 9 Capscrew 10 Washers 11 Vent Plug 12 Charging Valve 13 Plug Sensor 14 Vent Plug 15 Wiper Seal 16 Rod Seal 17 Step Seal 18 Socket Head Capscrew 19 Backup Ring See note 20 O Ring 21 Housing Bearing 22 Ball Check H03013 Rear Suspensions H3 5 ...

Page 288: ...NOTES H3 6 Rear Suspensions H03013 ...

Page 289: ... nitrogen charging must be correct and this dimension be maintained during nitrogen charging 3 Nitrogen charge pressure must be correct For best results HYDRAIR II suspensions should be charged in pairs fronts together and rears together If rears are to be charged the fronts should be charged first NOTE Set up dimensions specified in the charts must be maintained during oiling and charging procedu...

Page 290: ...may be used Blocks must be capable of supporting the weight of the truck during oiling and charging procedures while avoiding contact with plated surfaces and seals on the suspension Refer to Figure 4 2 for front suspension support block placement and Figure 4 4 for rear sup port block placement FRONT SUSPENSION 1 Park unloaded truck on a hard level surface Block wheels apply parking brake 2 Thoro...

Page 291: ...ient capacity to lift the truck weight Be certain that all personnel are clear of lift area be fore lift is started 1 With nitrogen charging blocks at hand Figure 4 2 use crane or jacks to raise the truck to provide clearance for the blocks 2 Remove oiling blocks and install nitrogen charg ing blocks Secure blocks so they will not fly free Lower truck frame until the blocks are firmly and squarely...

Page 292: ... piston Operator comments on steering response and suspension rebound should also be noted REAR SUSPENSION 1 Park unloaded truck on a hard level surface Apply parking brake 2 Thoroughly clean area around charging valve on suspensions Remove protective covers from charging valves and metal covers from the sus pension piston NOTE If suspensions are collapsed it will be neces sary to raise the truck ...

Page 293: ...nd squarely seated between the piston flange and cylinder housing NOTE Prevent damage to plated surface oil seals and capscrew heads Dry nitrogen is the only gas approved for use in HYDRAIR II suspensions and accumulators Charging of these components with oxygen or other gases may result in an explosion which could cause fatalities serious injuries and or ma jor property damage Use only nitrogen g...

Page 294: ... Operator comments on steering response and suspension rebound should also be noted OIL AND NITROGEN SPECIFICATIONS CHARTS HYDRAIR II OIL SPECIFICATIONS Ambient Temperature Range Part No Approved Sources 30 F above 34 5 C above VJ3911 Mobil 424 Mobil D T E 15 Texaco TDH Oil AMOCO ULTIMATE Motor Oil 5W 30 Sunfleet TH Universal Tractor Fluid Chevron Tractor Hydraulic Fluid Conoco Power Tran III Flui...

Page 295: ...al Relay Valve J3 15 Disassembly J3 17 Cleaning and Inspection J3 17 Assembly J3 17 Differential Pressure Switch J3 18 Valve Test and Adjustment J3 19 Differential Pressure Switch Adjustment J3 21 Hydraulic Brake Accumulators J3 22 Brake Accumulator Bleeddown Procedure J3 22 Accumulators Hydraulic Components Cabinet J3 22 Removal J3 22 Installation J3 22 Disassembly J3 22 Cleaning and Inspection J...

Page 296: ...J5 Operation J5 1 Maintenance J5 2 Brake Disc Wear Indicator J5 2 Brake Rebuild J5 4 Disassembly J5 4 Cleaning and Inspection J5 7 Assembly J5 8 Seal Gap Adjustment Rear Brake Assembly J510 Floating Ring Seal Assembly Installation J5 11 Wet Disc Brake Bleeding Procedure J5 14 PARKING BRAKE J7 Operation J7 1 Maintenance J7 2 Inspection J7 2 Removal J7 2 Installation J7 3 Disassembly J7 4 Cleaning a...

Page 297: ... weatherproof cabinet Figure 2 1 behind the cab The hydraulic components cabinet is easily accessible for brake sys tem diagnostic and service work The dual relay valve for the rear brakes is located in the rear axle housing Two additional accumulators are mounted on the frame rail behind the right front tire The brake manifold contains dual circuit isolation check valves accumulator bleed down va...

Page 298: ... Brake Manifold 13 Pressure Reducing Valve PR 14 Brake Lock Solenoid SV1 15 Park Brake Solenoid SV2 16 Front Brake Accum Bleed Valve 17 Automatic Apply Valve 18 Low Accum Test Port LAP1 19 Rear Brake Accum Bleed Valve 20 Low Brake Pressure Switch 21 Park Brake Pressure Switch 22 Stop Light Pressure Switch 23 Brake Lock Degradation Switch 24 Rear Brake Pressure Test Port BR 25 Front Brake Pressure ...

Page 299: ...rking brakes are spring applied and hydrauli cally released NOTE Whenever the park brake solenoid is de ener gized a spring in the solenoid valve will shift the spool diverting oil pressure from the parking brakes to direct the oil back to the hydraulic tank Normal Operation key switch on engine running Parking brake switch ON The parking brake solenoid 15 Figure 2 1 is de energized The oil pressu...

Page 300: ...right circuits of the front or rear wheel brakes is greater than a preset level the differen tial pressure switch located on the dual relay valve at either the front or rear wheels will turn on the low brake pressure light and buzzer The pressure differential switches complete a path to ground in order to turn on the low brake pressure light and buzzer The differential pres sure switches provide d...

Page 301: ...ol B1 14 Reaction Plunger B1 15 Base Plate 16 Reaction Plunger B2 17 Regulator Sleeve B2 18 Regulator Spool B2 19 Spool Return Spring B2 20 Regulator Springs B2 21 Staging Seat A Adjustment Collar Maximum Pressure Contact Area B Automatic Apply Piston Area C PX Port D Tank Port E Reactionary Pressure Area F Brake Apply Port G Orifice H Supply Port NOTE B1 Rear Brakes B2 Front Brakes FIGURE 2 2 BRA...

Page 302: ...nd slow to release FIGURE 2 3 REAR BRAKE HOSES 1 BS Left Right Brake Cooling Oil Supply 2 LBR Left Brake Cooling Return Line 3 T Return To Tank 4 P1 Pressure Inlet From Accumulator 5 Axle Housing 6 Wheel Motor 7 RBR Right Brake Cooling Return Line 8 RBP Right Brake Pressure Test Port 9 LBP Left Brake Pressure Test Port 10 PX Pilot Inlet Brake Apply Line 11 PB Parking Brake J2 6 Brake Circuit J0202...

Page 303: ...e Brake Valve is a pressure modulating valve actu ated mechanically brake pedal or hydraulically through the automatic apply valve 8 Figure 3 1 The Brake Valve controls the pressure delivered to the front and rear service brake dual relay valves which provide the apply pressure for the front wheel and rear wheel disc brake assemblies Apply pressure can be modulated from zero to maximum braking eff...

Page 304: ... 7 Slide brake valve downward and remove from cab 8 Move brake valve assembly to a clean work area for disassembly Installation 1 Place the brake valve assembly into position and secure in place with capscrews and lockwashers Tighten capscrews to standard torque 2 Remove plugs from brake valve assembly and hydraulic lines Install fittings and connect lines to brake valve assembly and tighten Conne...

Page 305: ...Figure 3 2 by removing the retaining clips 2 then remove the pivot shaft 3 with a punch and hammer 5 Remove the four button head allen screws 3 Figure 3 3 securing the boot retainer plate 4 6 Remove the boot retainer plate 4 boot 2 and actuator cap 1 as an assembly by grasping the boot and gently lifting from the valve body 1 Brake Valve 2 Retainer Clip 3 Pivot Shaft 4 Bushings 5 Shims 6 Retainer ...

Page 306: ...until the regulator sleeve 19 pops loose 19 Repeat the above procedure to loosen the B2 regulator sleeve 20 Turn the valve on its side on the work bench and remove the regulator sleeves 19 from the valve body NOTE Throughout the following steps it is important to keep the circuits and circuit components identified as to which side of the unit they came from For a given circuit all the components h...

Page 307: ...Back up Ring 14 O Ring 15 Back up Ring 16 O Ring 17 Back up Ring 18 O Ring 19 Regulator Sleeve 20 Spool Return Spring 30 O Ring 31 Retaining Plug 32 Base Plate 33 Washer 34 Capscrew 35 Differential Pres sure Switch 36 Capscrew 21 Reaction Plunger B1 22 Reaction Plunger B2 23 Wiper Seal 24 Back up Ring 25 Poly Pak Seal 26 Valve Body 27 Seal 28 Seal 29 Set Screw Orifice Plug J03019 1 99 Brake Circui...

Page 308: ...tuator base Be sure the base is supported to avoid breaking the base 3 Thoroughly clean the actuator base and set aside Boot and Cap 1 Examine the boot 2 Figure 3 3 for any cracks tears or other damage If damage is evident the boot must be replaced To replace the boot follow the procedure below 2 Remove the boot from the actuator cap 1 and discard the old boot Thoroughly clean the sides of the cap...

Page 309: ... O ring groove located at the large diameter end of the actuation plunger 3 2 Install a split Glyde ring over the O ring Twist and squeeze the split Glyde ring into a small circle before installing to insure a tight fit over the O ring 3 Repeat Steps 1 2 for the second plunger Assembly of Valve NOTE Start with either side circuit of the valve and build that side complete through Step 4 before star...

Page 310: ...12 Install the spool return spring 20 into spool 12 13 Insert reaction plunger 21 or 22 into regulator spool 14 Install regulator spool 12 into regulator sleeve 19 15 Repeat Steps 6 through 14 for the second circuit 16 Lightly lubricate the large retainer plate O ring 30 and install into the counter bore in the bottom end of the valve 17 Install the retainer plug 31 into the counter bore on the bo...

Page 311: ... Attach 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 8 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 ...

Page 312: ... continuity tester NOTE It is possible to check the pressures with the brake valve installed and connected to the vehicle Remove the brake pedal assembly and actuator cap and boot assembly to adjust individual brake circuit pressures FIGURE 3 9 TEST BENCH SET UP 1 Motor 2 Pump 3 System Pressure Gauge 4 Needle Valve 9 Simulated Brake Volume 10 Rear Brake Pressure Gauge 11 Relief Valve 5 Needle Valv...

Page 313: ...placing it under the pivot pin and on top of the threaded plunger assembly each circuit can be actuated individually Refer to Figure 3 9 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 c...

Page 314: ... actuator must be installed on the brake valve body prior to final test and adjustment Refer to Installation of Brake Pedal Actuator to Brake Valve NOTE The Final Test and Adjustment procedure can also be performed with the brake valve installed in the truck To perform final test with brake valve mounted in the truck install valve per instructions in Installation Install 3000 psi 20 682 kPa gauges...

Page 315: ...d set screw 21 to brake pedal actuator 17 2 Insert nylon bushings 4 into brake pedal actua tor 3 Install one retaining clip 2 to one end of pivot shaft 4 Align pedal structure to brake valve 1 and par tially insert pivot pin Move pedal structure to the B2 side of valve and insert shims 5 between pedal structure and brake valve ear to fill gap Fully insert the pivot shaft 3 Install the remain ing r...

Page 316: ...earing 8 Pivot Shaft 9 Place 0 010 in Shim Here 10 Jam Nut 11 Capscrew 12 Pedal Structure 13 Pad 14 Nut 15 Capscrew 16 Electronic Retard Pedal Assembly 17 Brake Pedal Actuator 18 Spring Pivot Lower 19 Spring 20 Spring Pivot Top 21 Set Screw 22 Jam Nut 23 Differential Pressure Switch J3 14 Brake Circuit Component Service J03019 1 99 ...

Page 317: ...to bleed down Before disabling brake circuit be sure truck wheels are blocked to prevent possible roll away Removal 1 Securely block the wheels to prevent possible roll away 2 Place selector switch in NEUTRAL turn the rest switch ON Turn key switch OFF to shut down engine and allow 90 seconds for steering system accumulators to bleed down Open valves 6 7 Figure 3 1 to bleed down all four brake acc...

Page 318: ...ers 8 Reaction Plunger 9 Sleeve 10 Seal 11 Spool Spring 12 Regulator Spool 13 Lower Spring Seat 14 Regulator Spring 15 Upper Spring Seat 16 Plunger 17 Sleeve 18 O Ring 19 Plug 20 Capscrew 21 Backup Ring 22 O Ring 23 Backup Ring 24 O Ring 25 O Ring 26 Switch 27 Body 28 Plug 29 Screw Plug 30 Spring 31 Piston 32 Spool Assembly J3 16 Brake Circuit Component Service J03019 1 99 ...

Page 319: ...1 Clean all metal parts with solvent and air dry 2 Apply a light film of type C 4 hydraulic oil to plungers 14 Figure 3 11 and insert in sleeves 15 Sleeves must slide smoothly and freely in sleeve bores If parts do not slide smoothly or excessive wear is apparent replace both the sleeve and plunger 3 Apply a light film of oil to regulator spools 12 and slide into bore of sleeves 9 Spools must slid...

Page 320: ...attach ing the differential pressure switch body 3 Figure 3 11 to the dual relay valve body 2 2 Remove switch assembly 26 and O ring 25 3 Remove plugs 28 4 Remove screw plug 29 5 Remove spring 30 and piston 31 6 Carefully push spool assembly 32 out of its bore Cleaning and Inspection 1 Clean all metal parts with solvent and air dry 2 Inspect spool assembly 32 Figure 3 11 and bore for scoring and o...

Page 321: ...nuity tester NOTE It is possible to check the pressures with the dual relay valve installed on the truck by using the brake treadle valve to modulate pilot pressure and monitoring brake apply pressure in the appropriate brake apply pressure lines FIGURE 3 12 DUAL RELAY VALVE BENCH TEST SETUP 1 Motor 2 Pump 3 Main Pressure Gauge 4 Pressure Regulator Pilot Pressure 5 Needle Valve Pilot Pressure Re l...

Page 322: ... Adjustment 1 With pump operating and supply and pilot pres sure adjusted as described in setup instructions inspect valve for leakage 2 With 2400 psi 16 545 kPa pilot pressure applied verify the following regulated output pressures B1 port gauge 10 reads 2400 75 psi 16 545 517 kPa B2 port gauge 9 reads 2400 75 psi 16 545 517 kPa 3 Close the pilot supply needle valve 5 and open the pilot pressure ...

Page 323: ... until switch opens 15 Slowly increase pilot pressure and verify switch contact closes at 300 30 psi 2 068 207 kPa 16 Reduce pilot pressure Close B1 needle valve 11 and open B2 circuit needle valve 12 17 Slowly increase pilot pressure and verify switch contacts close at 300 30 psi 2 068 207 kPa as read on B1 circuit gauge 10 18 If necessary adjust screw plug 29 and repeat steps 12 through 17 19 In...

Page 324: ...l 1 Shut down engine to bleed steering accumulators Exhaust all pressure from the brake system by opening accumulator manual drain valves 2 Remove the valve guard and Dyna seal from top of accumulators 3 Depress valve core to release gas precharge pressure from accumulator bladder Refer to Fig ure 3 13 4 Remove accumulator mounting bracket Loosen and remove accumulator from the brake mani fold Plu...

Page 325: ...ion 1 After disassembly clean all parts with an ap proved cleaning solution 2 Blow all parts dry with air and keep free from 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 FIGURE 3 14 LOCKNUT REMOVAL FIGURE 3 15 SPACER REMOVAL FIGURE 3 16 ANTI EXTRUSI...

Page 326: ...rod out of shell with one hand while feeding bladder into shell with other hand 7 Position name plate over valve stem and install valve stem nut by 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 p...

Page 327: ...ficiently to compress gas ket swivel connector 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 3...

Page 328: ...ator Plug all hoses and openings to prevent possible contamination of the system 5 Attach a lifting device to the accumulator to be removed 6 Remove the mounting band capscrews washers and nuts 3 and remove the mounting bands 4 7 Raise the accumulator until clear of mounting bracket and move to a clean work area for disas sembly Installation 1 Lift accumulator into position on the mounting bracket...

Page 329: ...st be absolutely free of any foreign matter larger than 3 microns 2 Inspect piston for damage If scored or otherwise damaged replace with a new part 3 Minor defects in the housing bore may be cor rected by honing a Measure the bore at several places along the length of the housing Make two measure ments 90 apart at each point to verify tube is not out of round FIGURE 3 27 ACCUMULATOR ASSEMBLY 1 Ca...

Page 330: ...ernal and external leaks at high pres sure A source of 5000 psi 35 MPa hydraulic pressure and nitrogen pressure of 1400 psi 9 65 MPa will be required A small water tank with the necessary safety guards in place will be necessary for a portion of the test Do not stand near gland during test procedure A box enclosure made of heavy steel plate is recom mended to contain the accumulator during oil pre...

Page 331: ...terclockwise 5 Depress the valve stem and hold down until all nitrogen has been released 6 If a loss in nitrogen pressure is the reason for recharging inspect the charging valve and accu mulator for damage Replace or repair items as necessary before charging procedure 7 Connect the nitrogen charging kit to the charging valves Open the regulator and charge the accu mulators simultaneously to 1400 p...

Page 332: ...cter 5 from lever as sembly 4 Lever Assembly Installation 1 Connect harness connecter 5 Figure 3 30 to lever assembly 4 Install lever assembly to steering column 3 2 Install capscrews 1 and lockwashers 2 Tighten socket head capscrews to 36 in lbs 4 1 N m torque FIGURE 3 30 COLUMN MOUNTED RETARDER CONTROL LEVER 1 Capscrew Socket Hd 5 Harness Connector 9 Locknut 13 Bracket 2 Lockwasher 6 Capscrew So...

Page 333: ...ot clockwise to full ON and re lease Be sure that the spring returns the pot to the OFF position 2 Using a reliable volt ohm meter 0 ohms should be read in the OFF position 3 Rotate the pot clockwise to full ON and hold 2500 500 ohms should be recorded Replace the potentiometer if it does not meet these specifications Assembly 1 If handle 16 Figure 3 30 or lever 15 has been removed from shaft 14 a...

Page 334: ...NOTES J3 32 Brake Circuit Component Service J03019 1 99 ...

Page 335: ...ing Circuit Test Procedure refer to Section L Hydraulic System FIGURE 4 1 HYDRAULIC COMPONENTS CABINET 1 Rear Brake Accumulator 2 Charging Valve 3 Front Brake Accumulator 4 Charging Valve 5 Relief Valve Hoist Power Down 6 Hoist Pilot Valve 7 Dual Relay Valve 8 Differential Pressure Sw 9 Park Brake Release Press PK2 10 Brake Cabinet 11 Brake Lock Shuttle Valve 12 Brake Manifold 13 Pressure Reducing...

Page 336: ... a person s body by pene trating the skin and cause serious injury and pos sibly 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 en gine shut down turning key switch Off and waiting 90 seconds Confirm the steering pressure is released by turning the steering wheel No front wheel move ment ...

Page 337: ...en BRAKE CIRCUIT ABBREVIATIONS AA Automatic Apply Pressure AF2 Accumulator Front Brake AF1 Supply Pressure to Brake Valve for Front Brakes AR2 Accumulator Rear Brake AR1 Supply Pressure to Brake Valve for Rear Brakes BF Brake Pressure Front BL Brake Lock Apply Pressure BR Brake Pressure Rear CP1 Cavity Plug One Direction Flow No specific function in this application CV CVR CVF Check Valve DSV High...

Page 338: ... on data sheet NOTE For best performance charge accumulators in the ambient conditions in which the machine will be operating 3 Close both accumulator bleeddown valves 4 Install pressure gauges at a Front brake test port B2 in brake cabinet 3000 psi 20 685 kPa gauge b Rear brake test port B1 in brake cabinet 3000 psi 20 685 kPa gauge c Park brake release pressure PK2 9 Figure 4 1 in brake cabinet ...

Page 339: ...to the test ports on the front brake backplates 18 Quickly and completely depress pedal Verify that within 1 second after brake is applied Left front brake pressure reads 2400 75 psi 16 545 517 kPa Right front brake pressure reads 2400 75 psi 16 545 517 kPa Both pressures must remain above their mini mum values for a minimum of 20 seconds Record on data sheet 19 Release pedal assure that each circ...

Page 340: ...mulators to bleed down completely 36 Turn key switch ON Very slowly open the rear brake accumulator bleeddown valve a small amount NVR 19 Figure 4 1 while observing LAP1 decreasing pressure Verify the low pressure warning lamp and buzzer activate within 100 psi 690 kPa of the pressure recorded in step 33 Record on data sheet Verify the brake pressures B1 and B2 be gin to rise within 100 psi 690 kP...

Page 341: ... For more specific details regarding Table I refer to previous chapter BRAKE CIRCUIT COMPONENT SERVICE BRAKE VALVE Differential Pressure Switch Adjustment 46 Shut down the engine and turn key switch OFF Allow steering accumulators to bleed down 47 Open both accumulator bleeddown valves and bleed entire brake system Close valves after all pressure is released 48 Reconnect hose 4 Figure 4 4 to Tee a...

Page 342: ...nd turn key switch OFF Allow steering accumulators to bleed down Open both accumulator bleeddown valves and bleed entire brake system Close valves after all pressure is released 53 Reconnect hose 5 Figure 4 4 to Tee at AR1 port bottom of hydraulic cabinet 54 Remove all test equipment and verify all hoses have been reconnected NOTE If hoses 4 Figure 4 5 and 10 are switched the rear brakes will be s...

Page 343: ...ve is out of balance Actuator piston defective Brake valve is defective A dual relay valve is defective Remove obstruction Adjust balance according to instructions Replace piston Rebuild or replace brake valve assembly Rebuild or replace dual relay valve assembly TROUBLE The Brakes are Not Going to Full Pressure Internal malfunction of modulating section of Brake Valve Supply pressure is low Impro...

Page 344: ...ed brakes Inspect brake system and repair leaks Replace timer TROUBLE A Low Brake Pressure Warning Occurs When Brakes are Applied Leak or other malfunction in one brake circuit Brake valve balance is out of adjustment Differential pressure switch is defective or improperly adjusted A dual relay valve is defective Inspect brake system and repair leaks Adjust collars according to instructions Check ...

Page 345: ...lve is open Accumulator precharge is low Leak in one circuit Malfunction in brake valve Close valve check precharge Recharge accumulator Check plumbing Remove disassemble clean reassemble or replace TROUBLE A Squeal is Heard When Controller is Operated Rapid operation of controller Brake Valve assembly is damaged Hydraulic oil is too hot Normal Replace the brake valve assembly Check entire hydraul...

Page 346: ...tor precharge too high or too low Brake Valve plumbed incorrectly Internal leakage in brake valve assembly Internal leakage in dual relay valve assembly Steering Brake pump is worn Pump unloader or compensator not adjusted correctly Check all steering and brake system components Check steering accumulator precharge Correct plumbing Replace brake valve assembly Rebuild or replace dual relay valve R...

Page 347: ...T Refer to appropriate Service Manual procedures and Bleed brakes Bleed park brakes STEP 9 Park brake indicator light off Park brake circuit pressure STEP 14 Pressure at which brake indicator light comes on Pressure at which stop lights come on STEP 15 Left rear brake pressure within one second LBP Right rear brake pressure within one second RBP Brake pressures remain above 2375 psi 16 375 kPa min...

Page 348: ...kes Pressure at which auto apply actuates STEP 36 Pressure when warning systems actuate rear brakes Pressure at which auto apply actuates STEP 40 Number of brake applications before auto apply actuates STEP 45 Front brake pressure at which differential switch actuates low brake pressure buzzer and lamp STEP 51 Rear brake pressure at which differential switch actuates low brake pressure buzzer and ...

Page 349: ...ied the piston moves to compress the rotating friction faced discs against the stationary steel discs The friction forces generated resist the rotation of the wheels As hydraulic pressure increases friction forces are increased and wheel rotation is slowed until maximum force is reached and the wheel is stopped The complete brake disc pack is cooled by hydraulic oil The low pressure cooling circui...

Page 350: ...llow both accumulators for the rear brakes and both accumulators for the front brakes to bleed down Before disabling brake circuit be sure truck wheels are blocked to prevent possible roll away Removal Installation 1 Place the selector switch in NEUTRAL apply the park brake turn the rest switch ON turn the key switch OFF and allow the steering accumulators to bleed down completely Block truck whee...

Page 351: ...essure from the brake sytem Close valves after all pres sure is released 10 Remove the brake disc wear indicator tool and reinstall O ring plug in port 11 To check the remaining brake assemblies repeat steps 4 through 10 NOTE Checking disc wear in all brake assemblies is recommended Disc wear in one brake assembly may be different from the other due to dissimilar operation of parts and or haul pro...

Page 352: ...r 1 from brake assembly Be certain to note shim packs installed at six loca tions on between seal carrier and hub Both Front and Rear Wheel Brakes Remove the front wheel brake assembly according to the instructions in Front Wheel Hub and Spindle Section G 5 Position brake assembly on work surface with ring gear retainer bars on bottom as shown in Figure 5 5 6 Remove socket head capscrews 2 Figure ...

Page 353: ...ion Disc 12 Inner Gear FIGURE 5 5 INITIAL DISASSEMBLY FIGURE 5 6 PISTON HOUSING ASSEMBLY REMOVAL 1 Piston Housing 2 Capscrew 3 Hardened Washer 4 O Ring 5 Ring Gear 1 Capscrew 2 Spring Guide 3 Piston Retract Spring 4 Piston Assembly 5 Piston Housing 6 Seal Assembly 7 Seal Assembly FIGURE 5 7 PISTON REMOVAL J05018 03 01 Disc Brake Assembly J5 5 ...

Page 354: ...ing from ring gear 5 Remove and discard O ring 4 15 Position piston assembly with retract springs on top as shown in Figure 5 7 16 Remove capscrews 1 Figure 5 7 spring guides 2 and piston retract springs 3 NOTE Capscrew 1 threads are coated with Loctite during assembly A small amount of heat applied to the piston housing may be required for easier removal 17 Loosen or remove plugs installed in pis...

Page 355: ...5 Inspect piston retract springs 3 Figure 5 7 Check springs for free height and test for height under load Replace if not within approximately 10 of specification Free Height 4 00 in 101 6 mm Height 225 lb 1000N working load 3 351 in 85 12 mm Height 600 lb 2669N working load 2 750 in 69 9 mm 6 Inspect friction disks for warping tooth wear and excessive friction material wear Replace if wear exceed...

Page 356: ...mis sible If leakage is greater disassemble piston assem bly and determine cause 8 After completion of piston leakage test release pressure remove hydraulic source and drain oil from piston apply cavity Plug ports to prevent contamination 9 Install O ring 4 Figure 5 6 in groove of ring gear 5 10 Attach lifting eyes to piston housing assembly and lower into position over ring gear Install cap screw...

Page 357: ...eal carrier in position until brake assem bly is installed on the truck FIGURE 5 9 INNER GEAR INSTALLATION 1 Cooling Oil Port 2 Brake Apply Pressure ports 3 Piston Housing 4 Shipping Bar 5 Inner Gear 6 Drain Plug 7 Capscrew Washer 8 Capscrew and Washer 9 Spacer 10 Wear Indicator Installation Port 11 Ring Gear FIGURE 5 10 DISC PACK INSTALLATION 1 Damper 2 Friction Disc 3 Separator Plate 4 Piston Ho...

Page 358: ...p c Measure dimension B at three equally spaced locations Add the three dimensions and divide by 3 to determine the average dimension d Subtract the dimension in step c from the dimension in step b to determine change in shim pack e Add or remove equal quantities and thick nesses of shims to the original shim pack as determined in step d at the six shim locations The shim pack must provide a final...

Page 359: ...sing tri chloroethane or any solvent avoid prolonged skin contact Use solvents only in well ventilated areas and use approved respirators to avoid breathing fumes Do not use near open flame or welding operations or other heated surfaces exceeding 900 F 482 C Do not smoke around solvents Both ramps must be dry Use clean lint free cloths or lint free paper towels for wiping NOTE Oil from adjacent be...

Page 360: ... Check variation in seal ring assembled height in four places 90 apart Height variation around the assembled ring should not exceed 0 51 0 05 in 1 30 0 01 mm for brake assembly floating seal or 0 45 0 04 in 1 14 0 01 mm for the hub seal 6 If small adjustments are necessary DO NOT PUSH DIRECTLY ON THE SEAL RING Make any required adjustments with installation tool 7 Toric can twist if it is dry on o...

Page 361: ...the oil evenly Make sure no oil comes in contact with the rubber toric rings or their mating surfaces Before assembling both seals housing together WAIT at least two minutes Let all tri chlo roethane evaporate Some may still be trapped between toric and housing ramp 10 Be certain both housings are in correct alignment and are square and concentric Move the parts slowly and carefully toward each ot...

Page 362: ...rake apply port on the brake backplate Close plug after oil runs clear and free of bubbles Repeat for remaining wheel NOTE The other cooling line has a single hex plug located adjacent DO NOT use this plug for bleeding brake Front Wheel Brakes NOTE The front wheel brakes are equipped with a diagnostic coupler on the brake backplate A hose with a mating fitting can be attached and used to direct th...

Page 363: ...noid valve SV2 lo cated on the brake manifold in the hydraulic compo nents cabinet is de energized removing hydraulic pressure from the parking brake assemblies Internal belleville springs in the park brake assemblies act on the piston to compress the disc pack preventing rota tion of a gear 4 Figure 7 1 mounted on the wheel motor rotor shaft When the parking brake is switched to the OFF posi tion...

Page 364: ...hen the wheel motor is removed from the truck whenever pos sible If repairs are necessary when the wheel motor is installed it will be necessary to setup a lifting device inside the rear axle housing to support the weight of the brake assembly when it is removed from the wheel motor If repairs are made when the wheel motor is removed follow the appropriate procedures below If repairs must be accom...

Page 365: ...OTE Two oil supply ports are provided on the lower half of the parking brake assembly Install the O ring fitting for attaching the supply hose 7 Figure 7 1 to the lowest port depending on whether the brake is to be installed on the right or left wheel motor Install an O ring plug in the unused port 1 Install two guide studs in wheel motor end frame to guide brake assembly into position Be certain ...

Page 366: ... Assembly 1 If dowel pins 2 Figure 7 2 have been removed press new dowel pins into holes in housing until fully seated against shoulder 2 Install a separator disc 12 over dowel pins Insert a spring 1 over each dowel pin Insert a friction disc 13 Insert springs 1 over dowels 3 Install another separator disc the 2nd friction disc and the remaining separator disc NOTE The internal teeth of the two fr...

Page 367: ...ure supply ports and attach a hydraulic power source Install an O ring plug in the remaining port a Slowly apply pressure and open the bleeder valve to bleed air from the piston cavity Close the bleeder and apply 300 psi 2068 kPa hy draulic pressure and hold for one 1 minute b Observe for oil leakage NO leakage is permit ted c If leakage occurs the brake assembly must be disassembled and repaired ...

Page 368: ... housing access door remove the cooling air duct tube and open access covers 4 Be certain the brake accumulator bleeddown valves are closed 5 Start the engine and allow the steering system to fully charge pump unloads Turn the parking brake to the OFF position 6 Connect a clear plastic hose to the parking brake bleeder screw Place the other end of hose in a container 7 Slowly open bleeder valveand...

Page 369: ... Strainers L3 15 Breathers L3 16 STEERING CIRCUIT L4 STEERING CIRCUIT OPERATION L4 1 COMPONENT DESCRIPTION L4 2 Steering Control Valve L4 2 Bleed Down Manifold Valve L4 3 Accumulators L4 5 Flow Amplifier L4 6 Steering Pump L4 16 STEERING CONTROL UNIT L5 Removal L5 1 Installation L5 1 REBUILD PROCEDURE L5 2 Disassembly L5 2 Cleaning and Inspection L5 3 Assembly L5 5 STEERING CIRCUIT COMPONENT REPAI...

Page 370: ...LTERS L9 HOIST CIRCUIT FILTER L9 1 STEERING CIRCUIT FILTER L9 3 Indicator Switch L9 4 HYDRAULIC CHECK OUT PROCEDURE L10 STEERING CIRCUIT CHECK OUT AND ADJUSTMENT PROCEDURE L10 1 Pump Pressure Control Adjustments L10 2 Steering Control Unit Flow Amplifier Leakage Test L10 3 Shock and Suction Valves L10 5 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES L10 6 Brake Cooling Circuit Test ...

Page 371: ... hoist circuit steering circuit and hydraulic brake circuit FIGURE 2 1 HYDRAULIC SYSTEM COMPONENTS AND PIPING 1 Hoist Cylinders 2 Hoist Valve 3 Hydraulic Tank 4 Bleeddown Manifold 5 Steering Accumulators 6 Hydraulic Components Cabinet 7 Flow Amplifier Valve 8 Heat Exchanger Brake System Cooling 9 Steering Cylinders 10 Brake System Auxiliary Accumulators 11 Hoist Circuit Filters 12 Steering Circuit...

Page 372: ...ian familiar with this injury is not received immediately Always maintain complete cleanliness when open ing any hydraulic connection Insure that all sys tem lines are capped while the component is removed from the truck Hoist Circuit Operation Hydraulic oil from the tank 8 Figure 2 2 is supplied to a gear type hoist circuit pump rated at 246 GPM 931 l min 1900 RPM and 2500 psi 17 2 MPa Oil from t...

Page 373: ...iew 1 Hoist Cylinders 2 Brake Hoist Return Oil Manifold 3 Overcenter Manifold 4 Hoist Valve 5 Bleeddown Manifold 6 Pump Drive Shaft 7 Hoist Circuit Filters 8 Hydraulic Tank 9 Hoist Valve Pilot Circuit Hoses L02028 Hydraulic System L2 3 ...

Page 374: ... steering cylinders 1 A relatively small volume of oil is supplied from the flow amplifier to the steering control unit mounted on the steering column in the cab When the operator moves the steering wheel oil is routed from the steering con trol unit back to the flow amplifier based on the direc tion and rate of speed of rotation of the steering wheel The flow amplifier provides a large volume of ...

Page 375: ...ew 1 Steering Cylinders 2 Manifold 3 Flow Amplifier Valve 4 Bleeddown Manifold 5 Steering Circuit Accumulators 6 Hoist Circuit Pump 7 Steering Brake Pump 8 Hydraulic Tank 9 Shut off Valve 10 Steering Brake Circuit Filter L02028 Hydraulic System L2 5 ...

Page 376: ...o lubricate the front wheel hub bearings Brake cooling circuit pressure is limited by orificed regulator valves located in the Brake Hoist Return Oil Manifold Figure 2 5 shows the piping and flow of oil through the Brake Hoist Return Oil Manifold The inter nal check valves crack open at 35 PSI 241 kPa Their opening pressure will be slightly higher as flow through it increases Refer to Section J fo...

Page 377: ... Right Front Brake Cooling Inlet Hose 5 Right Front Brake Cooling Outlet Hose 6 Left Front Brake Cooling Inlet Hose 7 Hydraulic Tank 8 Brake Hoist Return Oil Manifold 9 Rear Brake Cooling Supply Return Lines 10 Hoist Valve 11 Rear Axle Housing FIGURE 2 6 DISC BRAKE COOLING SYSTEM L02028 Hydraulic System L2 7 ...

Page 378: ...NOTES L2 8 Hydraulic System L02028 ...

Page 379: ...ting the need to completely drain the tank 3 Removethe rear axleblower duct to allow thehoist pump to be lowered from the pump module mounting bracket for removal Remove duct sup port bracket 4 Close the pump supply shut off valves Always maintain complete cleanliness when open ing any hydraulic connection Insure that all sys tem lines and components are capped while the component is removed from ...

Page 380: ...mately 500 lbs 227 kg Use a suitable lifting or support device that can handle the load safely FIGURE 3 2 HYDRAULIC PUMPS 1 Pump Outlet Hoses 2 Pump Mount Capscrews 3 Hoist Pump 4 Pump Mount Capscrews 5 Steering Brake Pump 6 Pump Mount Bracket 7 Outlet Hose FIGURE 3 3 STEERING BRAKE PUMP REMOVAL 1 Hoist Pump 2 Nut Washer 3 Dowel 4 O ring 5 Capscrew 11 Steering Brake Pump 12 Pump Case Return Fittin...

Page 381: ...lifting or support device that can handle the load safely 2 Attach a suitable lifting or support device to the hoist pump capable of handling approximately 250lbs 113kg Movepump into position in truck 3 Lubricate the steering pump spline shaft and align with coupling 9 Install hoist pump to steering pump and install capscrews 10 with hardened washers and tighten to standard torque Raise pumps up i...

Page 382: ...ove nuts 17 Figure 3 3 Remove bearing plate 20 Figure 3 4 with transition plate 22 and O ring 26 Remove capscrews securing the bearing plate to the transition plate and remove O ring 23 Remove dowels if damaged or if replacement of the transition plate is necessary FIGURE 3 4 HOIST PUMP 1 Drive Gear Shaft 2 Seal 3 Idler Gear 4 Stud 5 Steel Ball 6 Flange 7 Dowel 8 Gear Plate 9 O ring 10 Connector P...

Page 383: ... stud O ring 4 8 Remove bearing plate 2 Figure 3 5 Remove O ring 23 and stud O rings 1 Remove dowels 20 if damaged or replacement of the bearing plate is necessary 9 Remove coupling 21 Remove snap ring 22 if damaged or replacement is necessary NOTE Disassembly of the rear pump section is now complete Do not remove thru studs at this time as the studs serve as guides for disassembly FIGURE 3 5 HOIS...

Page 384: ...hammer to loosen Remove O ring 8 Remove dowels 6 if damaged or if replacement of the flange 5 or gear plate 7 is necessary 13 Remove steel rings backup ring O ring and re tainer Remove drive gear 1 and idler 3 from gear plate 7 Remove both pressure plates 18 FIGURE 3 6 HOIST PUMP DISASSEMBLY Front Section 1 Drive Gear Shaft 2 Seal 3 Idler Gear 4 Steel Ball 5 Flange 6 Dowel 7 Gear Plate 8 O ring 9 ...

Page 385: ...t of the flange bore Refer to Figure 3 8 Use care not to mar scratch or damage the seal bore surface or bearings 16 After the seals and snap ring have been removed clean the bore thoroughly If necessary the bore may be smoothed with number 400 emery paper only FIGURE 3 7 PREPARATION FOR SEAL REMOVAL 1 Flange 2 Bearings 3 Wooden Blocks FIGURE 3 8 SHAFT SEAL REMOVAL 1 Flange 2 Punch 3 Bearings L0302...

Page 386: ...tor plates or bearing plate should be replaced NOTE Replacing new bearing in the flange connector plates or bearing plate is not recommended due to close tolerances and special tooling required for crimping the bearing in place to prevent bearing spin 6 Inspect the flange seal bore for scratches or gouges which may interfere with shaft seal instal lation 7 For additional pump and system inspection...

Page 387: ...e up and the milled slot facing toward the discharge side slide pressure plate 2 Figure 3 13 down into the gear bores until it rests on the backup ring and O ring Do not force the plate down the gear bores If it hangs up on the way down work it back and forth until it slides freely into place 13 Coat the inside of the gear plate and the gears with clean hydraulic oil NOTE To ensure the gear pump i...

Page 388: ...e O ring 7 Install dowel 14 if removed Lubricate the I D of the bearings 17 and install connector plate 6 Install snap ring 8 and coupling 9 FIGURE 3 13 PRESSURE PLATE INSTALLATION 1 Gear Plate 2 Pressure Plate 3 Slot FIGURE 3 14 HOIST PUMP REASSEMBLY 1 Drive Gear Shaft 2 Idler Gear 3 Gear Plate 4 Relief 5 O ring 10 Thru Studs 11 Steel Ring 12 Backup Ring 13 O ring Retainer 14 Dowel 15 Isolation P...

Page 389: ...rings 26 Install O rings 8 9 and dowel 25 ifremoved Install gear plate 10 Make sure relief in gear plate is toward bearing plate 7 FIGURE 3 15 HOIST PUMP REASSEMBLY 1 Drive Gear Rear 2 Dowel 3 O ring 4 O ring 5 Coupling 6 Connector Plate 7 Bearing Plate 15 Bearing Plate 16 Transition Plate 17 O ring 18 Not Used 19 Coupling 20 Nut 21 O ring 22 Dowel 23 Dowel 24 O ring 25 Dowel 26 Bearings 8 O ring ...

Page 390: ...e and tran sition plate 15 16 to the connector plate 11 and secure in place with nuts 20 Tighten nuts to standard torque 26 Lubricate the thru stud threads and install two oppositestud nuts and hardened washers Tighten nuts to 240 to 250 ft lbs 325 to 339 N m torque 27 Using an 18 inch 45 cm adjustable wrench check pump drive shaft rotation The drive shaft will be tight but should turn freely with...

Page 391: ...ar of drive gear and rear pressure plate only 3 Incorrect installation 1 Did shaft bottom in mating part 2 Any interference between pump and machine 1 Eroded pump housing 2 Eroded pressure plates 4 Aeration Cavitation a Restricted oil flow to pump inlet b Aerated Oil 1 Tank oil level correct 2 Oil viscosity as recommended 3 Restriction in pump inlet line 4 Air leak in pump inlet line 5 Loose hose ...

Page 392: ...il in the hydraulic system an oil analysis should be made before replacing any component If foreign particles are evident system must be flushed Refer to Hydraulic Sys tem Flushing instructions Removal 1 Turn keyswitch Off and allow at least 90 seconds for the steering accumulator to bleed down NOTE Be prepared to contain approximately 250 gal 947 L of hydraulic oil If the oil is to be reused clea...

Page 393: ...ws 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 over heated The quantity and size of any particles may be an indication of excessive wear of components in the hydraulic system 1 Clean thestrainerswith fresh cleaning solvent from the inside out 2 Inspect the str...

Page 394: ...ound the breather filters clean and free of debris build up If there is any sign that the breather filters are oil soaked replace the filters as soon as possible and check for proper oil level Once the breather filters become oil soaked they will plug very quickly NOTE Plugged breather filters can cause pressure build up inside the hydraulic tank and can cause the service brakes to drag L3 16 Hydr...

Page 395: ...ass the element at 50 psi 345 kPa System pressureis regulated to between 2750psi 19 0 MPa and 3025 psi 20 9 MPa by an unloader valve located on the bottom of the steering pump case FIGURE 4 1 STEERING SYSTEM COMPONENTS Bottom View 1 Steering Cylinders 2 Manifold 3 Flow Amplifier Valve 4 Bleeddown Manifold 5 Steering Circuit Accumulators 6 Hoist Circuit Pump 7 Steering Brake Pump 8 Hydraulic Tank 9...

Page 396: ...the flow amplifier valve The flow amplifier directs oil flow to the appropriate ports on the steering cylinders as determined by inputs from the steering control unit as the operator steers the truck see Figure 4 2 Oil entering the steering control unit is blocked until the steering wheel is turned in a desired direction The valve then directs oil to the flow amplifier which in turn provides a hig...

Page 397: ...ing the accumulators is bled back to the hydraulic tank Brake pressure however will not bleed down due to internal check valves in the brake manifold and bleeddown manifold check valve see schematic After approximately 90 seconds the solenoid will de energize to close the return port to tank By this time all the oil in the accumulators should be returned to tank At start up the steering circuit wi...

Page 398: ...o Flow Amplifier 13 Quick Disconnect Supply Port 14 Steering Circuit Return From Flow Amplifier 15 Quick Disconnect Return Port 16 Spare Return Port 17 Autolube Pump Supply 18 Hoist Pilot Return 19 Hoist Pilot Power Down 20 Hoist Pilot Power Up 21 Tank Return Port 22 Hoist Power Up 23 Hoist Power Down 24 Hoist Up Limit Solenoid 25 Relief Valve 4000 psi 28 0 MPa 26 Not installed 27 Steering Accumul...

Page 399: ...ators and increase steering system pressure The accumulators also provide oil for a limited period of time to be used in case the pump becomes inop erative Low Precharge Warning Switch Pressure switches located in the top of each accumu lator monitor nitrogen pressure and are used to acti vate the accumulator precharge warning light if the nitrogen pressure drops below 1100 psi 7 6 MPa The switche...

Page 400: ... valve and is used in the steering circuit to provide the high volume of oil required for the steering cylinders The flow amplifier uses the amount of flow from the steering control unit to determine a proportional amount of flow to send from the bleed down manifold to the steering cylinders L4 6 Steering Circuit L04031 ...

Page 401: ...FIGURE 4 5 FLOW AMPLIFIER VALVE L04031 Steering Circuit L4 7 ...

Page 402: ...ast the spool to the closed amplifier valve and also out port P through a hose to port P on the steering control unit In the steering control unit it goes to a closed area in the control 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 5 MPa the...

Page 403: ...FIGURE 4 6 FLOW AMPLIFIER NO STEER L04031 Steering Circuit L4 9 ...

Page 404: ...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 proportion as is hole G The number of holes K 7 in sleeve E deter mine the amount of additional oil that is added to the steering control unit oil passing through hole G This combined oil going to the center area Q of the directional valve passes out port ...

Page 405: ...FIGURE 4 7 FLOW AMPLIFIER LEFT STEER L04031 Steering Circuit L4 11 ...

Page 406: ...port R and shifts the directional valve the opposite direction The oils flow through the amplifier valve exactly the same Thecombined oil from theamplifier valvepasses 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 the tank The LS oil operates e...

Page 407: ...FIGURE 4 8 FLOW AMPLIFIER RIGHT STEER L04031 Steering Circuit L4 13 ...

Page 408: ...tion relief valve inside the flow amplifier assembly at port CR will open at its adjusted setting 3100 psi 21 4 MPa and allow oil to escape from the pressurized ends of the cylinders preventing a higher pressure 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 through the CR port relief valve to f...

Page 409: ...FIGURE 4 9 FLOW AMPLIFIER NO STEER EXTERNAL SHOCK LOAD L04031 Steering Circuit L4 15 ...

Page 410: ...bearing 33 supports the outboard end of the driveshaft and abushing typebearing 47 supportsthe inboard end The pump cylinder barrel is carried in a polymerous journal type bearing 41 The valve plate has two crescent shaped ports inlet and outlet Pumping pistons 44 in the cylinder barrel are held against a swashblock 28 by a shoe retainer 17 The shoe retainer is held in position by thefulcrum ball ...

Page 411: ...r 21 Saddle Bearing 22 Roll Pin 23 Link 24 O Ring 25 Stroke Adjuster 26 Retainer Ring 27 Pin 28 Swashblock 29 Dowel Pin 30 Saddle 31 Roll Pin 32 Retainer Ring 33 Bearing 34 Shaft Retainer Ring 35 Shaft 36 Seal Retainer 37 Pump Housing 38 Shaft Seal 39 O Ring 40 Fulcrum Ball 41 Cylinder Bearing 42 O Ring 43 Elbow Fitting 44 Piston Shoe Assy 45 Cylinder Barrel 46 Gasket 47 Bearing 48 Valve Plate 49 ...

Page 412: ...escent to port B until it s innermost stroke is reached At that point the piston bore again passes from the right to the left side crescent and the operating cycle is repeated Half Pump Volume Figure4 12shows that theposition ofthecontrol piston 1 is near the center of its travel The swashblock is not angled as steep as before and therefore the pistons have a shorter stroke As the piston stroke ge...

Page 413: ...avitation under certain conditions If the truck is oper ating at high altitude and problems are experienced consultthe Komatsu FactoryRepresentative for adjust ment procedures Figure 4 15 shows the schematic of the pump and the pressure control valves FIGURE 4 14 STEERING PUMP ASSEMBLY 1 Outlet Port 2 Case Drain 3 Stroke Adjuster 4 Unloader Valve Press Adjust 5 Compensator Press Adjust 6 4 Way Val...

Page 414: ...NOTES L4 20 Steering Circuit L04031 ...

Page 415: ...itioins and release to assure that springs in control valve FREELY return the steering wheel to neutral If wheel is tight loosen control unit mounting cap screws and realin valve 4 Grease drive coupling through grease fitting 7 with a molybdenum disulphide or multi purpose NLGI grease 5 Remove plugs from four hydraulic lines Be certain that the previously tagged hydraulic lines are connected to th...

Page 416: ... proper relocation during reassembly Re fer to Figure 5 4 3 Remove end cover capscrews and washers Re move capscrew with rolled pin 3 Figure 5 4 Mark hole location of capscrew with rolled pin on end cover to facilitate reassembly FIGURE 5 2 STEERING CONTROL UNIT 1 Brake valve 2 Steering Control Unit 3 LS Port Hose 4 L Port Hose 5 T Port Hose 6 P Port Hose 7 R Port Hose FIGURE 5 3 VALVE PORT IDENTI...

Page 417: ... 6 and bearing assem bly 7 11 Remove ring 8 and pin 9 and carefully push inner spool out of outer sleeve 12 Press the neutral position springs 10 out of their slot in the inner spool 13 Remove the dust seal 2 Figure 5 6 using a screwdriver Take care not to scratch or damage the dust seal bore Cleaning and Inspection 1 Clean all parts carefully with fresh cleaning sol vent 2 Inspect all parts caref...

Page 418: ... 5 O ring 6 Kin Ring 19 End Cover 20 Washers 21 Rolled Pin 22 Capscrew With Pin 23 Capscrews 13 Tube 14 O ring 15 Distribution Plate 16 Gear Wheel Set 17 O ring 18 O ring 7 Bearing Assembly 8 Ring 9 Pin 10 Neutral Position Springs 11 Cardan Shaft 12 Spacer L5 4 Steering Control Unit L05021 ...

Page 419: ...s place a screwdriver in the spool slot as shown in Figure 5 9 2 Place one flat neutral position spring on each side of the screwdriver blade Do not remove screw driver 3 Push two curved neutral position springs in be tween one side of the screwdriver blade and a flat spring Repeat for the opposite side Remove the screwdriver 4 Slide the inner spool in the sleeve Compress the ends of the neutral p...

Page 420: ...n 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 11 NOTE Cross pin must remain horizontal when spool and sleeve are pushed into bore to prevent pin from dropping out of spool FIGURE 5 10 BEARING INSTALLATION 1 Sleeve 2 Cross Pin 3 Ring 4 Bearing ...

Page 421: ...tate the gear slightly to find the matching splines on the cardan shaft Splines are machined to insure proper alignment 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 marks as a reference and install using ...

Page 422: ...NOTES L5 8 Steering Control Unit L05021 ...

Page 423: ...ng disassembly Installation 1 Install bleeddown manifold Tighten mounting cap screws to standard torque 2 Unplug lines and attach Tighten connections securely Install new O rings at flange fittings 3 Attach electrical leads to solenoids and pressure switch If check valves or relief valves were re moved replace using new O ring seals 4 Start the engine and check for proper operation and leaks Check...

Page 424: ...Loosen the mounting band 3 Figure 6 3 cap screws and remove the mounting bands 6 Raise the accumulator until clear of mounting bracket and move to a clean work area for disas sembly Installation 1 Lift accumulator into position on the mounting bracket Accumulator should be positioned with the antirotation block positioned between the two stop blocks on the lower mounting bracket 2 Secure the accum...

Page 425: ...e absolutely free of any foreign matter larger than 3 microns 2 Inspect piston for damage If scored or otherwise damaged replace with a new part 3 Minor defects in the housing bore may be cor rected by honing a Measure the bore at several places along the length of the housing Make two measure ments 90 apart at each point to verify tube is not out of round FIGURE 6 4 ACCUMULATOR ASSEMBLY 1 Capscre...

Page 426: ...ernal and external leaks at high pres sure A source of 5000 psi 35 MPa hydraulic pressure and nitrogen pressure of 1400 psi 9 65 MPa will be required A small water tank with the necessary safety guards in place will be necessary for a portion of the test Do not stand near gland during test procedure A box enclosure made of heavy steel plate is recom mended to contain the accumulator during oil pre...

Page 427: ...ge Replace or repair items as necessary before charging procedure 6 Connect the nitrogen charging kit to the charging valves Open the regulator and charge the accu mulators simultaneously to 1400 psi 9 65 MPa NOTE If a loss in nitrogen pressure occurred during operation oil may still be present in the accumulator below the piston This oil can be bled off during the nitrogen charging procedure by t...

Page 428: ...recision unit manufac tured to close tolerances therefore complete cleanli ness is a must when handling the valve Work in a clean area and use lint free wiping materials or dry compressed air Use a wire brush to remove foreign material and debris from around the exterior of the valve before disassembly Clean solvent and type C 4 hydraulic oil should be used to insure cleanliness and initial lubric...

Page 429: ...L06021 Steering Circuit Component Repair L6 7 ...

Page 430: ...ired Remove orifice screw 13 11 Remove orifice screw 45 Remove check valve 47 NOTE If further disassembly is required for the shock and suction valves refer to Figure 6 8 NOTE The flow amplifier valve is equipped with two identical shock and suction valves The shock and suction valves are only serviced as complete valve assemblies O rings 1 3 Figure 6 8 are replaceable The check valve 47 and count...

Page 431: ... stop 20 springs 21 22 and spring control 23 Install orifice screws 24 33 if removed from main spool 27 Install main spool 27 9 Install amplifier spool assembly 53 Install priority valve spool 44 and spring 43 Install spring 52 10 Install spring control 29 springs 30 31 and spring stop 32 11 Lubricate O rings 6 7 8 with molycote grease and position on cover 5 Install end cover 5 Install capscrews ...

Page 432: ...ressure can have sufficient force to enter a person s body by pene trating the skin and cause serious injury and pos sibly death if proper medical treatment by a physician familiar with this injury is not received immediately FIGURE 6 10 STEERING CYLINDER MOUNTING 1 Steering Cylinder 2 Tie Rod 3 Capscrew 4 Locknut 5 Bearing Retainer 6 Capscrew 7 Lockwashers 8 Retainer 9 Mount Bracket Frame 10 Bear...

Page 433: ... to compress O D of seal until it fits tightly on piston 2 Install bearing 4 in piston groove Cylinder Assembly 1 Install new bearing 13 Figure 6 11 rod seal 12 rod wiper 11 backup ring 7 and O ring 6 in gland 8 2 Push rod 10 through top of gland slowly advanc ing rod over rod seal and rod wiper 3 Install piston assembly 3 on rod Secure piston to rod with locknut 2 Tighten locknut to 2000 ft lbs 2...

Page 434: ...ntainers must be used with a 3 micron filtering system available for refill 3 Disconnect the suction line and outlet 7 Figure 6 12 at the steering pump 5 Disconnect and cap pump case drain line from fitting at top of pump housing Plug all lines to prevent oil con tamination The steering pump weighs approximately 250 lbs 113 kg Use a suitable lifting device capable of handling the load safely 4 Sup...

Page 435: ...p to bleed any trapped air Tighten hose connection cap screws to standard torque If trapped air is not bled from steering pump pos sible 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 components cabinet open both brake accumulator needle valves completely to allow the steering pump to start u...

Page 436: ...2 13 14 15 and 16 Figure 6 13 MUST be removed BEFORE further disassembly of control piston 8 Without disturbing jam nut 16 unscrew gland 15 and remove stroke adjuster as a complete assembly 9 Back out capscrews 1 Figure 6 15 then remove cap 4 10 Remove bias control spring 1 Figure 6 14 Valve Plate Group NOTE Valve plate 11 Figure 6 15 is a slight press fit in the pump housing 11 Support valve plat...

Page 437: ... Lifting Eyes 6 Name Plate 7 Screw Drive 8 Name Plate 9 Plug 10 O Ring 11 Plate 12 O Ring 13 Stem 14 O Ring 21 Housing 22 Seal Retainer 23 Elbow Fitting 24 Plug 25 O Ring 26 Seal 15 Gland 16 Jam Nut 17 Pin 18 O Ring 19 Pin 20 O Ring L06021 Steering Circuit Component Repair L6 15 ...

Page 438: ... 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 L6 16 Steering Circuit Component Repair L06021 ...

Page 439: ...he next step for further disassembly which will make their removal easier Driveshaft Group 28 Remove bearing retaining ring 3 Figure 6 13 Use a mallet on the tail shaft and tap driveshaft 1 out from the front of the pump housing 29 Remove seal retainer 22 from pump housing Use a mallet and tap saddle 20 Figure 6 14 out from the inside of the pump housing Saddle bear ings 24 can then be easily remo...

Page 440: ... 14 and cradle All shoes must be equal within 0 0001 in 0 003 mm If one or more piston shoe assemblies 13 needs to be replaced all piston shoes assem blies must be replaced c Inspect cylinder bearing 26 and matching cylinder barrel bearing mating surface for gall ing pitting or roughness Replace if necessary FIGURE 6 15 PUMP REAR HOUSING 1 Capscrew 2 O Ring 3 Plug 4 Cap 5 Back Up Ring 6 O Ring 7 C...

Page 441: ...in wear area to thickness in a non wear area Replace saddle bearings if difference is greater than 0 004 in 0 102 mm 13 Check mating surface of swashblock for cracks or excessive wear Replace if necessary 14 Swashblock movement in saddle and saddle bear ing must be smooth FIGURE 6 16 UNLOADER COMPENSATOR CONTROLS 1 Valve Plate 2 O Ring 3 O Ring 4 O Ring 5 Plug 6 O Ring 13 Plug 14 O Ring 15 Orifice...

Page 442: ...oroughly with CLEAN hydraulic fluid Apply fluid generously to all wear surfaces Swashblock Group 2 Press or tap roll pin 22 Figure 6 14 into pump housing 18 Figure 6 13 3 Press new shaft seal 26 into saddle 20 Figure 6 14 using an arbor press Install O ring 21 into the groove in the saddle 4 Press four roll pins 23 into saddle 20 until they bottom then press saddle bearing 24 onto the pins to loca...

Page 443: ...hoe assemblies 13 into corresponding marked during disassem bly holes completing the rotating group The assembled rotating group weighs approxi mately 30 lbs Assistance from others and use of proper lifting techniques is strongly recom mended to prevent personal injury 21 The rotating group can now be carefully installed over the end of the driveshaft and into the pump housing 22 When installing t...

Page 444: ...ng this next step to prevent the washer and retaining ring from falling into pump housing 41 Install second control link washer 15 and control link retaining ring 14 onto pin 42 Once assembled remove capscrew from pin NOTE The valve plate is a slight press fit into pump housing Make sure pilot diameter on valve plate is aligned with mating diameter on the pump housing prior to assembly 43 Insert f...

Page 445: ...TROUBLE Wander truck will not stay in straight line Air in system due to low oil level pump cavitation leaking fitting pinched hoses etc Loose cylinder piston Broken centering springs spool valve steering valve Worn mechanical linkage Bent linkage or cylinder rod Severe wear in steering control unit Correct oil supply problem or bleed air Repair or replace steering cylinder Repair or replace steer...

Page 446: ...linder seals Check for loose fitting bearings at anchor points in steering linkage between cylinder and steered wheels Repair or Replace steering cylinder TROUBLE Binding or poor centering of steered wheels Binding or misalignment in steering column or splined coupling and steering control unit High back pressure in tank can cause slow return to center Should not exceed 300 psi 2068 kPa Large part...

Page 447: ...age No oil to pump inlet Bleed air from pump and or system Inspect hoist and steering pump replace drive shaft Check for external leaks internal system pressure loss Check hydraulic tank oil level Make certain pump inlet shut off valve is open TROUBLE Low pump output Low pump pressure Internal pump wear Restricted inlet Insufficient oil supply High pressure filter restricted Check unloader valve o...

Page 448: ...eak at pump inlet Insufficient inlet oil supply Internal pump damage Check pressure and adjust pressure controls Warm oil before starting or install proper viscosity oil Inspect inlet hose connections and shut off valve Check hydraulic tank level Clean suction strainer Make certain shut off valve is open Repair or replace pump TROUBLE Erratic pump load unload cycle Pressure compensator adjusted in...

Page 449: ...nd suction relief valve Pressure setting of shock valve too low Disassemble valve check and clean shock and suc tion valves Replace valves if necessary Adjust pressure settings TROUBLE Inability to steer no pressure build up Defective steering control unit Repair or replace steering control unit TROUBLE Resistance when initially turning steering wheel Air in LS line Priority valve spring compressi...

Page 450: ...NOTES L6 28 Steering Circuit Component Repair L06021 ...

Page 451: ...wering of the dump body Hoist valve functions are controlled by the operator through the lever connected to the hoist pilot valve 4 located in the hydraulic components cabinet A hoist limit solenoid 5 located in the bleeddown manifold shifts the hoist valve out of POWER UP before the hoist cylinders extend to their maximum physical limit When the hoist valve is in the HOLD or FLOAT posi tion hoist...

Page 452: ...iction through the filter element is sensed by an indicator switch This switch will turn on a cab mounted red warning light to indicate filter service is required The indicator light will illuminate when restric tion reaches approximately 40 psi 276 kPa Actual filter bypass will result when the filter element restric tion reaches approximately 50 psi 345 kPa HOIST VALVE The hoist valve Figure 7 2 ...

Page 453: ... at the bottom of the spool will overcome the top spring bias and the spool will shift to connect the work port to the low pressure core The check poppets located in the spool section permit free flow from the work port to the pilot port and restrict flow from the pilot port to the work port These check poppets control spool response and spool movements during void conditions Tank Ports Front Spoo...

Page 454: ...ment procedure of the hoist limit switches Pilot Operated Check Valve The Pilot Operated Check Valve 6 Figure 7 1 lo cated in the bleeddown manifold is opened by power down pilot pressure to allow oil in the raise port to by pass the hoist up limit solenoid for initial power down operation while the solenoid is activated by the hoist limit switch OVERCENTER MANIFOLD The overcenter manifold 4 Figur...

Page 455: ...HOIST CIRCUIT OPERATION The following pages describe the hoist circuit operation in the FLOAT POWER UP HOLD and POWER DOWN positions Refer to Figures 7 5 through 7 9 L07023 Hoist Circuit L7 5 ...

Page 456: ...of the flow control valve 2 causing the valve to compress the spring and open allowing the oil to flow the through hoist valve port 23 to the service brakes for brake disc cooling and eventually back to the tank Between the hoist valve port 23 and the brakes or heat exchanger the cooling supply tee s to orificed regulator valves If supply pressure attempts to increase above 35 psi 240 kPa the regu...

Page 457: ...End Work Port 10 Tank Return Port 11 Supply Port 12 Pilot Supply Port 13 Hoist Limit Solenoid 14 Raise Pilot Port 15 Down Pilot Port 16 Power Down Relief Valve 1500 psi 17 Anti void Check Valve 18 Load Check Valve 19 High Pressure Passage 20 Low Pressure Passage 21 Pilot Operated Check Valve 22 Primary Low Pressure Valve 26 psi 23 Brake Cooling Circuit Port 24 Overcenter Manifold L07023 Hoist Circ...

Page 458: ...e top of the spool through Ports 15 through the pilot valve spool and out port 10 of the pilot valve to the bleed down manifold and to the tank No pressure is present on the top of spool 7 Cylinder return 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 cyli...

Page 459: ...d End Spool 10 Return Port 11 Supply Port 12 Pilot Supply Port 13 Hoist Limit Solenoid 14 Raise Pilot Port 15 Down Pilot Port 16 Power Down Relief Valve 1500 psi 17 Anti void Check Valve 18 Load Check Valve 19 High Pressure Passage 20 Low Pressure Passage 21 Pilot Operated Check Valve 22 Primary Low Pressure Valve 26 psi 23 Brake Cooling Port 24 Overcenter Manifold L07023 Hoist Circuit L7 9 ...

Page 460: ...l valve 2 to open and route the incoming pump oil to the brake cooling circuit through port 23 and back to the tank Both pilot ports 14 15 in the pilot valve are closed by the pilot valve spool In this condition pressure is equalized on each end of each main spool 7 8 allowing the springs to center the spools and close all ports to trap the oil in the cylinders and hold the body in its current pos...

Page 461: ...nd Spool 10 Return Port 11 Supply Port 12 Pilot Supply Port 13 Hoist Limit Solenoid 14 Raise Pilot Port 15 Down Pilot Port 16 Power Down Relief Valve 1500 psi 17 Anti void Check Valve 18 Load Check Valve 19 High Pressure Passage 20 Low Pressure Passage 21 Pilot Operated Check Valve 22 Primary Low Pressure Valve 26 psi 23 Brake Cooling Port 24 Overcenter Manifold L07023 Hoist Circuit L7 11 ...

Page 462: ...l valve closes If the body is at the maximum up position the hoist limit switch has the hoist limit solenoid activated therefore closing the raise port 14 on the hoist valve Power down pilot pressure in ports 15 pushes open the pilot operated check valve 21 located in the bleeddown manifold so the pilot pressure in ports 14 is open to tank through the Pilot valve spool As oil attempts to return fr...

Page 463: ...d End Spool 10 Return Port 11 Supply Port 12 Pilot Supply Port 13 Hoist Limit Solenoid 14 Raise Pilot Port 15 Down Pilot Port 16 Power Down Relief Valve 1500 psi 17 Anti void Check Valve 18 Load Check Valve 19 High Pressure Passage 20 Low Pressure Passage 21 Pilot Operated Check Valve 22 Primary Low Pressure Valve 26 psi 23 Brake Cooling Port 24 Overcenter Manifold L07023 Hoist Circuit L7 13 ...

Page 464: ... The oil returning from the head end of the hoist cylinders builds pressure on the bottom of the head end spool 8 exactly like in POWER DOWN allowing the returning oil to transfer to the low pressure passage 20 The back pressure in the low pressure passage created by the primary low pressure relief valve 22 causes pressure under the rod end spool 7 to move the spool upward This connects the low pr...

Page 465: ...ead End Work Port 10 Tank Return Port 11 Supply Port 12 Pilot Supply Port 13 Hoist Limit Solenoid 14 Raise Pilot Port 15 Down Pilot Port 16 Power Down Relief Valve 1500 psi 17 Anti void Check Valve 18 Load Check Valve 19 High Pressure Passage 20 Low Pressure Passage 21 Pilot Operated Check Valve 22 Primary Low Pressure Valve 26 psi 23 Brake Cooling Port 24 Overcenter Manifold L07023 Hoist Circuit ...

Page 466: ...NOTES L7 16 Hoist Circuit L07023 ...

Page 467: ...n to allow body to lower against safety cable and relieve hoist cyl inder pressure 3 Thoroughly clean the exterior of the hoist valve 4 Mark disconnect and cap or plug all line connec tions to help prevent hydraulic oil contamination refer to Figure 8 1 5 Remove capscrews and lockwashers securing the hoist valve to its mounting bracket The hoist valve weighs approximately 425 lbs 193 Kg Use a suit...

Page 468: ...the valve sections 1 Remove the four tie rod nuts and washers 7 Figure 8 2 from one end of the valve Slide the tie rods from the valve and separate the sections 2 Inspect the machined sealing surfaces for scratches or nicks If scratches or nicks are found remove by lapping on a smooth flat steel surface with fine lapping compound 3 Lubricate the new O rings lightly with multipur pose grease Replac...

Page 469: ...oppet removal in cover 2 Figure 8 5 is required refer to step 4 and figure 8 6 4 Remove sleeve 9 backup ring 8 O ring 7 backup ring 6 Remove backup ring 5 O ring 4 backup ring 3 and restrictor poppet 2 5 Repeat steps 1 through 4 for the opposite inlet section if disassembly is required FIGURE 8 6 RESTRICTOR POPPET REMOVAL Inlet Cover 1 Inlet Cover 2 Restrictor Poppet 3 Backup Ring 4 O Ring 5 Backu...

Page 470: ...e 4 Install springs 3 5 Install cover 2 Install capscrews 1 Tighten capscrews to 60 ft lbs 81 N m torque Connect external tube tighten nuts to 25 ft lbs 34 N m torque REAR SPOOL SECTION Work Ports Disassembly NOTE It is not necessary to remove the inlet sections 1 or 4 Figure 8 2 to accomplish spool section 2 or 3 disassembly 1 Match mark or identify each part when removed in respect to its locati...

Page 471: ... Poppet 7 Ball 15 Spool End 16 Spring Blue 17 O Ring 18 Poppet 19 Spool Cover 20 Spool Assembly 21 Restrictor Poppet Green 22 Restrictor Poppet White 8 O Ring 9 Restrictor Poppet 10 O Ring 11 Spring 12 Restrictor Poppet Red 13 Spool Housing 14 Spool Assembly L08024 Hoist Circuit Component Repair L8 5 ...

Page 472: ... spool 20 Install spring seat 2 Apply Loctite to the threads of spool end 15 Install spool end and tighten to 25 ft lbs 34 N m torque Install Green poppet 21 Apply Dri loc 204 to the threads of plug 3 Install plug and tighten to 15 ft lbs 20 N m torque NOTE Poppets 12 21 and 22 may be color coded and must be installed in their original location 3 Repeat step 2 for the opposite end of spool 20 to i...

Page 473: ...8 12 from housing 3 Remove and discard O rings 5 6 4 Remove capscrews and remove bottom cover 9 from spool housing Remove and discard O rings 5 Remove springs 8 Push spools 7 out of housing bores Cleaning and Inspection 1 Discard all O rings Clean all parts in solvent and blow dry with compressed air 2 Inspect springs for breaks or distortion 3 Inspect housing bores and surfaces of spools for nick...

Page 474: ...FIGURE 8 12 TANK PORTS SPOOL SECTION ASSEMBLY 1 Spool Housing 2 Plug 3 O RIng 4 Spool Cover 5 O Ring 6 O Ring 7 Spool 8 Spring 9 Spool Cover L8 8 Hoist Circuit Component Repair L08024 ...

Page 475: ...re valve in place with mounting hardware 2 2 Position hydraulic lines 3 over valve ports and assemble fittings Tighten hydraulic line connec tions securely 3 Place hoist control lever in spring centered posi tion Adjust pilot valve spool until the centerline of the 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 an...

Page 476: ...s 19 spring 4 and spacer 5 7 Remove relief valve 2 Figure 8 15 from the spool housing 1 8 Match mark the inlet and outlet housings in relationship to the spool housing to insure correct location during reassembly 9 Remove nuts 8 10 Figure 8 14 and remove tie rods 9 Separate the valve housings Re move O ring 11 Remove the poppet check and spring located on the outlet housing side of the spool housi...

Page 477: ...own in Figure 8 16 6 Install a new O ring 27 Figure 8 14 and wiper 26 Install seal retainer 25 7 Install spacer 5 spring seats 19 and spring 4 Thread detent pin 3 into spool 14 Slight pressure will be required to compress the detent spring Tighten detent pin to 84 96 in lbs 9 11 N m torque Install spring 20 Carefully install spool into spool housing 8 Apply grease to the cross holes of the detent ...

Page 478: ...o prevent it from falling or causing injury when re moving from the truck Use a suitable lifting device that can handle the load safely 4 At the upper mount remove self locking nut 4 Figure 8 18 from pin retaining capscrew Re move capscrew 5 Use a brass drift and ham mer to drive pin 1 from bore of mounting bracket 5 Carefully lower cylinder until it lays against the inside dual tire The hoist cyl...

Page 479: ...eye with the bore of the upper mounting bracket Refer to Figure 8 18 4 Align retaining capscrew hole in pin with hole in mounting bracket and install pin Install cap screw 5 and self locking nut 4 and tighten to standard torque 5 Install new O rings in grooves on hose flange connections and lubricate with clean hydraulic oil Position flanges over hoist cylinder ports and install flange clamps Secu...

Page 480: ...r 4 Housing 5 Plate 6 Rod Bearing Retainer 7 Capscrew 8 Seal 9 Snap Ring 10 Cover 11 Capscrews 12 O Ring 13 Bearing 14 Bearing 15 Seal 16 Seal 17 Bearing 18 Buffer Seal 19 Bearing 20 Rod Seal 21 Rod Wiper 22 Quill Assembly 23 Backup Ring 24 Bearing L8 14 Hoist Circuit Component Repair L08024 ...

Page 481: ...0o to position the lower mounting eye at the top Hook a lifting device to the eye on the rod 1 and lift the rod and third stage cylinder assembly out of the cylinder housing NOTE As internal parts are exposed during disassem bly protect machined surfaces from scratches or nicks 8 Rotate the cylinder housing 180o Remove the retainer installed in step 6 9 Fabricate a round disc 12 5 in 318 mm in dia...

Page 482: ...ng a tight ening torque of 1000 ft lbs 1356 N m b If the quill moves remove quill clean threads in cover assembly and quill and reinstall using the procedure in Quill Installation 5 When a cylinder assembly is dismantled the capscrews 7 Figure 8 20 should be checked carefully for distress and if in doubt replace them FIGURE 8 21 QUILL INSTALLATION 1 Cap Assembly 2 Quill Assembly NOTE SS1143 Tighte...

Page 483: ... Allow primer to dry 3 to 5 minutes 4 Apply Loctite Sealant 277 Komatsu part num ber VJ6863 or equivalent 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 time will require 24 hours i...

Page 484: ...ckness as shown in Figure 8 21 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 22 and quill assembly 2 Allow primer to dry 3 to 5 minutes 3 Apply Loctite Sealant 27...

Page 485: ...the second stage cylinder 2 Note the proper orientation of the rod seal 20 backup ring install with radi used corner toward seal and white dot away from seal 8 Attach a lifting device to the rod eye 1 and align it over the housing 4 Lower the rod into the housing Lubricate the rod with hydraulic oil 9 Rotate housing 180 to position the cover end at the top Remove retainer installed in Step 5 Insta...

Page 486: ...release it to place the hoist pilot valve in the HOLD position leave in this position during entire procedure 4 Start the engine on the good truck place the hoist control in the power down position and increase engine RPM to high idle to dump the disabled truck If the body of the disabled truck fails to raise increase the good truck power down relief pressure as follows a Shut down engine and allo...

Page 487: ... required if the restriction indicator lamp turns on Premature filter restriction may indicate a system com ponent 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 system Unless the fluid appears contami nated or has a strong foul o...

Page 488: ...ove and discard backup ring 7 and O ring 6 6 Clean bowl in solvent and dry thoroughly Installation 1 Install new element 9 Install new O ring 6 and backup ring 7 2 Install bowl on filter head and tighten Lock in place with setscrew 8 3 Install bottom plug 13 and bleed plug 11 INDICATOR SWITCH The indicator switch 5 Figure 9 1 is factory preset to actuate at 35 psid 240 kPa The switch and warning l...

Page 489: ...lacement may be required if the restriction indicator lamp turns on Premature filter restriction may indicate a system com ponent 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 system Unless the fluid appears contami nated or has ...

Page 490: ...hould be tested periodically for proper operation The indicator switch is not repairable and if inoperative replace switch assembly Figure 9 3 shows a pressure switch tester and Figure 9 4 shows a test block to accept the switch during testing The test block may be fabricated as shown Test Procedure 1 With the key switch Off allow at least 90 seconds for the accumulators to bleed down 2 Disconnect...

Page 491: ... Moore Heavy Duty Division Sealed Power Corp 29784 Little Mack Roseville MI 40866 9984 Phone 313 774 9500 FIGURE 9 3 INDICATOR SWITCH TESTER Kent Moore Part No J 33884 4 FIGURE 9 4 INDICATOR SWITCH PRESSURE TEST BLOCK L09008 Hydraulic System Filters L9 5 ...

Page 492: ...NOTES L9 6 Hydraulic System Filters L09008 ...

Page 493: ...the GF Cutout Switch in the CUTOUT position during test procedures See Figure 3 1 page E3 2 Propulsion System for GF switch location STEERING CIRCUIT CHECK OUT ADJUSTMENT PROCEDURE The steering circuit hydraulic pressure is supplied from the piston pump and steering accumulators Some steering system problems such as spongy or slow steering or abnormal operation of the Low Steering Pressure warning...

Page 494: ... level in tank and add oil if required Be certain suction line shut off valves are open 3 Remove plug and install an accurate 5000 psi 35 000 kPa pressure gauge at the steering pressure GPA test port 4 Figure 10 1 located on the suction side of the pump Install a second 5000 psi 35 000 kPa gauge in the bleeddown manifold test port TP2 3 Figure 10 2 4 Turn unloader valve adjustment screw 2 Figure 1...

Page 495: ...egins to increase pump cycles from unload to load once pressure has dropped to 2750 psi 18 960 kPa 16 Shut down engine and allow accumulators to bleed down completely Turn the steering wheel to verify no pressure remains 17 Remove gauges and cap test ports Steering Control Unit and Flow Amplifier Leakage Test 1 Disconnect the flow amplifier return hose 9 Figure 10 2 at the bleeddown manifold Plug ...

Page 496: ...old 6 After test is complete shut down the engine using the shutdown switch located on the console 7 Re attach vacuum source to hydraulic tank and draw a vacuum before disconnecting tank return hose from pilot valve return hose Attach tank return hose to bleeddown manifold Attach hoist pilot return hose to fitting on manifold 8 Remove vacuum source Remove test equip ment and reinstall all remainin...

Page 497: ...heet 7 Steer the truck to the opposite stop The other gauge should read 3100 psi 21 370 kPa Record on Data Sheet 8 If pressure is incorrect during step 6 or 7 the shock and suction valves must be replaced NOTE The shock and suction valves are only serviced as complete units and cannot be adjusted while in stalled in the flow amplifier valve 9 After the above test is complete lower the steer ing re...

Page 498: ...n test port marked TPD located on front face of manifold 3 Install a 0 3500 PSI 0 25 000 kPa gauge in each hoist pump filter pressure test port 4 Install a 0 100 psi 0 1000 kPa low pressure gauge at the upper left test port in the brake hoist return manifold 3 to monitor rear brake cooling supply pressure Brake Cooling Circuit Test 1 Start engine and run at low idle Place hoist control lever in th...

Page 499: ...tion if the front pump section pressure was incorrect 1 If power up relief pressure is incorrect in either the front or rear inlet section adjust pressure as follows a Lower body until it is resting on frame rails and shut down engine Wait at least 90 seconds until accumulators bleed down b Relieve all hydraulic pressure from hoist sys tem c Move hoist control lever to the power down position and ...

Page 500: ...ower down relief valve 2 Figure 10 6 1 To increase power down relief pressure turn adjusting screw in clockwise 2 To decrease power down relief pressure turn adjusting screw out counter clock wise 2 Recheck power down relief pressure step 3 after valve adjustment Install cap on relief valve 3 Shut down engine allow accumulators to bleed down Remove gauges hoses etc FIGURE 10 6 POWER DOWN RELIEF VA...

Page 501: ...asing engine speed in steps of 300 rpm while in third stage and observing pressure gauge 2 Continue monitoring pressure gauge until engine high idle is attained c If gauge indicates 3000 psi 20 7 MPa while at high idle in POWER UP and in third stage counterbalance valve adjustment is correct d If gauge does not indicate 3000 psi 20 7 MPa while in third stage and at high idle or a lesser rpm during...

Page 502: ...line shut off valves are open 7 Bleed trapped air inside steering pump Refer to Steering and Brake Pump Section L Flushing Procedure 1 Set all controls in the Neutral position Do not steer the truck or operate controls until the next step is completed 2 Start the engine and run at 1000 RPM for five minutes This will circulate oil with all valves in the neutral position 3 To increase flow and turbu...

Page 503: ...cycle if possible to exercise the braking functions a mini mum of 30 times Insure the braking is also exer cised in Reverse as would be seen in a typical haul cycle 13 If the truck is equipped with any hydraulically operated attachment the attachment must also be cycled in a similar manner following the checkout procedure or Operational Instructions for the device 14 Shut down engine and turn key ...

Page 504: ...NOTES L10 12 Hydraulic Check out Procedure L10012 ...

Page 505: ...NG CONTROL VALVE AND FLOW AMPLIFIER LEAKAGE TESTS STEP 4____________ Flow amplifier return hose leakage STEP 5____________ Steering control unit return hose leakage BLEEDDOWN MANIFOLD LEAKAGE TEST STEP 5____________ Bleeddown solenoid steering relief and piloted check valve leakage SHOCK AND SUCTION VALVES TEST STEP 6____________ Shock and suction valve pressure left steer STEP 7____________ Shock...

Page 506: ...ure low idle POWER UP DOWN position STEP 3 ____________ Brake cooling circuit pressure 1500 RPM HOLD FLOAT position STEP 4 ____________ Brake cooling circuit pressure 1500 RPM POWER UP DOWN position POWER UP RELIEF PRESSURE TEST STEP 2 ____________ Hoist relief pressure front pump section ____________ Hoist relief pressure rear pump section POWER DOWN RELIEF PRESSURE TEST STEP 3 ____________ Power...

Page 507: ... 1 Environmental Impact M9 1 Operator Cab Conditioning M9 2 Principles of Refrigeration M9 2 Major System Components M9 4 System Servicing M9 7 Evacuating the System M9 18 System Troubleshooting M9 19 24 VDC ELECTRIC SUPPLY SYSTEM NIEHOFF 240 amp ALTERNATOR M13002 M13 1 Electrical System Description M13 1 Battery Maintenance and Service M13 1 Battery Charging System Niehoff 240 amp Alternator M13 ...

Page 508: ...NOTES M1 2 Index M01034 03 01 ...

Page 509: ...ire Electric Detection and Actuation System are shown in Figure 2 3 1 Control Module Figure 2 3 2 Provides the electrical connections necessary be tween the power lead and the linear detection wire to the power lead supplying electrical power via the squib to the actuator Also provides a visual check of power availability pressing the switch button will illu minate the green indicator light if ele...

Page 510: ...f a battery con nector and conductor lead wires to connect the actua tion system to the truck electrical system battery circuit The battery connector is equipped with a 5 ampere in line fuse replaceable Test Kit Figure 2 3 6 Provides for checking of elec trical continuity and consists of an indicator light as sembly and an End of Linelinear detection wirejumper assembly Squib Figure 2 3 7 Is an el...

Page 511: ...the way Secure the wire to mounting surfaces decks struts hydraulic hoses in the area or any secure non moving part of the protected equipment Always keep the previously mentioned guidelines in mind when installing the wire Preliminary Test Before Final Hook Up All necesssary linear detection and power wire instal lation is now completed Before arming the actuator with the squib it is necessary to...

Page 512: ...eed to the end of the last length of detec tion wire and remove the jumper assembly Figure 2 3 12 Finally put original plugged blank connector onto detection wire The test module light should immediately go out If light does not go out refer to Troubleshooting d Remove the test kit from the system by first disconnecting the squib connector from the test module Figure 2 3 14 NOTE Retain these compo...

Page 513: ...stud of squib Figure 2 3 17 Handtighten as firmly as possible Placing the Electric Detection Actuation System Into Service To place the Electric Detection and Actuation System into service proceed as follows 1 Check all fasteners for tightness Insure jam nut on actuator body is securely tightened 2 Before installing actuator cartridge push manual puncture lever several times to insure smooth opera...

Page 514: ...due to abrasion at wall pene trations around corners etc b Check for damage from direct impact or other abuse c Check mounting locations for tightness d Insure mounting hardware has not come loose or been broken either of which would allow the wire to sag 4 Weigh the actuation cartridge on the Electric De tection and Actuation System Replace cartridge if the weight is 1 4 oz 7 g less than that sta...

Page 515: ...ghten firmly by hand IN CASE OF FIRE Procedure to follow during and after a fire In the event of a fire the following steps should be taken 1 Turn the machine Off 2 Manually activate fire suppression system if pos sible 3 Move away from the machine taking a hand port able extinguisher along if you can 4 Stand by with aportable fireextinguisher to put out any possible re ignition of the fire after ...

Page 516: ...he entire length s of detection wire involved in the fire area Before the system is put back into service it is impor tant that the inside chamber of the actuator be cleaned thoroughly Failure to do so may cause excessive carbon build up on the internal O ring and piston chamber This build up will also stop the puncture pin from returning to its upmost position To clean actuator See Figure 2 3 22 ...

Page 517: ...ection loose SUGGESTED CORRECTIVE ACTION Install jumper assembly Reconnect Loosen green lens install new bulb Look for possible short in external power wiring and change fuse Install new length Charge battery or install new one Clean and tighten TROUBLE Test Module Light Will Not Go Out POSSIBLE CAUSES Jumper assembly left in place on end of detection wire Damaged section at detection wire SUGGEST...

Page 518: ...NOTES M2 3 10 Ansul Checkfire Electric Detection and Actuation System M02003 ...

Page 519: ...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 520: ... 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 521: ...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 522: ...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 523: ...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 524: ...NOTES M5 4 Wiggins Quick Fill Fuel System M05002 10 96 ...

Page 525: ...UNC Misc lifting requirements WA4826 Eye Bolt 1 25 7 UNC PART NO DESCRIPTION USE EB1759 NItrogen Charging Kit Suspension Accumulator Nitrogen Charging PART NO DESCRIPTION USE EF4875 Roll Out Assembly Power Module Removal Installation M08012 9 99 Special Tools M8 1 ...

Page 526: ... Handle Use with PB8326 TZ2734 PART NO DESCRIPTION USE TZ2734 3 4 Female Adapter Torque Wrench Extension PART NO DESCRIPTION USE BF4117 Seal Installation Tool Front Rear Disc Brake FLoating Ring Seal Installation ED3447 Seal Installation Tool Rear Axle Hub Adaptor Floating Ring Seal Installation M8 2 Special Tools M08012 9 99 ...

Page 527: ...ie Rod Assembly Refer to Section G PART NO DESCRIPTION USE EF9160 Electrical Harness Payload Meter II Download Refer to Section M Payload Meter PART NO DESCRIPTION USE EF9302 Indicator Assembly Measure Brake Disc Wear Refer to Section J M08012 9 99 Special Tools M8 3 ...

Page 528: ...U Part Number F6 555 766 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 In...

Page 529: ...ons Figure 8 3 Note the bolt pattern marked X on pusher plate structure when removing the capscrews from the spindle b Capscrews may be seized in place To mini mize possible damage to threads in spindle remove the capscrews in a circular pattern using at least 2 steps of lower torque after the capscrews have started to move This is the opposite procedure as used during installation of the steering...

Page 530: ...que in a circular pattern until the tapered piston breaks loose or the specified 1580 ft lbs torque on the 1 25 capscrew is reached 6 If the specified torque is reached and the tapered piston is still not loose apply heat at 2 places 180 opposite to the spindle Do not exceed 850 F saturated temperature of the spindle 7 Tighten capscrews again to the maximum speci fied torque and using a large hamm...

Page 531: ... in Plate Outside Diameter O D DIMENSION G 12 37 in Pusher Cylinder O D DIMENSION C 19 25 in Bolt Circle Diameter B C DIMENSION H 9 00 in Pusher Cylinder I D DIMENSION D 2 00 in Plate Inside Diameter I D DIMENSION I 1 75 in Cylinder Wall Thickness DIMENSION E 1 37 in Plate Thickness NOTE Surface A A must be parallel to B B M08012 9 99 Special Tools M8 7 ...

Page 532: ...NOTES M8 8 Special Tools M08012 9 99 ...

Page 533: ...ore 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 FIGURE 9 1 BASIC AIR CONDITIONING SYSTEM TYPICAL 1 Blower Switch 2 Thermostatic Switch 3 Battery Supply 4 Circuit breaker 5 Blower 6 Temperature Sensor 7 Evaporator 8 Expansion Valve 9 Suction Line 10 Test gauges Mani...

Page 534: ...ling 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 downtimecosts arehigh enough to encour ageserviceareas to perform preventativemaintenance at regular intervals on vehicleair conditioning systems Cleaning checking belt tightness and ...

Page 535: ...igerant 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 discharge valve high side on to the condenser Ambient air passing through the condenser removes the heat from the circulating refrigerant resulting in the conversion of the refrigerant from gas to liquid The liq...

Page 536: ...or to a liquid The action is affected by the pressure of the refrigerant in the coil and air flow through the condenser Condensing pres sure in an A C system is the controlled pressure of the refrigerant which affects the temperature at which it condenses to liquid giving off large quantities of heat in theprocess Thecondensing point is sufficiently high to create a wide temperature differential b...

Page 537: ...change Therefore a blower becomes avital part oftheevaporator assembly It not only draws heat laden air into the evaporator but also forces this air over the evaporator fins and coils where the heat is surrendered to the refrigerant The blower forces the cooled air out of the evaporator into the cab Heat exchange as explained under condenser opera tion depends upon a temperature differential of th...

Page 538: ...An electromagnetic clutch is used in conjunction with the thermostat to disengage the compressor when it is not needed such as when a defrost cycle is indicated in the evaporator or when the system is turned off The stationary field clutch is the most desirable type sinceit has fewer parts to wear out Thefield ismounted to the compressor by mechanical means depending on the type field and compress...

Page 539: ...ng warnings must be observed when servicing AC systems Provide appropriate protection for your eyes gog gles or face shield when working around refriger ant A drop of the liquid refrigerant on your skin will produce frostbite Wear gloves and exercise ex treme care when handling refrigerant If even the slightest trace of refrigerant enters in your eye flood the eye immediatelywith cool water and se...

Page 540: ...pes 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 and has not been contaminated by a mixture of refrigerant types Re...

Page 541: ...ve The low sidefitting hasasmaller diameter than thehigh 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 completely evacuate all of the refrigerant air and moisture from the system by deliberately lowering the pressure with...

Page 542: ...ale 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 included in many of the commercially available recovery or recov ery recyc...

Page 543: ...he manifold for tightness 3 Locate the low and high side system service fittings 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 service valves at this time This gauge hook up process will be the same ...

Page 544: ...l not require a lengthy process Closing the valve will then insure the hose is purged It is now safe to open the other manifold valves Adding Refrigerant to the System without a charging station After determining that the system is low and requires additional refrigerant perform the following proce dures 1 Connect the center hose from the manifold gauge set to the refrigerant dispensing valve on t...

Page 545: ...ing to determine if the system is full Again using the pres sures that were mentioned above Do not open high side hand valve High side sys tem pressure is greater than refrigerant container Serious personal injury may result if the container explodes Use hand valve to regulate low side reading during charging DO NOT EXCEED 40 psi maximum Exceeding this pressure may cause compressor failure RECOVER...

Page 546: ...ioner compo nents are repaired or replacement parts are secured and the AC system is reassembled Evacuation re moves air and moisture from the system Then the AC system is ready for the charging process which adds new refrigerant to the system Evacuating the System 1 Attach the high and low side hoses to the appro priate connections 2 Start the vacuum pump and run it for five minutes 3 Check the g...

Page 547: ...develop in two or three places The first is around the compressor shaft seal often accompanied by an indication of fresh re frigerant oil If a system is not operated for a while winter months the shaft seal may dry out and leak slightly The centrifugal force of the clutch pulley spin ning can also cause the problem When the system is operated and lubricant wetstheseal theleak may stop Such leaks c...

Page 548: ...ons NOTE To help prevent air moisture or debris from entering an open system cap or plug open lines fittings or components and lubricant containers until connected and as soon as they are disconnected Keep all connections clean also caps and plugs used so debris can t enter accidentally Hoses and Fittings When replacing hoses be sure to use the same type and ID hose you removed When hoses or fitti...

Page 549: ...es you to bypass clutch circuit control devices Clutch pulley bearing failure is indicated by bearing noise when the AC system is off or the clutch is not engaged Premature bearing failure may be caused by poor alignment of the clutch and clutch drive pulley Sometimes it may be necessary to use shims or en large the slots in the compressor mounting bracket to achieve proper alignment Excessive clu...

Page 550: ...nch 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 Figure9 10 Then open thelow sidehand valves to maximum 2 Open the discharge valve on the vacuum pump or remove the dust cap from the discharge outlet Turn the pump on and watch the low side ga...

Page 551: ...r 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 Check the ducts and doors for proper function Refrigerant Charge Make sure system is prop erly charged with the correct amount of refriger ant PREL...

Page 552: ...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 Troubleshooting Chart lists typical mal functions encountered in air conditioning systems In dications and or problems may differ from one system to ...

Page 553: ... test TROUBLE Little or No Cooling Indications Low side pressure VERY LOW High side pressure VERY LOW Discharge Air Warm No bubbles observed in sight glass may show oil streaks Pressure sensing switch may have compressor clutch disengaged Refrigerant excessively low leak in system 1 Add Refrigerant make sure system has at least 50 of its normal amount and leak test system 2 It may be necessary to ...

Page 554: ...or oil level refill compressor oil as necessary 4 Evacuate system 5 Charge system with new recycled refrigerant 6 Check A C operation and do system performance test Air and or Moisture in the System Indications Gauge Reading Low Side Normal High Side Normal Air and or Moisture in the System Gauge Reading Low Side Normal High Side Normal Cause Air and or moisture in the system The air from the vent...

Page 555: ...e Repair Procedure Test Warm diaphragm and valve body with your hand or very carefully with a heat gun Activate system and watch to see if the low pressure gauge rises Next carefully spray a little nitrogen or any sub stance below 32 F on the capillary coil bulb or valve diaphragm The low side gauge needle should drop and read at a lower suction pres sure on the gauge This indicates the valve was ...

Page 556: ...s not stuck Clean the surfaces of the evaporator outlet and the capillary coil or bulb Make sure the coil or bulb is securely fastened to the evaporator outlet and covered with insula tion material Operate the system and check performance Repair Procedure If the test did not result in proper operation of the expansion valve the valve is defective and must be replaced Re cover all refrigerant from ...

Page 557: ... com ponents fan and drive belt fan clutch operation and the radiator shutter Cause The condenser is not functioning correctly or there may be an overcharge of refrigerant inside the system Another possibility is lack of air flow through the condenser fins during testing Engine cooling system component malfunction can cause high pres sure by blocking air flow radiator shutter or not pro viding air...

Page 558: ...oo high A new thermostat may have been in stalled incorrectly Cause The thermostat switch is not functioning properly or at all Repair Procedure Replace the thermostatic switch When removing the old thermostat re place it with one of the same type Take care in removing and handling the thermostat and thin capillary tube attached to it Do not kink or break the tube Position the new thermostat capil...

Page 559: ...from condenser should be hot to touch Replace if system is opened COMPONENT Maintenance Interval months 3 6 12 Done 4 EXPANSION VALVE Inspect capillary tube if used leakage dam age looseness 5 EVAPORATOR Clean dirt bugs leaves etc from fins w compressed air Check solder joints on inlet outlet tubes leak age Inspect condensate drain 6 OTHER Components Check discharge lines hot to touch Check suctio...

Page 560: ...NOTES M9 28 Air Conditioning System M09010 6 97 for HFC 134a Refrigerant ...

Page 561: ... or overcharging Normal water usage for a unit operating 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 No water consumption may indicate undercharging or sul phated plates Troubleshooting Two mo...

Page 562: ...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 pro nounced 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 thirt...

Page 563: ...rating TROUBLESHOOTING PROCEDURES On Truck Most 24 volt charging system problems can be diag nosed with the alternator installed on the truck oper ating under normal conditions Many problems can be attributed to loose or corroded cable connectors It is essential that all battery charging circuit cables are in satisfactory condition and all connections are clean and securely tightened Equipment Req...

Page 564: ...e working near the engine when running Use caution when work ing 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 en gine immediately and refer to Table II If batteries are sufficiently discharged amps should be high 220 amps 10 and voltage should be between 27 2 and 28 8 volts normal range...

Page 565: ...age 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 re placed FIGURE 13 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 Batteries FIGURE 13 3 REGULATOR BYPASS TEST 1...

Page 566: ...ocknut 35 Socket Head Screw 36 Fan Guard FIGURE 13 4 PARTS ILLUSTRATION 1 Locknut 2 Flat Washer 3 Drive Pulley 4 Pulley Bushing 5 Retainer Ring 6 Front Bearing 7 Capscrew Washer 8 Cover Plate 9 Control Unit Cover 10 Screw 11 Control Unit 12 Screw 13 Rotor 14 Shaft Core 15 B Bolt Assembly 16 Retainer Ring 17 Nut 18 Front Stator M13 6 24VDC Electric Supply System M13002 2 99 with 220 Amp Niehoff Alt...

Page 567: ...oint Defective regulator Defective alternator NO VOLTAGE OUTPUT Causes of no voltage output No drive belt No battery B voltage at alternator s B termi nal except isolator type systems No link from R terminal to energize E ter minal on alternator when engine operating Defective regulator Defective alternator TOOLS AND EQUIPMENT 1 Voltmeter Digital type preferred 1 Ammeter Digital Inductive type pre...

Page 568: ...re more than a few de grees Group 31 batteries may accept rates up to 5 amps over several hours with minimal tempera ture 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 tempera ture over a long period of time 4 8 hrs and may lead to an overcharge condition if temp...

Page 569: ...n alternator DAMAGE WILL OCCUR IF UNIT IS OPERATED WITH STRAP CONNECTED AND B APPLIED Hold a steel wrench or screwdriver near alternator drive pulley wrench or screwdriver held near drive pulley will be attracted to pulley by magnet ism If there is no magnetic attraction alternator may not be turned on Go to Regulator Test that follows and continue test If there is magnetic attraction alternator i...

Page 570: ...rminal shut engine down and inspect link from R terminal to E Run engine and re test charging circuit GO TO REGULATOR IF REQUIRED Disconnect voltage regulator from alternator There are no static tests available for the regulator Continue test GO TO REGULA TOR CONNECTO R ON ALTERNATOR Connect a jumper wire from ground on alternator into F pin of connector attached to alternator Hold a steel wrench ...

Page 571: ... M3 2 SPECIFICATIONS M3 3 SERVICE PARTS LIST M3 4 EXPLODED VIEW M3 5 ON VEHICLE TEST M3 6 BENCH TEST M3 8 STATIC TESTS M3 9 ALTERNATOR DISASSEMBLY M3 12 ALTERNATOR ASSEMBLY M3 17 SERVICE TOOL INSTRUCTIONS M3 26 M13003 04 01 Niehoff Alternator Overhaul Manual M13 1 ...

Page 572: ...nergize Terminal Nut 60 70 in lbs 6 8 7 9 Nm Regulator Hold Down Screw for taptite screws 32 in lbs 45 in lbs 3 6 Nm 5 Nm Fan Nut 50 ft lbs 67 8 Nm Field Coil Screw 8 10 in lbs 9 1 1 Nm ALTERNATOR DIMENSIONS 1 Mounting Bolt 1 2 UNC 45 ft lbs 61 N m torque 5 Voltage Regulator 2 Mounting Bolt 12 50 Dia 65 ft lbs 88 N m torque 6 Fan Nut 50 ft lbs 68 N m torque 3 Ground Bolt 3 8 16 11 ft lbs 15 N m to...

Page 573: ...urve 2 A link between E and R terminal must be used in order to provide self energizing If residual magnetism is lost self energizing will not occur until magnetism is reestablished This is done by disconnecting the link and applying 24V momen tarily to the E terminal while the alternator is operating After disconnecting the 24V signal from E terminal connect the link between the R and E terminal ...

Page 574: ...0 c BF3713 2 RING RETAINING 21 0 BF1992 2 LOCKWASHER 1 22 0 BF1991 2 CAPSCREW 3 8 16NC X 5 8 1 23 0 BF3719 12 CAPSCREW 10 32NF X 1 2 1 24 0 BF3721 9 NUT 8 32NC 1 25 0 BF1976 1 SHELL STATOR FIELD ASSEMBLY 25 a BF1977 1 STATOR FRONT 25 b BF1980 9 STUD 25 c 1 SHELL 2 25 d BF1981 1 BUSHING TENSION 25 e BF1978 1 COIL 25 f BF1979 1 STATOR REAR 26 0 BF3722 18 SCREW PAN HEAD 6 32NF X 3 8 1 27 0 BF3723 9 N...

Page 575: ...ALTERNATOR PARTS Refer to previous page for Parts List M13003 04 01 Niehoff Alternator Overhaul Manual M13 5 ...

Page 576: ...tage at the E terminal with engine running Test Set up 5 Discharge Battery as Follows a Disable fuel system b Turn all lights and accessories ON Crank the engine for 10 15 seconds to discharge bat tery then stop cranking engine c Turn all lights and accessories off d Enable fuel system 6 Determine setpoints of regulator The setpoint of the alternator is 28V Normal range is within 0 2V of setpoint ...

Page 577: ...ir alternator Go to Static Tests LOW NORMAL Charging system is OK LOW HIGH Stop test If battery and voltmeter check OK regulator and or field coil must be replaced Table 13 2 VOLTAGE REGULATOR SYSTEM VOLTAGE FACTORY SETTING NORMAL RANGE 24 27 5 27 2 27 8 28 0 27 7 28 3 ON VEHICLE TEST Bypass Test Disconnect plug between alternator and regulator and momentarily touch F terminal from alternator plug...

Page 578: ...or OK Go to Test 2 LOW HIGH Stop test Bench malfunction or wiring error TEST 2 FULL LOAD TEST With load set to rated output nameplate 10 run alternator at 5000 rpm Refer to Table 13 4 Table 13 4 FULL LOAD TEST AMPS VOLTS DIAGNOSIS HIGH LOW Test bench battery is discharged or defective Allow to charge or replace HIGH NORMAL Charging system OK HIGH HIGH Stop test Regulator and or field coil should b...

Page 579: ... lead to terminal F connect to other lead to terminal B and observe meter reading Reverse leads and observe meter reading In one direction the meter should read less than 600 ohms In the other direction the ohmmeter should read very high If ohmmeter reads zero in both directions output transistor is shorted and regulator must be replaced TEST 2 Check Function Of Clamping Diode Set ohmmeter to x100...

Page 580: ...rip Connections Set ohmmeter scale according to Table 13 6 and make ohmmeter connections between the terminal strip in side the control box and control box terminals located on the outside of the control box Table 13 6 CONTROL BOX CONTINUITY CHECKS OHMETER SCALE TERMINAL STRIP CONNECTION Figure 13 4 CONTROL BOX EXTERNAL CONNECTION Figure 13 5 READING x10K F GND B VERY HIGH x1 F F PIN ZERO x1 F F T...

Page 581: ...ween B terminal and each of the six heat sink phase terminals S All six readings should be very high If any reading is not alike the diode rectifier assembly is defective and the front housing assembly must be replaced STATOR TESTS NOTE The front stator related Phase leads are P1 P2 P3 The rear ststor phase leads are P4 P5 P6 The Alternator has two separate assemblies that will be checked individu...

Page 582: ...h brass or aluminum Figure 13 7 3 Remove nut and hardened washer 4 Remove fan assembly from alternator PULLEY REMOVAL 1 Use a 15 16 socket wrench on the pulley nut Clamp the pulley in a vise jaws padded with brass or aluminum and loosed pulley nut Figure 13 8 2 Remove pulley nut and hardened washer 3 With a gear puller remove the pulley from the shaft 4 Remove woodruff key from shaft 5 Remove pull...

Page 583: ... below Alternate Method 2b Using an air hammer air chisel with a blunt tipped tool vibrate the area around the rotor element to rotor core attaching studs The vibra tions should loosen any built up rust in that area Remove the rotor element If resistance is still felt use the method described in 2a plus the air hammer REAR BEARING REMOVAL There are two types of rear bearing systems in use 1 For pr...

Page 584: ...re 13 13 C 7 Remove the six phase leads from the diode studs and push the phase leads back through the large openings in front housing this will facilitate sepa ration of front housing from tube 8 Remove nine flanged locknuts from stator tube assembly studs at front of front housing Note The Front housing is attached to the rotor shaft core assembly 9 Separate front housing with the rotor shaft co...

Page 585: ... plate Be careful not to move or reroute the phase lead 5 Disconnect the field leads from F terminal and B terminal of the terminal block 6 Disconnect the regulator harness ground wire from the end housing lead 2 7 Remove the terminal block from the housing NOTE Two nuts are used as spacers underneath the terminal block on attaching screws 8 Desolder B lead from the terminal block Take care to pos...

Page 586: ...otor element to rotor core attaching studs The vibra tions should loosen the built up rust in that area Remove the rotor element If resistance is still felt use the method described in 2a above plus the air hammer FIELD COIL REMOVAL Do not attempt to repair field coil Replace the whole assembly 1 Mark the position of field coil leads white wires with spade terminals on stator New fields will be po...

Page 587: ...re told otherwise For stator installation see BF4822 Stator Service Tool Instructions ALTERNATOR ASSEMBLY FIELD COIL ASSEMBLY 1 Lay stator and shell assembly on its side phase leads to the left Figure 13 20 2 Insert field coil from right hand side of stator and shell assembly field leads white wires with spade terminals facing toward phase leads 3 As field coil is inserted into stator and shell as...

Page 588: ...s to 8 10 lb in 0 9 1 1 Nm torque Note If field coil leads cannot be threaded through stator openings with the terminal attached unsolder terminals remove sleeving and then insert leads After field coil is in place slip sleeving on field leads resolder terminals to wires and slip sleeving back over terminal FRONT BEARING ASSEMBLY 1 Clean bearing I D surface of front housing 2 Install retaining rin...

Page 589: ...b in 7 3 Nm Note Center studs or holes of core in the center of slot in rotor plate FRONT HOUSING ROTOR SHAFT CORE ASSEMBLY Note When replacing shaft and core assembly using ring seal refer to Figure 13 35 before proceeding with assembly 1 Support rotor shaft and core assembly on blocks with the rear bearing end down 2 Position bearing in front housing assembly onto shaft drive side of housing fac...

Page 590: ...ld leads white wires through the hole in the front housing to the control box Con nect the field leads to the control box terminal strip one lead to the B terminal the other lead to the F terminal Figure 13 28 Figure 13 4 Note Do not allow sleeving on leads to slide down leads phase terminal without sleeves can short to front housing 6 Using 6 nuts coat with Loctite attach the six phase leads blac...

Page 591: ...ep the regulator connector flat with A pin properly positioned NOTE Wires in steps 7 8 should slant away from both E R terminals down and left as viewed from outside 7 Position the insulating sleeving over wire termi nals prior to attaching ring terminals to E R or phase terminals studs NOTE Assembly sequence for E R terminal or phase terminals is insulator flat washer terminal nut FIGURE 13 29 1 ...

Page 592: ...nd shell assembly Figure 13 32 NOTE Align stud or screw holes of core with scribe marks on rotor or center studs or screw holes of core in the center of slots in rotor plate as shown in Figure 13 32 2 Use six flanged locknuts or self tapping screws to fasten rotor assembly to shaft and core assembly Apply loctite to studs before installing locknuts Torque flanged locknuts to 45 in lbs 5 0 Nm screw...

Page 593: ...ent Remove old shaft core assembly Remove the shaft core assembly from alternator as directed in this publication Remove the front seal from the old end housing Install New Shaft core Assembly Figure 13 35 Remove the ring seal from the new shaft core assembly if present Install the shaft core assem bly into the alternator as directed in this manual END HOUSING ASSEMBLY CONTINUED 3 Apply Loctite to...

Page 594: ... this point can damage housing LOOSE FIT REAR BEARINGS Before starting installation of loose fit rear bearings check that O ring is greased grease with Amoco Rykon or equivalent and properly installed in O ring groove in housing bore Continue with bearing instal lation as above 3 Turn shaft by hand to make sure it spins freely Fan and fan hardware can now be installed REGULATOR ASSEMBLY 1 Set regu...

Page 595: ... to 50 in lbs 68 N m Note Brass or aluminum jaw protectors must be in serted into vise jaws to prevent damage to pullley PULLEY ASSEMBLY NOTE Do not hold fan to prevent shaft rotation Fan damage may result 1 Install pulley bushing on shaft 2 Press Woodruff Key into shaft 3 Position pulley on shaft 4 Install pulley nut and hardened washer on shaft Place alternator and pulley into vise With a 15 16 ...

Page 596: ... thrust plate so that the guide pin does not re enter the slot Lower the top thrust plate and allow it to rest on top of the guide pin 9 Lubricate approximately 1 of the jack screw where it enters the pressure plate with white lube or a wheel bearing type of grease Also place a dab of this grease on both sides of the thrust washer that is placed under the hex head of the jack screw 10 Position the...

Page 597: ... hole that will allow the locating pin to pass through both the locating rod and shell drain hole 3 Place new stator on the stator indexing pins on the bottom thrust plate NOTE Proper placement of the stator is achieved when the single stator lead aligns with a stator slot next to the other stator s single lead The finished shell assembly will have a slot arrangement of two leads space two leads s...

Page 598: ...f the top thrust plate Record this measurement as starting pont to be used later 10 Check the position of stator leads by looking through the large torque arm holes in the top thrust plate Turn jack screw until significant re sistance is encountered NOTE If the tool assembly starts to rotate insert torque arm into holes in the top thrust plate for addi tional leverage 11 Check the distance the sta...

Page 599: ...ycles M20 11 Other Data M20 11 OPERATOR FUNCTIONS M20 12 Using the Operator Load Counter M20 12 Description M20 12 Viewing the Operator Load Counter M20 12 Clearing the Operator Load Counter M20 12 Dimming the Lights on the Display M20 12 INITIAL SETUP OF PAYLOAD METER M20 13 Switch Settings M20 13 Checking the Operator Check Mode M20 13 Checking the Service Check Mode M20 14 Setting UP 00 M20 14 ...

Page 600: ...CEDURE M20 25 Replacing the Battery M20 25 After Replacing the Battery M20 26 SUSPENSION PRESSURE SENSOR M20 26 Removal M20 26 Installation M20 27 INCLINOMETER M20 27 Removal M20 27 Installation M20 27 SCOREBOARD M20 28 Description M20 28 Making Connections M20 28 Wiring Diagram M20 29 Normal Operation of the Scoreboard M20 30 PAYLOAD METER BACK PANEL M20 30 Connections AMP Pin Identification M20 ...

Page 601: ...ious operating data This data includes 1 The payload time distance and travel speed for each cycle 2 The date and time that the engine was started and stopped 3 The date and time of each fault that occurred or was canceled 4 The total payload and the overall number of cycles for a specific time period This data is retained even when the power is switched off The stored data is backed up by an inte...

Page 602: ...loading Clearing data Display of Abnormalities or Warnings Setting the speed limit Setting the date and time 6 Calibration Clear Switch Used to calibrate the machine when the condi tions regulate this action Also used with the TOTAL SFT switch to clear total payload and overall number of cycles 7 Total Shift Switch Used to display payload and overall number of cycles each time the load is dumped W...

Page 603: ...ght relays The relays operate three deck mounted lights on each side of the truck There is one green light one amber light and one red light Figure 20 3 While the truck is stopped being loaded and the hoist lever is in the float position the appropriate lights will remain on according to the following schedule The shovel or loader operator can predict the payload weight by observing these lights D...

Page 604: ...up or nose down Linkage Factor The linkage factor is part of the complex calculations performed by the payload meter to determine the load in the truck The linkage factor is dependent on the load on the rear suspensions Figure 20 3 shows the side view of a truck The nose pin is marked with a star and there are three arrows pointing to different spots of the rear tire This figure shows how the supp...

Page 605: ...pi cally weigh light and under report the load Typical Data From Service Check Mode A sample data set is shown in Figure 20 4 This data was taken in the laboratory and is used in Figure 20 5 to calculate the final load Note that the front suspen sion pressures were converted into the front sprung weight using the formulas above Figure 20 5 The front sprung weight is then multiplied by the front in...

Page 606: ...ulation procedure 1 Press and hold the LIGHT INC and MODE switches until CHEC is flash ing on the display 2 Press and hold the CAL CLR switch until CALL0 is flashing on the display 3 Press the CAL CLR switch to cycle through the following data The sequence repeats 4 Press MODE once and CHEC will flash on the display 5 Press MODE once and the meter will return to normal operation Front Weight 6 106...

Page 607: ...load is dumped Time Minute Minute 1 59 Payload Metric tons Short tons 0 6553 5 Travel Time When Empty Minute 0 6553 5 Travel Distance When Empty Miles Km 0 25 5 Maximum Travel Speed When Empty Mph Kmh 0 99 Average Travel Speed When Empty Mph Kmh 0 99 Time Stopped When Empty Minute 0 6553 5 Time Stopped During Loading Minute 0 6553 5 Travel Time When Loaded Minute 0 6553 5 Travel Distance When Load...

Page 608: ...ad Metric tons Short tons 0 999900 0 Total payload from the time when the engine was started until the time the engine was shut off Total Number Of Cycles Number 0 9999 Totals for the time that the engine was running The engine operation numbers are included in the fault and warning data ITEM UNIT RANGE REMARKS Error Code Displayed by a combination of letters and numbers representing a specific er...

Page 609: ...occurred or was canceled depends on the operation that was performed when the key switch was in the ON position and the engine was not running CONTENT ITEM UNIT RANGE REMARKS Set Up Data That The Operator Can Check Speed Limit Km MPH 0 99 Option Code Digital Number 0 13 Communication Mode Calibration Data Year Year 0 99 Date and time when calibrated Month Month 1 12 Day Day 1 31 Hour Hour 24 Hour ...

Page 610: ...ons hauled since the last time the counter was cleared The total is displayed in hundreds of tons 5 Press the TOTAL SFT switch again The number displayed is the number of haul cycles since the last time the cycle counter was cleared 6 Press the TOTAL SFT switch again is dis played for 2 seconds before the display returns to normal operations Clearing the Operator Load Counter 1 Press the TOTAL SFT...

Page 611: ...lled Set switch 4 for the appropriate model Checking the Operator Check Mode The Operator Check Mode is used to check and change several settings These should be checked before the payload meter is put into service 1 Press and hold the MODE switch The display will show 2 Press the MODE switch once The display will show Refer to Data All Clear on Page 17 to clear the haul cycle data 3 Press the MOD...

Page 612: ...ODE switches The display will show 2 Press and hold the LIGHT INC and TOTAL SFT switches The display will show 3 Press the CAL CLR switch once The display will show 4 Press the CAL CLR switch once The display will show 5 Press the LIGHT INC switch until PL 00 is displayed ONLY PL 00 IS RECOMMENDED 6 Press the MODE switch The display will show 7 Press MODE and the meter will return to normal operat...

Page 613: ...the engine running and the truck stopped press and hold the CAL CLR switch until CAL is flashing on the display 2 Drive the truck until the speed is approximately 6 10 MPH 10 15 Km H 3 Press the CAL CLR switch once 4 Drive until the display switches back to the time of day This will take up to 30 seconds 5 The payload meter is now calibrated and ready for normal operation Carry out this operation ...

Page 614: ...er Is Used 5 The display will show This display indicates method of measurement where US indicates METRIC Tons US oo indicates U S Tons 6 The display will show This function is not used SU indicates Switch 8 is up SU oo indicates Switch 8 is down 7 The display will show This display indicates the Machine ID code where xxx indicates a value between 0 and 200 8 The display will show This display ind...

Page 615: ...red number 6 Press the TOTAL SFT switch and the display will then indicate 7 Press the LIGHT INC switch to change the tens digit to the desired number 8 Press the MODE switch to return to normal opera tion 9 The Option Code selects the PLM communication mode as follows Option Code COMMUNICATION MODE 0 Stand Alone 10 PMC Mode 530M only 12 Modular Mining Mode Scoreboard and User Data Commmunication ...

Page 616: ...ch and the display will then indicate 9 Press the LIGHT INC switch to change the day 10 Press the TOTAL SFT switch and the display will then indicate 11 Press the LIGHT INC switch to change the month 12 Press the TOTAL SFT switch and the display will then indicate 13 Press the LIGHT INC switch to change the year 14 Press the MODE switch to return to normal opera tion DOWNLOAD OF INFORMATION Payloa...

Page 617: ...N C1 Shift selector is not in N Electric trucks C1 oo Brake lock is on C1 Brake lock is off Condition of the Body Up Switch signal The panel will display C2 XX for 3 seconds then indicate C2 oo Body up switch is in up position C2 Body up switch is in down position Condition of the Engine Oil Pressure signal The panel will display C3 XX for 3 seconds then indicate C3 oo Engine is running C3 Engine ...

Page 618: ...M20 20 Payload Meter II M20007 10 00 ...

Page 619: ...M20007 10 00 Payload Meter II M20 21 ...

Page 620: ...il Pressure C3 oo Engine Run C3 Engine Stopped C4 Alternator R Terminal C4 oo Alternator Charging C4 Alternator Stopped C5 Analog 1 Not Used C6 Analog 2 Not Used C7 Digital 1 Not Used C8 Digital 2 Not Used C9 Speed Vehicle Speed C10 Travel Distance under the current loaded or empty state xx xx Miles C11 Current Status Note Sample values are shown 03 01 Empty Stopped 01 02 Empty Traveling 06 03 Loa...

Page 621: ...and PL 10 These modes divide the data trans mitted by Modular Mining and the data stored in the payload meter s memory Additionally each mode handles the UP factor differently and can calculate different loads for the same haul cycle For these reasons it is recommended that the payload meter be set to use PL 00 in all cases PL 00 Modular Mining Transmission The data is captured at the last transit...

Page 622: ...y until A XX is displayed where XX is one of the following XX Gear Ratio Remarks 00 31 875 Original 01 36 400 High Traction 02 28 125 Standard 03 26 625 High Speed NOTE The Payload Meter is originally set to 00 4 Press the TOTAL SFT switch and XX will flash 5 Press theLIGHT INC switch to select the desired gear ratio 6 Press the MODE switch and CHEC will be displayed 7 Press the MODE switch and th...

Page 623: ...r carry out the memory card dump operation 2 Turn the keyswitch to the OFF position 3 Remove the four mounting screws holding the payload meter in position and then pull the pay load meter out away from the instrument panel Figure 20 7 NOTICE Be careful not to let dirt metal or spare parts to drop inside the controller at any time 4 Remove the electrical connector Remove the screws on the top surf...

Page 624: ...red Except for the calibration data all the data recorded in the previous steps is also erased 10 After this procedure has been performed the system is ready for normal function SUSPENSION PRESSURE SENSOR The pressure sensors are mounted on top of each suspension The sensors produce a voltage signal from 1 5 volts output The pressure sensor is mounted to the suspension cylinder using a Schrader Va...

Page 625: ... wire lead from harness 2 Remove the three capscrews nuts and lockwash ers 4 Figure 20 13 and inclinometer 3 Installation 1 Install inclinometer 3 Figure 20 13 with cap screws nuts and lockwashers 4 2 Connect inclinometer wiring to the truck wiring harness Figure 20 14 Be sure that wires are connected correctly Adjustment 1 Park the truck on a 0 grade 2 Loosen the three Inclinometer mounting cap s...

Page 626: ...communications between the Payload Meter and Modular Mining The Modular Mining system acknow ledges each message from the meter Sharing this RS232 port with the Personal Computer for downloading can also create problems with com munications The Payload Meter can confuse mes sages from the PersonalComputer and Scoreboard To eliminate this problem the Scoreboard must be turned off during downloading...

Page 627: ...M20007 10 00 Payload Meter II M20 29 ...

Page 628: ...ed by the Payload Meter waiting for the oscillations in the suspensions to settle out before calculating a current load The Scoreboard will display the current load calculated by the Payload Meter after each swingload If the truck operator releases the brake lock and begins to drive before the last swingload calculation is made the Scoreboard will never display the last swingload The Scoreboard wi...

Page 629: ...1 5VDC Normal 8 Inclinometer 9 Body Rise Signal Body Down Open Body Up Gnd 10 Break Lock Signal Neutral Signal Lock Off Open Lock On Gnd 11 12 CN4 AMP 040 8 Pins Black Optional Input Reserved No Description 1 Optional Input GND 2 Analog Input 1 3 Analog Input 2 4 Digital Input 1 5 Digital Input 2 6 7 CN1 AMP MIC MKII 13 Pins White Connector No Description Comments 1 Power 24V Battery 2 Lamp Relay ...

Page 630: ... 39G 24 volt PLM power 39AA Load light green 39BA Load light amber 39CA Load light red 73FSL TCI 100 load signal 930E only 73MSL TCI 70 load signal 930E only 714A Speed signal 714AT Speed signal 63L Body up gnd up open down 39H Brake lock gnd release open lock 35L1 PLM RS232 RTS request to send 35L2 PLM RS232 signal ground 35L3 PLM RS232 receive 35L4 PLM RS232 transmit 35L5 PLM RS232 CTS clear to ...

Page 631: ...memory and reset to its factory settings This includes and OP UP PL P SEL and E SEL settings The meter will restart and display F CAL 6 Start the engine 7 Set the time date OP PL and UP settings All other user settings should updated at this time 8 Calibrate the Payload Meter by holding the CAL button until CAL flashes 9 Release the Brake Lock Park Brake for 330M and begin driving 5 8 MPH on level...

Page 632: ...ES PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM L G HAGENBUCH holder of U S Patent Numbers 4 831 539 and 4 839 835 M20 34 Payload Meter II M20007 10 00 ...

Page 633: ...AT N4 1 Adjustment N4 1 Removal N4 1 Installation N4 1 HEATER AIR CONDITIONER N4 2 Operation N4 2 HEATER COMPONENTS N4 3 Circuit Breakers N4 3 Heater Control Components N4 3 Heater Coil N4 3 Fan Motor and Speed Control N4 4 Actuators N4 4 Filter N4 4 OPERATOR CAB CONTROLS N5 STEERING COLUMN N5 1 Removal N5 1 Installation N5 1 STEERING WHEEL AND CONTROLS N5 3 DYNAMIC RETARDING N5 3 CENTER CONSOLE N...

Page 634: ...NOTES N1 2 Index N01020 03 01 ...

Page 635: ...ponents 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 FIGURE 2 1 CAB ASSEMBLY 1 M...

Page 636: ...tor switch in NEUTRAL and apply the parking brake Be certain the parking brake applied indi cator lamp in the overhead panel is illuminated 2 Place the drive system in the REST mode by turning the Rest switch on the instrument panel ON Be certain the REST warning lamp is illumi nated 3 Shut down the engine using the keyswitch If for some reason the engine does not shut down use the shutdown switch...

Page 637: ...itioning system 7 Evacuate air conditioning system a Attach a recycle recovery station at the air conditioning compressor service valves Re fer to Heater Air Conditioning System in Sec tion M for detailed instructions b Evacuate air conditioning system refrigerant c Remove the air conditioner system hoses which are routed to the bottom of the cab from the receiver drier and compressor Cap hoses an...

Page 638: ...harging with refrigerant 8 Close brake accumulator bleed down valves 9 Close battery disconnect switch 10 Service hydraulic tank and engine coolant as required 11 Start the engine and verify proper operation of all controls 12 Complete air conditioning system recharging pro cedures CAB DOOR The cab door assemblies are similar except for the hinge side Each is hinged on the rear edge with a heavy d...

Page 639: ... If the paper is loose all around REPEAT STEP 2 If the paper is firmly gripped but can be removed with out tearing it open door and tighten the jam bolt completely without affecting the adjustment 5 If the paper slips out from the door seal easily along the top and not at the bottom the door itself will have to be adjusted Or if the paper slips out easier at the bottom than at the top the door wil...

Page 640: ... seal will ensure good contact on the inside seal to prevent dust and moisture from entering the cab Door Handle Plunger Adjustment If the door handle becomes inoperative it can either be adjusted or replaced The following is a procedure for adjusting the exterior door handle plunger 1 Determine the amount of free play in the door release plunger by pushing in on the plunger until it just contacts...

Page 641: ...awls again d Press the outside door button to see if pawls open e If mechanism operates properly go on to STEP 6 If mechanism does not work properly re place with a new door latch assembly then continue with STEP 6 6 Remove the mounting screws 3 from the outside door handle With the door handle removed ad just the plunger counter clock wise to increase the height of the door handle release button ...

Page 642: ...engage the window regulator roller from the track on the bottom of the glass Then slide the panel away from the cab to disengage the other top roller and the lower roller from their tracks Place the panel out of the way after removal 7 Remove 2 screws Figure 2 8 holding the roller track to the bottom of the door glass 8 Support glass in door frame as shown 1 Figure 2 9 Remove screws 2 that hold th...

Page 643: ... clear the door frame if still on glass 10 Move window glass and frame to an area where the glass can be removed Slide the glass down and out of the window channels 11 Before installing new window glass first inspect the window frame In each corner there is an L shaped bracket with 2 screws in it to hold the corners of the frame together Check the screws 1 Figure 2 13 to be sure they are tight Als...

Page 644: ...r felt insert is back in place after installing the screws 18 Reinstall window regulator track bracket as seen in Figure 2 7 Be sure nylon bushings and gaskets are installed properly to prevent damage to the glass 19 Lift window glass in frame and install window regulator roller track to bracket installed in step 18 See Figure 2 8 20 Holding window glass as seen in Figure 2 9 a few inches from the...

Page 645: ... Mount window regulator to the inner panel with the 4 mounting screws removed in step 2 Be sure screws are tight 5 Refer to door glass replace procedure and follow steps 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 assem bly The oute...

Page 646: ...ound 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 perimeter 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 the edge of the opening Go all th...

Page 647: ...fe or a piano wire type cutting device carefully remove all of the remaining glued on glass 3 Carefully clean and remove all broken glass chips from any remaining window adhesive The surface should be smooth and even NOTE Removal of all old ahesive is not required just enough to provide an even bedding base 4 Apply 4 to 6 SM2897 glass installation bumpers 8 equally spaced around the previously mar...

Page 648: ...center of the cab opening and press the weatherstrip over the edge of the opening 3 4 Figure 2 18 b Continue installing weatherstrip while going all the around the opening When the ends of the weatherstrip meet at the starting lower center of the cab opening there must be 0 5 in of overlapping material NOTE The ends of the weatherstrip material need to be square cut to assure a proper fit c Lift b...

Page 649: ...rews and washers Tighten mounting screws to 16 ft lbs 22 N m torque 3 Align linkage with motor output shaft arm and push onto retainer Rotate retainer clockwise until locked in place 4 Reconnect motor to cab harness connector 5 Verify proper operation of wipers Wiper Arm and Shaft Replacement Removal 1 Lift wiper arm cover 1 Figure 3 2 and remove arm retaining nut 2 and spring washer 3 2 Remove ho...

Page 650: ...the hydraulic components cabinet behind the cab has a 3 8 liter 1 gal plastic reservoir 1 Figure 3 3 with a 24 volt electric pump 2 The washer is controlled by the windshield wiper switch mounted on the instrument panel and is acti vated by pressing the knob 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 ...

Page 651: ... the same enclosure The same blowers used for heating move air across the evaporator to provide cooled air through the outlet vents All heater and air conditioner controls are mounted on a pod on the face of the enclosure HEATER COMPONENTS NOTE Figures 3 4 and 3 5 illustrate both the heater system and air conditioning system parts contained in the cab mounted enclosure Refer to Section M for addit...

Page 652: ... linear actuators 22 Figure 3 5 are installed inside the heater housing and are used to actuate the flappers for the following Defroster outlet Bi level or floor outlets Inside or outside air selection A failure to switch one of the above modes of operation may be caused by a faulty actuator Test Visually inspect the flapper 8 26 or 31 and linkage for the function being diagnosed Make certain the ...

Page 653: ...itch 19 Selection Control 20 Thermostat 21 Hose 22 Actuator 23 Flapper Bracket 24 Junction Block 25 Relay 26 Bi level Flapper 27 Flapper Bracket 28 Circuit Breaker 29 Resistor 12 Volt 30 Resistor 24 volt 31 Defroster Flapper 32 Grommet 33 Electrical Box Cover 34 Blower Mount 35 Blower Assembly 36 Blower Housing 37 Blower Wheel 38 Venturi 39 Blower Motor 40 Motor Mount 41 Cover Plate 42 Wiring Harn...

Page 654: ...NOTES N3 6 Cab Components N03011 7 98 ...

Page 655: ...r pillow Switch 7 controls the lower air pillow and switch 8 controls the upper air pillow To inflate press on top of rocker switch and hold for desired support then release To deflate press on bottom of rocker switch and hold for desired support then release Adjust each pillow for desired support Removal 1 Remove capscrews 11 Figure 4 1 and hardware that secures the seat base to the riser Remove ...

Page 656: ...he enclosure Refer to Figure 4 2 for the following Defroster Switch 1 This is a 2 position toggle switch down is OFF Up provides air flow through the defroster vents Outside Inside Air Control Switch 2 This is a 2 position toggle switch down recirculates cab air Up allows outside air to flow through heater or air conditioner coils Heat Vent Control Switch 3 This is a 2 position toggle switch down ...

Page 657: ...6 Figure 4 2 is rotated throughout the red area If the motor fails to operate the heater control module may be defective A mechanical defect in the water control valve 3 Figure 4 3 may allow heated water to pass through the hose between the valve and the heater core when in the off position Verify the motor in the valve operates properly throughout its range from full off to full on If the hose is...

Page 658: ...to switch one of the above modes of operation may be due to a faulty actuator Test Visually inspect the flapper and linkage for the function being diagnosed Make certain the flapper is not bind ing or obstructed preventing movement from one mode to the other Verify voltageis present at theactuator when thetoggle switch is closed or absent when the toggle switch is opened If voltage is proper disco...

Page 659: ...e Switch 19 Toggle Switch 20 Thermostat 21 Hose 22 Actuator 23 Flapper Bracket 24 Junction Block 25 Relay 26 Bi level Flapper 27 Flapper Bracket 28 Circuit Breaker 29 Resistor 12 Volt 30 Resistor 24 volt 31 Defroster Flapper 32 Grommet 33 Electrical Box Cover 34 Blower Mount 35 Blower Assembly 36 Blower Housing 37 Blower Wheel 38 Venturi 39 Blower Motor 40 Motor Mount 41 Cover Plate 42 Wiring Harn...

Page 660: ...NOTES N4 6 Operator Comfort N04020 ...

Page 661: ... harness from the steering column at the connector 5 Remove screws retaining seal retainer plates 8 where steering column enters the instrument panel Remove both retainer plates 6 Remove the four capscrews and washers 7 at the mounting bracket Access to these cap screws is from outside the cab through the ac cess opening 7 Lift the steering column to disengage the column from the steering shaft 6 ...

Page 662: ...ner 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 Payload Meter Download Connector 15 Payload Meter II 16 Air Cleaner Vacuum Gauges 17 Windshield Wipers N5 2 Operator Cab Controls N05044 ...

Page 663: ...ill illuminate to indicate turn direction se lected 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 Headlight beam When high beams are selected the indicator in the top center of the instru ment panel will illuminate DYNAMIC RETARDING Dynamic Retarding is a braking torque not a brake produced through...

Page 664: ...vice brakes Completely depress ing the pedal causes full application of both dy namic retarding AND the service brakes An indicator light in the overhead panel B3 Figure 5 6 will illuminate and an increase in pedal resistance will be felt when the Service Brakes are applied For normal truck operation Dynamic Retarding lever or foot operated pedal should be used to slow and control the speed of the...

Page 665: ...ades which the vehicle can safely negotiate for three minutes These speeds are faster than the continuous values reflecting the thermal capacity of various system com ponents System components can accept heating at a higher than continuous rate for a short period of time beyond which the system would become over tem perature If the vehicle is operated at short term grade and speed limits for a per...

Page 666: ...s concerning selected truck functions Refer to INSTRUMENT PANEL AND INDICATOR LIGHTS for a detailed description of these indicators WINDSHIELD WIPERS The windshield wipers 13 Figure 5 2 are powered by an electric motor Refer to INSTRUMENT PANEL AND INDICATOR LIGHTS for a location and descrip tion of the windshield wiper and washer controls PAYLOAD METER The Payload Meter 15 Figure 5 2 and Download...

Page 667: ...unted on top of the right hand portion of the Console structure 17 Engine Diagnostic Port 9 Pin F N R SELECTOR SWITCH The Selector Switch 2 Figure 5 4 is mounted on a console to the right of the operator s seat It is a three position switch which controls the Forward Neutral Reverse motion of the truck When the Selector Switch handle is in the center N position it is in Neutral The handle must be ...

Page 668: ...The Ash Tray 4 Figure 5 4 is used for extinguishing and depositing smoking materials DO NOT use for flammable materials such as paper wrappers etc Be certain that all fire ash is extinguished LIGHTER The LIGHTER 5 Figure 5 4 may be used for lighting cigars cigarettes Always use CAUTION with smoking materials This socket may also be used for a 12 VDC power supply L H WINDOW CONTROL SWITCH This swit...

Page 669: ...recommendations for truck operation DO NOT exceed these recommended MAXIMUM speeds when descending grades with a loaded truck Throttle pedal position will override RSC setting If operator depresses throttle pedal to increase truck speed Dynamic Retarding will not come on unless truck overspeed setting is reached or foot operated retard pedal is used When throttle pedal is released and RSC switch i...

Page 670: ... 9 PIN connector 17 Figure 5 4 is for use by qualified personnel to access the diagnostic informa tion for the Engine Control System QUANTUM TCI DOWNLOAD PORT This connector 15 Figure 5 4 is for use by qualified personnel to access the Truck Control Interface TCI diagnostic information and data PASSENGER SEAT The Passenger Seat 16 Figure 5 4 is mounted on top of the right hand portion of the Cente...

Page 671: ...his 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 indicator or control identifies that this indicator or control is NOT used This symbol identifies a rotary con trol or switch Rotate the knob clockwise or counterclockwise for functions This symbol identifies...

Page 672: ...24 Engine Hourmeter 11 Not used on 930E 25 Hydraulic Brake Oil Temperature 12 Wheel Brake Lock Switch N O 26 AC REST Switch 13 Parking Brake Switch N O 27 Headlights Switch N O 14 Digital Tachometer 28 Wiper Washer Switch 29 Panel Illumination Lights Dimmer Rheostat 21 712D 31TS 710 49 22 712D 38G 710 49 23 15V 72MT 49 710 24 11L 36 25 15V 34BT 710 49 26 710 72RQ 27 11D 41L 41TS 28 High 66S Low 66...

Page 673: ...ST SWITCH 26 Figure 5 5 3 Allow engine to cool gradually by running at low idle for 3 to 5 minutes or use the Engine Shutdown with Timer Delay as described on the following page 4 With truck stopped and engine cooled down turn keyswitch counterclockwise to Off for normal shutdown of engine If engine does not shutdown with keyswitch use Engine Shutdown Switch on center console see Operator Controls...

Page 674: ...allow for proper engine cool down before stopping 2 With keyswitch Off and engine stopped wait at least 90 seconds Insure steering circuit is com pletely bled down by turning steering wheel back and forth several times No front wheel movement will occur when hydraulic pressure is relieved 3 Verify all the LINK VOLTAGE lights turn off within 5 minutes after the engine is shut down One is located in...

Page 675: ...ing position apply the brake lock by pressing the rocker switch toward the On symbol To release press the rocker switch toward the Off symbol Use at shovel and dump only to hold truck truck in position Do not use this switch to stop truck unless foot operated treadle valve is inoperative Use of this switch applies rear service brakes at full unmodu lated pressure Do not use brake lock for parking ...

Page 676: ... SPEEDOMETER The speedometer 18 Figure 5 5 indicates the truck speed in miles per hour MPH or with OPTIONAL speedometer it may indicate truck speed in kilometers per hour KPH VOLTMETER The voltmeter 19 Figure 5 5 indi cates the voltage of the 24V battery system Normal indicated voltage at high RPM is 27 to 28 volts with bat teries in fully charged condition When keyswitch 10 is On and engine is NO...

Page 677: ...the truck move Selector Switch to Neutral apply the Park Brake and operate engine at 1200 1500 RPM to reduce system temperature If temperature gauge does not move into the Green range after a few minutes and the RED overhead indicator light does not go out shutdown truck and notify maintenance personnel immediately REST SWITCH The REST switch 26 Figure 5 5 is a rocker type switch with a locking de...

Page 678: ...erclockwise against the stop The intermittent wiper position is located between Off and the first detent position when rotating the knob clock wise Rotating the knob closer to the first detent position decreases the time interval between wiper strokes Rotate the knob clockwise to the first detent posi tion for slow speed Rotate the knob to the second detent position for fast speed To use the Winds...

Page 679: ... Amber 12MD 47L C4 5 Min Shutdown Timer Amber 12MD 23L1 D4 Retard Speed Control Amber 12MD 31R E4 CHECK ENGINE Amber 12MD 419 Row Column Indicator Description Indicator Color Wire Index A5 No Power Red 12M 75 6PI B5 Propulsion System Warning Amber 12F 79WI C5 Propulsion System Temperature Amber 12F 34TW D5 Hydraulic Oil Temperature High Red 12F 34TGI E5 STOP ENGINE Red 12FD 528AL A6 No Propel Red ...

Page 680: ...t con tinues to illuminate and the alarm con tinues to sound low steering pressure is indi cated The remaining pressure in the accumula tors allows the operator to control the truck to a stop Do not attempt further operation until the malfunction is located and corrected C1 Low Accumulator Precharge Pressure The low accumulator precharge warning light if illumi nated indicates low nitrogen prechar...

Page 681: ...ound A3 Parking Brake This amber parking brake indicator will illuminate when the parking brake is applied Do not attempt to drive truck with parking brake applied B3 Service Brake This amber service brake indicator light will illuminate when the service brake pedal is applied or when wheel brake lock or emergency brake is applied Do not attempt to drive truck from stopped position with serv ice b...

Page 682: ...ly operated Manual Backup switch 3 Figure 5 5 Instru ment Panel is turned on C4 Engine Shutdown Timer 5 Minute Idle When the Engine Shutdown Timer switch 2 Figure 5 5 Instrument Panel has been activated this indica tor light will illuminate to indicate that the shutdown timing sequence has started Refer to Instrument Panel for operation of this switch D4 Retard Speed Control Indicator This amber l...

Page 683: ...ulic tank Continued operation could damage components in the hydraulic system If this condition occurs the operator should safely stop the truck move Selector Switch to Neutral apply the Park Brake and operate engine at 1200 1500 RPM to reduce system temperature If temperature gauge 25 Figure 5 5 does not move into the Green range after a few minutes and the RED overhead indictor light does not go...

Page 684: ...r PROPEL SYSTEM NOT READY indica tor light functions during start up much like the hour glass icon on a computer screen This light indicates the computer is in the process of performing the self diagnostics and set up functions at start up Propulsion will not be available at this time D6 REDUCED PROPULSION The amber Reduced Propulsion light is used to indi cate that the full AC Drive System perfor...

Page 685: ... the bottom side of the rocker switch for the Check position All lamps should illuminate except those which are for Op tional equipment that may not be installed The warn ing horn should also sound Any lamp bulbs which do not illuminate should be replaced before operating the truck Releasing the spring loaded switch will allow the switch to return to the Off position LINK ON WARNING LIGHT The LINK...

Page 686: ...NOTES N5 26 Operator Cab Controls N05044 ...

Page 687: ...250 Hours P2 8 500 Hours P2 10 1000 Hours P2 11 2500 Hours P2 12 5000 Hours P2 12 LINCOLN AUTOMATIC LUBRICATION SYSTEM Rotary Pump P3 1 General Description P3 1 System Components P3 3 System Operation P3 4 Injector Operation P3 6 General Instructions P3 7 Lubricant Required P3 7 System Priming P3 7 Lubricant Pump P3 7 Injectors P3 8 System Checkout P3 8 Lubrication Cycle Timer Check P3 9 Filter As...

Page 688: ...NOTES P1 2 Index P01024 ...

Page 689: ...brication intervals is normally adjustable For adjustments to these devices consult the Lincoln Automatic Lubrication System in this section 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 gauge ...

Page 690: ...th proper coolant mixture as speci fied by the engine manufacturer until coolant is visible in the sight gauge 3 Install radiator cap 4 Run engine for 5 minutes check coolant level 5 If coolant is not visible in the sight gauge repeat steps 1 through 4 Any excess coolant will be discharged through the vent hose after the engine reaches normal operating temperature Engine coolant must always be vis...

Page 691: ...P02034 Lubrication and Service P2 3 ...

Page 692: ... for oil recommendations Lube Key A Inspect exhaust piping for security 4 FUEL FILTERS Fuel Separators Drain water from bottom of each filter housing 5 HYDRAULIC TANK Check oil level in tank add if necessary Refer to Hydraulic Tank Service Oil should be visible in sight glass DO NOT OVERFILL Lube Key B 6 FUEL TANK Fill as required 7 BATTERIES Not Shown Check electrolyte level and add water if nece...

Page 693: ... soap and water rinse completely clean and air dry with maximum of 40 psi 275 kPa Reinstall filter 14 AUTOMATIC LUBE SYSTEM a Check grease reservoir fill as required Lube Key D b Inspect system and check for proper operation Be certain the following important areas are receiving adequate amounts of grease Lube Key D Steering Linkage Final Drive Pivot Pin Rear Hydrair Suspension Pin Joints Upper Lo...

Page 694: ...Separators Refer to the engine manufacturer s maintenance manual for fuel filter replacement instructions 2 HYDRAULIC SYSTEM FILTERS Replace filter elements only after the initial 50 and 250 hours of operation then at each 500 hours of operation thereafter 3 FAN DRIVE ASSEMBLY Check the torque for the six fan mounting capscrews 175 ft lbs 237 N m Truck Serial Number_______________________ Site Uni...

Page 695: ...allation check 1 HYDRAULIC SYSTEM FILTERS Replace filter elements only after the initial 100 and 250 hours of operation then at each 500 hours of operation thereafter Truck Serial Number_______________________ Site Unit Number__________________________ Date ___________Hour Meter______________ Name of Service person______________________ COMMENTS d INITIALS P02034 Lubrication and Service P2 7 ...

Page 696: ...nstructions as specified by the filter manufacturer The tightening instructions are normally printed on the outside of the filter Do not use a wrench or strap to tighten filter elements c Check the fan belt tension Refer to Cummins Operation Maintenance manual for specific fan belt adjustment instruc tions 2 FUEL FILTERS Change the Fuel Filters Fuel Separators Refer to Cummins Operation Maintenanc...

Page 697: ...ures 6 REAR AXLE HOUSING Check the rear axle housing for fluid leaks by removing the two drain plugs on the bottom of the axle housing If fluid is present the cause must be found and corrected before releasing truck to operation 7 STEERING LINKAGE Check torque on pin re taining nuts steering linkage 525 ft lbs 712 N m Check torque on tie rod retaining cap screws 310 ft lbs 420 N m 8 MAGNETIC PLUG ...

Page 698: ...ont and rear 4 THROTTLE AND BRAKE PEDAL Not Shown Lubricate treadle roller and hinge pins with lubri cating oil Lift boot from mounting plate and apply a few drops of lubricating oil between mounting plate and plunger 5 HOIST LIMIT SWITCH Not Shown Check op eration Clean and adjust as necessary 6 HOIST ACTUATOR LINKAGE Not Shown Check operation Clean lubricate and adjust as necessary 7 PARKING BRA...

Page 699: ...manual for correct additive mixture 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 AUXILIARY BLOWER Apply a few pumps o...

Page 700: ...r filter Use low pressure cold water or low pressure air to clean tubes Refer to the service manual NOTE Do not use a hot pressure washer or high pressure air to clean tubes hot water high pressure causes pre cleaner tubes to distort Truck Serial Number _____________________ Site Unit Number ________________________ Date ____________Hour Meter_____________ Name of Service person___________________...

Page 701: ...ischarged to the outlet port Over pressurizing of the system modifying parts using incompatible chemicals and fluids or using worn or damaged parts may result in equipment damage and or serious personal injury DO NOT exceed the stated maximum working pressure of the pump or of the lowest rated component in the system Do not alter or modify any part of this system unless approved by factory authori...

Page 702: ...earing 11 R H Suspension Bottom Bearing 12 R H Body Pivot Pin 13 R H Hoist Cylinder Top Bearing 14 R H Hoist Cylinder Bottom Bearing 15 R H Anti Sway Bar Bearing 16 Vent Hose 17 Junction Box 18 Pressure Switch N O 2500 psi 17 237 kPa 19 Grease Pump 20 Vent Valve 21 Filter 22 Grease Supply to Injectors 23 Truck Frame 24 Injector NOTE The above illustration shows the standard location for the lube p...

Page 703: ...he 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 0 so the injectors can recharge for their next output cycle Lubrication Cycle Timer 1 Figure 3 4 The solid state lubrication cycle timer provides a 24 VDC timed interval signal to energize the solenoid valve 5 Figure 3 1 providing oil flow to operate ...

Page 704: ...injectors will meter the appropriate amount of grease to each lubrication point 6 When grease pressure reaches the pressure switch 3 Figure 3 4 setting the switch contacts will close and energize the relay RB7K5 remov ing power from the hydraulic motor pump sole noid and the the pump will stop The relay will remain energized until grease pressure drops and the pressure switch opens again or until ...

Page 705: ...ed it will latch and remain energized as long as the keyswitch is on In addition RB7K4 will also remain energized and the Low Lube Pressure Warning lamp will remain on to notify the operator a problem exists and the system requires service FIGURE 3 4 ELECTRICAL SCHEMATIC 1 Lubrication Cycle Timer 2 Circuit Breaker CB7 In Electrical Interface Cabinet 3 Pressure Switch N O 2500 psi 17 237 kPa 4 Rela...

Page 706: ...AGE 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 meas uring 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 causing the slide valve 5 to move so that th...

Page 707: ...mp housing must be filled to the proper level with SAE 10W 30 motor oil Oil level should be checked at 1000 hour intervals To add oil remove pipe plug 3 Figure 3 5 and fill housing to bottom of plug hole Pump Pressure Control High pressure hydraulic fluid from the truck steering system is reduced to 325 to 350 psi 2 240 to 2 413 kPa by the pressure reducing valve located on the manifold on top of ...

Page 708: ...nt is needed turn the adjusting screw to the point where about 0 19 inch 4 8 mm threads are showing The injector will be set at minimum delivery point with about 0 009 inch 0 22 mm thread showing NOTE The above information concerns adjustment of injector delivery volume The timer adjustment should also be changed if overall lubricant delivery is too little or too much Injector output should NOT be...

Page 709: ...state timer with the truck keyswitch ON Normal reading should be 18 26 VDC depend ing upon whether or not the engine is running Lubrication Cycle Timer Adjustment The timer is factory set for a nominal 2 5 minute off time interval Dwell time is approximately 1 minute 15 seconds A longer interval off time is obtained by turning the Selector knob 3 Figure 3 7 to the desired position NOTE Set timer b...

Page 710: ...ng 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 assembly 9 through 20 from the tube 13 Using a 50 in 13 mm diameter wooden or plastic rod push the cup seal 22 and the pump cylinder 24 from the reciprocating tube 14 Remove the pump plunger 20 from...

Page 711: ...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 Ring 49 O Ring 50 Nut 51 Bronze Bearing 52 O Ri...

Page 712: ...at 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 bushing 51 into housing tube 55 11 I...

Page 713: ...red to the normal interval Subsequent 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 C...

Page 714: ...lace pressure switch Refer to Pressure Control Valve Adjustment Replace grease with a lower viscosity lubricant Remove inspect and clean if necessary Inspect sealing surfaces between checks Replace if rough or pitted Repair lubricant supply line Check oil pressure and flow to motor TROUBLE Lube Cycle Timer Not Operating Timer BAT connection is not on grounded member Timer BAT connection not on cir...

Page 715: ...se 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 adjustmen...

Page 716: ...Check grease reservoir level a Fill reservoir if low b Check reservoir for contaminants Clean if required c Check that all filler plugs covers and breather vents on the reservoir are intact and free of contaminants 4 Inspect all bearing points for a bead of lubricant around the bearing seal It is good practice to manually lube each bearing point at the grease fitting provided on each Injec tor Thi...

Page 717: ...Retention Cable B3 4 Body Up Switch D3 13 Brake Accumulators J3 22 Brake Circuit J2 1 Bleeding Procedures Service Brakes J5 14 Parking Brake J7 6 Checkout Procedure J4 5 Failure Modes Checkout Procedure J4 6 Troubleshooting J4 9 Brake Disc Wear Indicator J5 2 Brake Parking J7 1 Brake Seal Assembly Rear J5 11 Brake Seal Gap Adjustment Rear J5 10 Brakes Wet Disc J5 1 Brake Valve J3 1 Test and Adjust...

Page 718: ...itch D3 14 Hoist Pilot Valve L8 9 Hoist Cylinders L8 12 Hoist Relief Valve Adjustment L10 7 Hoist Valve L8 1 Hood B2 2 Hub Wheel G3 1 HYDRAIR II Suspensions Front H2 1 Rear H3 1 Oil and Nitrogen Specifications H4 6 Hydraulic System Disc Brake Cooling System L2 6 Filters L9 1 Hoist Pump L3 1 Strainers L3 15 Schematic R1 1 Steering Brake Pump L6 12 System Flushing L10 10 Tank L3 14 Troubleshooting H...

Page 719: ...M8 1 Specifications HYDRAIR II Oil H4 6 HYDRAIR II Nitrogen H4 6 Hydraulic Oil P2 1 Lubrication Chart P2 3 Truck Specifications A2 3 Spindle Front Wheel Hub G3 1 Starter Disconnect Relay D2 3 Status Warning Indicator Lights N5 20 Steering Accumulator Charging Procedure L6 5 Column N5 1 Circuit Checkout and Adj Procedure L10 1 Control Valve L5 1 Cylinders L6 10 Troubleshooting L6 23 Strainer Hydrau...

Page 720: ...r Adjustment L10 2 Steering Control L5 1 Unloader Adjustment L10 2 W Weights Truck A2 4 Wheel Bearing Adjustment Front Wheel G3 7 Front Wheel Bearing Seal Adjustment G3 9 Wheel Hub and Spindle G3 1 Wheel Motors G5 4 Wheels and Tires Front G2 2 Rear G2 3 Window Service Cab N2 7 Windshield Washer N3 2 Windshield Wiper N3 1 Q1 4 Alphabetical Index Q01028 04 01 ...

Page 721: ...SYSTEM SCHEMATICS INDEX HYDRAULIC BRAKE SYSTEM SCHEMATIC HH341 HYDRAULIC SUPPLY BRAKE COOLING SCHEMATIC w HUSCO VALVE HH347 ELECTRICAL SCHEMATIC EJ2134 R01048 930E Schematics R1 1 with Cummins QSK60 Series Engine ...

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Page 737: ...NOTES R1 2 930E Schematics R01048 with Cummins QSK60 Series Engine ...

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