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CEBM017904

Shop
Manual

DUMP TRUCK

SERIAL NUMBERS A30462 - A30600

®
Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-
sonnel must read and understand this manual before operating or maintaining this machine.

This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.

This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis-
closed except in accordance with written authorization from KAC.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The
Company reserves the right to make changes or add improvements at any time without incurring any obli-
gation to install such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication.
Customers should contact their local Komatsu distributor for information on the latest revision.

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.

CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. Wash hands after handling.
NON-OEM PARTS IN CRITICAL SYSTEMS

For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.

Replacement parts manufactured and supplied by unauthorized sources may not be


designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.

Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.

Use of non-OEM parts places full responsibility for the safe performance of the
Komatsu product on the supplier and user. Komatsu will not in any case accept
responsibility for the failure or performance of non-OEM parts in its products,
including any damages or personal injury resulting from such use.
FOREWORD

This manual is written for use by the operator and/or the service technician. It is designed to help these persons to
become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All
operators and maintenance personnel should read and understand the information in this manual before operating
the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and
cautions should be understood and followed when operating the truck or performing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other
general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major
serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator
group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire
mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed
repairs.

The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of
what is found on the truck.

This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,”
“front,” or “rear” are made with respect to the operator's normal seated position unless specifically stated otherwise.
When assembly instructions are provided without references to specific torque values, standard torque values
should be used. Standard torque values are shown in torque charts in the General Information section of this
manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque
specifications have ±10% tolerance unless otherwise specified.
A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck
Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight)
rating.

The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter “E” designates an Electrical wheel motor drive system.
The Product Identification Number (vehicle serial number) contains information which identifies several
characteristics of this unit. For a more detailed explanation, see the end of Section A4.

The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other
components. The vehicle design and application guidelines are sensitive to the maximum GVW.
GVW is total weight: empty vehicle weight + fuel & lubricants + payload.

To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck
(which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and
subtract it from the GVW. The result is the allowable payload.

NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload.
To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be
removed as often as practical.

Exceeding the allowable payload will reduce the expected life of truck components.

A00041 12/06 Introduction A-1


This “ALERT” symbol is used with the signal words,
“DANGER”, “WARNING”, and “CAUTION” in this
manual to alert the reader to hazards arising from
improper operating and maintenance practices.

“DANGER” identifies a specific potential hazard WHICH WILL


RESULT IN EITHER INJURY OR DEATH if proper precautions
are not taken.

“WARNING” identifies a specific potential hazard WHICH


MAY RESULT IN EITHER INJURY OR DEATH if proper
precautions are not taken.

“CAUTION” is used for general reminders of proper safety


practices OR to direct the reader’s attention to avoid unsafe
or improper practices which may result in damage to the
equipment.

A-2 Introduction 12/06 A00041


TABLE OF CONTENTS

SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

ENGINE SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D

ELECTRIC PROPULSION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E

DRIVE AXLE, SPINDLES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G

HYDRAIR® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H

BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L

OPTIONS AND SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q

SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R

A00041 12/06 Introduction A-3


KOMATSU MODEL 930E-4 DUMP TRUCK

A-4 Introduction 12/06 A00041


SECTION A
GENERAL INFORMATION
INDEX

MAJOR COMPONENTS & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

GENERAL SAFETY AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

STANDARD TORQUE CHARTS AND CONVERSION TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

STORAGE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7

A01001 02/94 Index A1-1


NOTES

A1-2 Index 02/94 A01001


MAJOR COMPONENTS & SPECIFICATIONS
TRUCK AND ENGINE OPERATOR’S CAB
The 930E-4 Dump Truck is an off-highway, rear The operator cab has been engineered for operator
dump truck with AC Electric Drive. The gross vehicle comfort and to allow for efficient and safe operation
weight is 1,100,000 lbs (498,960 kg). The engine is a of the truck. The cab provides wide visibility with an
Komatsu SSDA16V160 rated @ 2700 HP (2014 kW). integral 4-post ROPS/FOPS structure and an
advanced analog operator environment. It includes a
MAIN ALTERNATOR tinted safety-glass windshield and power-operated
side windows, a deluxe interior with a fully adjustable
The diesel engine drives an in-line alternator at
seat with lumbar support, a fully adjustable/tilt
engine speed. The alternator produces AC current
steering wheel, controls mounted within easy reach
which is rectified to DC within the main control
of the operator, and an analog instrument panel
cabinet. The rectified DC power is converted back to
which provides the operator with all instruments and
AC by groups of devices called "inverters", which are
gauges which are necessary to control and/or
also within the main control cabinet. Each inverter
monitor the truck's operating systems.
consists of six phase modules under the control of a
gate driver power converter (GDPC). The two
GDPCs control the operation of each phase module.
POWER STEERING
Each phase module contains paired positive and The truck is equipped with a full time power steering
negative semiconductor switches referred to as system which provides positive steering control with
insulated gate bipolar transistors (IGBT). The IGBTs minimum operator effort. The system includes
cycle on and off at varying frequencies to create an nitrogen-charged accumulators which automatically
AC power signal from the DC supply. provide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
The AC power signal produced by each inverter is a
variable-voltage, variable-frequency (VVVF) signal.
DYNAMIC RETARDING
Frequency and voltage are changed to suit the
operating conditions. The dynamic retarding is used to slow the truck
Cooling air for the control/power group and wheel during normal operation or control speed coming
motors, as well as the alternator itself, is provided by down a grade. The dynamic retarding ability of the
dual fans mounted on the alternator shaft. electric system is controlled by the operator through
the activation of the retarder pedal (or by operating a
AC INDUCTION TRACTION MOTORIZED lever on the steering wheel) in the operators cab and
by setting the RSC (Retarder Speed Control).
WHEELS
Dynamic retarding is automatically activated, if the
The alternator output supplies electrical energy to the truck speed goes to a preset overspeed setting.
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction BRAKE SYSTEM
motors with full-wave AC power.
Service brakes at each wheel are oil-cooled multiple
The two wheel motors convert electrical energy back disc brakes applied by an all-hydraulic actuation
to mechanical energy through built-in gear trains system. Depressing the brake pedal actuates both
within the wheel motor assembly. The direction of the front and rear brakes after first applying the retarder.
wheel motors is controlled by a directional control All wheel brakes will be applied automatically if the
lever located on the center console. brake system pressure decreases below a preset
minimum.
SUSPENSION
The parking brake is a dry disc type, mounted
® inboard on each rear wheel motor, and is spring-
Hydrair II suspension cylinders located at each
wheel provide a smooth and comfortable ride for the applied and hydraulically-released with wheel speed
operator and dampens shock loads to the chassis application protection (will not apply with truck
during loading and operation. moving).

A02074 1/07 Major Components & Specifications A2-1


A2-2 Major Components & Specifications 1/07 A02074
SPECIFICATIONS
These specifications are for the standard Komatsu 930E-4 Truck. Customer options may change this listing.

ENGINE

Komatsu SSDA16V160
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2700 HP (2014 kW) @ 1900 RPM
Flywheel HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2550 HP (1902 kW) @ 1900 RPM
Weight (Wet)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9608 kg (21,182 lbs)
* Weight does not include Radiator, Sub-frame, or Alternator.

AC ELECTRIC DRIVE SYSTEM

(AC/DC Current)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Electric GTA-41
Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340 m³/ min (12,000 cfm)
Motorized Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GDY106 AC Induction Traction Motors
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.62:1
Maximum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5 km/h (40 mph)
* Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.
Komatsu and GE must analyze each job condition to ensure proper application.

DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard
Maximum Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5400 HP (4026 kW)
Continuous* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 HP (2460 kW)
* Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.

BATTERY ELECTRIC SYSTEM


Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four 8D, 12 volt wet batteries with disconnect switch
Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 CCA
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 260 Amp Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts

SERVICE CAPACITIES
Crankcase (including lube oil filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 liters (74 gallons)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594 liters (157 gallons)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4542 liters (1200 gallons)
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325 liters (350 gallons)
Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 liters (25 gallons) per wheel

A02074 1/07 Major Components & Specifications A2-3


HYDRAULIC SYSTEMS
Hoist and Brake Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931 L/min (246 gpm) @ 1900 RPM and 17,237 kPa (2500 psi)
Steering/Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 18,961 kPa (2750 psi)
Relief Pressure - Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17,237 kPa (2500 psi)
Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27,579 kPa (4000 psi)
Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947 liters (250 gallons)
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 Rating =200

SERVICE BRAKES
All Hydraulic Actuation with Traction System Wheel Slip/Slide Control
Front and Rear Oil-Cooled Multiple Discs on each wheel
Total Friction Area / Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97,019 cm² (15,038 in²)
Maximum Apply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17,238 kPa (2500 psi)

STEERING
Twin hydraulic cylinders with accumulator assist to provide constant rate steering
Emergency power steering automatically provided by accumulators
Turning Circle (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.4 m (97 ft. 7 in.)

TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53/80 R63
Rock Service, Deep Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless
Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . patented Phase I New Generation™ rims

STANDARD DUMP BODY CAPACITIES AND DIMENSIONS


Capacity
Heaped @ 2:1 (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211 m3 (276 yd3)
Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171 m3 (224 yd3)
Width (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 m (26 ft. 9 in.)
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 m (10 ft. 7 in.)
Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.06 m (23 ft. 2 in.)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

NOTE: Optional capacity dump bodies are available.

A2-4 Major Components & Specifications 1/07 A02074


WEIGHT DISTRIBUTION

Empty Vehicle Loaded Vehicle


Front Axle (49.3%). . . . . . . 103,301 kg (227,738 lbs) Front Axle (33.0%) . . . . . 165,554 kg (364,980 lbs)
Rear Axle (50.7 %) . . . . . . 107,518 kg (237,034 lbs) Rear Axle (67.0%) . . . . . 336,124 kg (741,020 lbs)
Total (with 50% fuel) . . . . . 210,819 kg (464,772 lbs) Total . . . . . . . . . . . . . . . 501,678 kg (1,106,000 lbs)

Standard Komatsu body . . . . 30,362 kg (66,936 lbs) Nominal Payload*. . . . . . . . 290,859 kg (641,228 lbs)
Standard tire weight. . . . . . . . 26,127 kg (57,600 lbs)
* Nominal payload is defined within Komatsu
America Corporation’s payload policy
documentation. Nominal payload must be adjusted if
the weight of any customized body or tires vary from
that of the standard Komatsu body and tires. Nominal
payload must also be adjusted to take into account
the additional weight of any custom/optional extras
fitted to the truck which are not stated within the
Standard Features list of the applicable specification
sheet.

A02074 1/07 Major Components & Specifications A2-5


NOTES

A2-6 Major Components & Specifications 1/07 A02074


SAFETY
GENERAL Fire Extinguisher And First Aid Kit
Safety records from most organizations will show that • Make sure that fire extinguishers are accessible
the greatest percentage of accidents are caused by and proper usage techniques are known.
unsafe acts performed by people. The remainder are • Provide a first aid kit at the storage point.
caused by unsafe mechanical or physical conditions.
Report all unsafe conditions to the proper authority. • Know what to do in the event of a fire.
• Keep the phone numbers of persons you should
The following safety rules are provided as a guide for
contact in case of an emergency on hand.
the operator. However, local conditions and
regulations may add many more to this list.

Read and follow all safety precautions. Failure to


do so may result in serious injury or death.

Safety Rules Clothing And Personal Items


• Only trained and authorized personnel may • Avoid loose clothing, jewelry, and loose long hair.
operate and maintain the truck. They can catch on controls or in moving parts
• Follow all safety rules, precautions and and cause serious injury or death. Also, never
instructions when operating or performing wear oily clothes as they are flammable.
maintenance on the truck. • Wear a hard hat, safety glasses, safety shoes,
• When working with another operator or a person mask and gloves when operating or maintaining
on work site traffic duty, make sure that all a truck. Always wear safety goggles, hard hat
personnel understand all hand signals that are to and heavy gloves if your job involves scattering
be used. metal chips or minute materials--particularly
when driving pins with a hammer or when
cleaning air cleaner elements with compressed
air. Also, ensure that the work area is free from
Safety Features other personnel during such tasks.

• Make sure that all guards and covers are in their


proper position. Have any damaged guards and
covers repaired. (See Operating Instructions -
“Preparing For Operation”.)
• Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. Use
these safety features properly.
• Never remove any safety features. Always keep
them in good operating condition.
• Improper use of safety features could result in
serious bodily injury or death.

A03039 5/08 General Safety & Operating Instructions A3-1


Leaving The Operator’s Seat Fire Prevention For Fuel And Oil
When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a
touch any control lever that is not locked. To prevent flame. Fuel is extremely flammable and can be
accidental operations from occurring, always perform hazardous. Keep flames away from flammable
the following: fluids.

• Move the directional control lever to PARK. Do • Keep oil and fuel in a designated location and do
not use the wheel brake lock when the engine not allow unauthorized persons to enter.
will be turned off. • When refueling, stop the engine and do not
• Lower the dump body to the frame. smoke.

• Stop the engine. When exiting the truck, always • Refueling and oiling should be done in well
lock compartments and take the keys with you. If ventilated areas.
the truck should suddenly move or move in an • Tighten all fuel and oil tank caps securely.
unexpected way, this may result in serious bodily
injury or death.

Mounting And Dismounting


• Use the handrails and steps when getting on or
off the truck.
• Never jump on or off the truck. Never climb on or
off a truck while it is moving.
• When climbing on or off a truck, face the truck
and use the hand-hold and steps.
• Never hold any control levers when getting on or
off a truck.
• Always maintain three-point contact with the
hand-holds and steps to ensure that you support
yourself.
• When bringing tools into the operator's
compartment, always pass them by hand or pull
them up by rope.
• If there is any oil, grease, or mud on the hand-
holds or steps, wipe them clean immediately.
Always keep these components clean. Repair
any damage and tighten any loose bolts.

A3-2 General Safety & Operating Instructions 5/08 A03039


Precautions With High Temperature Fluids Prevention Of Injury By Work Equipment
Immediately after truck operation, engine coolant, Never enter or put your hand, arm or any other part of
engine oil, and hydraulic oil are at high temperatures your body between movable parts such as the dump
and are pressurized. If the cap is removed, the fluids body, chassis or cylinders. If the work equipment is
are drained, the filters are replaced, etc., there is operated, clearances will change and may lead to
danger of serious burns. Allow heat and pressure to serious bodily injury or death.
dissipate before performing such tasks and follow
proper procedures as outlined in the service manual.
Unauthorized Modification
Any modification made to this vehicle without
authorization from Komatsu America Corp. can
possibly create hazards.
Before making any modification, consult the
authorized regional Komatsu America Corp.
distributor. Komatsu will not be responsible for any
injury or damage caused by any unauthorized
To prevent hot coolant from spraying: modification.
1. Stop the engine.
2. Wait for the coolant temperature to decrease.
Precautions When Using ROPS
3. Depress the pressure release button on the cap
to vent cooling system pressure. The ROPS is intended to protect the operator if the
truck should roll over. It is designed not only to
4. Turn the radiator cap slowly to release the support the load of the truck, but also to absorb the
pressure before removing. energy of the impact.
To prevent hot engine oil spray: • The Rollover Protection Structure (ROPS) must
1. Stop the engine. be properly installed before the truck is operated.

2. Wait for the oil temperature to cool down. • ROPS installed on equipment manufactured and
designed by Komatsu America Corp. fulfills all of
3. Turn the cap slowly to release the pressure the regulations and standards for all countries. If
before removing the cap. it is modified or repaired without authorization
from Komatsu, or if it is damaged when the truck
rolls over, the strength of the structure will be
compromised and will not be able to fulfill its
Asbestos Dust Hazard Prevention
intended purpose. Optimum strength of the
Asbestos dust is hazardous to your health when structure can only be achieved if it is repaired or
inhaled. If you handle materials containing asbestos modified as specified by Komatsu.
fibers, follow the guidelines below: • When modifying or repairing the ROPS, always
consult your nearest Komatsu distributor.
• Never use compressed air for cleaning.
• Even with the ROPS installed, the operator must
• Use water for cleaning to control dust.
always use the seat belt when operating the
• Operate the truck or perform tasks with the wind truck.
to your back whenever possible.
• Use an approved respirator when necessary.

A03039 5/08 General Safety & Operating Instructions A3-3


Precautions For Attachments PRECAUTIONS BEFORE OPERATION
• When installing and using optional equipment, Safety is thinking ahead. Prevention is the best safety
read the instruction manual for the attachment program. Prevent a potential accident by knowing the
and the information related to attachments in this employer's safety requirements and all necessary job
manual. site regulations. In addition, know the proper use and
• Do not use attachments that are not authorized care of all the safety equipment on the truck. Only
by Komatsu America Corp. or the authorized qualified operators or technicians should attempt to
regional Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.
attachments could create a safety problem and
adversely affect the proper operation and useful Safe practices start before the operator gets to the
life of the truck. equipment.
• Any injuries, accidents, and product failures Safety At The Worksite
resulting from the use of unauthorized
attachments will not be the responsibility of • When walking to and from a truck, maintain a
Komatsu America Corp. or the authorized safe distance from all machines even when the
regional Komatsu distributor. operator is visible.
• Before starting the engine, thoroughly check the
area for any unusual conditions that could be
Precautions For Starting The Truck dangerous.
Start the engine from the operator’s seat only. Never • Examine the road surface at the job site and
attempt to start the engine by shorting across determine the best and safest method of
cranking motor terminals. This may cause a fire, or operation.
serious injury or death to anyone in truck’s path. • Choose an area where the ground is as
horizontal and firm as possible before performing
the operation.
• If you need to operate on or near a public road,
protect pedestrians and cars by designating a
person for work site traffic duty or by installing
fences around the work site.
• The operator must personally check the work
area, the roads to be used, and the existence of
obstacles before starting operations.
• Always determine the travel roads at the work
site and maintain them so that it is always safe
for the machines to travel.
• If travel through wet areas is necessary, check
the depth and flow of water before crossing the
shallow parts. Never drive through water that
exceeds the permissible water depth.

A3-4 General Safety & Operating Instructions 5/08 A03039


Fire Prevention In Operator’s Cab - Before Starting The Engine
• Remove wood chips, leaves, paper, and other • Do not leave tools or spare parts lying around. Do
flammable items that have accumulated in the not allow trash to accumulate in the cab of the
engine compartment. Failure to do so could result truck. Keep all unauthorized reading material out
in a fire. of the truck cab.
• Check the fuel, lubrication, and hydraulic • Keep the cab floor, controls, steps and handrails
systems for leaks. Repair any leaks. Clean any free of oil, grease, snow and excess dirt.
excess oil, fuel or other flammable fluids, and
• Check the seat belt, buckle and hardware for
dispose of them properly.
damage or wear. Replace any worn or damaged
• Make sure that a fire extinguisher is present and parts. Always use the seat belts when operating a
in proper working condition. truck.
• Do not operate the truck near open flames. • Read and understand the contents of this
manual. Pay special attention to Sections 30 and
32 pertaining to safety and operating instructions.
Become thoroughly acquainted with all gauges,
instruments and controls before attempting
operation of the truck.
• Read and understand the WARNING and
CAUTION decals in the operator's cab.
• Make sure that the steering wheel, horn, controls
Preparing For Operation and pedals are free of any oil, grease or mud.
• Check the operation of the windshield wiper,
• Always mount and dismount while facing the
condition of wiper blades, and the washer fluid
truck. Never attempt to mount or dismount the
reservoir level.
truck while it is in motion. Always use handrails
and ladders when mounting or dismounting the • Be familiar with all steering and brake system
truck. controls, warning devices, road speeds and
loading capabilities before operating the truck.
• Check the deck areas for debris, loose hardware
and tools. Check for people and objects that
might be in the area.
Mirrors, Windows And Lights
• Become familiar with and use all protective
equipment devices on the truck and ensure that • Remove any dirt from the surface of the
these items (anti-skid material, grab bars, seat windshield, cab windows, mirrors and lights.
belts, etc.) are securely in place. Good visibility may prevent an accident.
• Adjust the rear view mirror to a position where
the operator can see best from the operator's
Ventilation In Enclosed Areas seat. If any glass or light is broken, replace it with
a new part.
If it is necessary to start the engine within an
enclosed area, provide adequate ventilation. Inhaling • Make sure that the headlights, work lights, and
exhaust fumes from the engine can kill. taillights are in proper working order. Make sure
that the truck is equipped with the proper work
lamps that are needed for the operating
conditions.

A03039 5/08 General Safety & Operating Instructions A3-5


OPERATING THE TRUCK
When Starting The Engine
• Never attempt to start the engine by shorting
across cranking motor terminals. This may cause
a fire, or serious injury or death to anyone in
The tire and rim assembly may explode if
truck’s path.
subjected to excessive heat. Personnel should
• Never start the engine if a warning tag has been move to a remote or protected location if sensing
attached to the controls. excessively hot brakes, smelling burning rubber
• When starting the engine, sound the horn as an or observing evidence of fire near the tire and
alert. wheel area.
• Start and operate the truck only while seated in If the truck must be approached to exstinguish a
the operator’s seat. fire, those personnel should do so only while
facing the tread area of the tire (front or back)
• Do not allow any unauthorized persons in the
operator's compartment or any other place on the unless protected by using large heavy equipment
truck. as a shield. Stay at least 50 ft. (15 m) from the
tread of the tire.
General Truck Operation
In the event of fire in the tire and wheel area
• Wear the seat belt at all times. (including brake fires), stay away from the truck
for at least 8 hours or until the tire and wheel are
• Only authorized persons are allowed to ride in
cool.
the truck. Riders must be in the cab and belted in
the passenger seat. • Keep serviceable fire fighting equipment on
• Do not allow anyone to ride on the decks or steps hand. Report empty extinguishers for
of the truck. replacement or refilling.

• Do not allow anyone to get on or off the truck • Always place the directional control lever in the
while it is in motion. PARK when the truck is parked and unattended.
Do not leave the truck unattended while the
• Do not move the truck in or out of a building engine is running.
without a signal person present.
• Park the truck a safe distance away from other
• Know and obey the hand signal communications vehicles as determined by the supervisor.
between operator and spotter. When other
machines and personnel are present, the • Stay alert at all times! In the event of an
operator should move in and out of buildings, emergency, be prepared to react quickly and
loading areas, and through traffic under the avoid accidents. If an emergency arises, know
direction of a signal person. Courtesy at all times where to get prompt assistance.
is a safety precaution!
• Immediately report any adverse conditions at the
haul road, pit or dump area that may cause an
operating hazard.
• Check for flat tires periodically during a shift. If
the truck has been operating on a “flat”, do not
park the truck inside a building until the tire cools.
If the tire must be changed, do not stand in front
of the rim and locking ring when inflating a tire
mounted on the truck. Observers should not be
permitted in the area and should be kept away
from the side of such tires.

A3-6 General Safety & Operating Instructions 5/08 A03039


Traveling In Reverse Traveling On Slopes
Before operating the truck: • Traveling on slopes could result in the truck
tipping over or slipping.
• Sound the horn to warn people in the area. Make
sure that the back-up horn also works properly. • Do not change direction on slopes. To ensure
safety, drive to level ground before turning.
• Check for personnel near the truck. Be
particularly careful to check behind the truck. • Do not travel up and down on grass, fallen
leaves, or wet steel plates. These materials may
• When necessary, designate a person to watch make the truck slip on even the slightest slope.
the area near the truck and signal the operator. Avoid traveling sideways, and always keep travel
This is particularly necessary when traveling in speed low.
reverse.
• When traveling downhill, use the retarder to
• When operating in areas that may be hazardous reduce speed. Do not turn the steering wheel
or have poor visibility, designate a person to suddenly. Do not use the foot brake except in an
direct work site traffic. emergency.
• Do not allow any one to enter the line of travel of • If the engine should stop on a slope, apply the
the truck. This rule must be strictly observed service brakes fully and stop the truck. Move the
even with machines equipped with a back-up directional control lever to PARK after the truck
horn or rear view mirror. has stopped.

Ensure Good Visibility


• When working in dark places, install work lamps
and head lamps. Set up extra lighting in the work
area if necessary.
• Discontinue operations if visibility is poor, such as
in mist, snow, or rain. Wait for the weather to
improve to allow the operation to be performed
safely.
Traveling
• When traveling on rough ground, travel at low
speeds. When changing direction, avoid turning Operate Carefully On Snow
suddenly.
• When working on snowy or icy roads, there is
• Lower the dump body and set the dump lever to danger that the truck may slip to the side on even
the FLOAT position before traveling. the slightest slope. Always travel slowly and
• If the engine stops while the truck is in motion, avoid sudden starting, turning, or stopping in
secondary steering and braking enable the truck these conditions.
to be steered and stopped. A fixed amount of • Be extremely careful when clearing snow. The
reserve oil provides temporary steering and road shoulder and other objects are buried in the
braking to briefly allow the truck to travel to a safe snow and cannot be seen. When traveling on
area. Apply the brakes immediately and stop the snow-covered roads, always install tire chains.
truck as quickly and safely as possible off of the
haul road, if possible.

Avoid Damage To Dump Body


Always be extremely cautious when working in
tunnels, on bridges, under electric cables, or when
entering a parking place or any other place where
there are height limits. The dump body must be
completely lowered before driving the truck.

A03039 5/08 General Safety & Operating Instructions A3-7


Driving Near High Voltage Cables When Loading
Driving near high-voltage cables can cause electric • Make sure that the surrounding area is safe. Stop
shock. Always maintain safe distances between the the truck in the correct loading position, then load
truck and the electric cable as listed below. the body uniformly.
Voltage Minimum Safety Distance • Do not leave the operator's seat during the
6.6 kV 3m 10 ft. loading operation.
33.0 kV 4m 14 ft.
Parking The Truck
66.0 kV 5m 17 ft.
• Choose a flat, level surface to park the truck. If
154.0 kV 8m 27 ft. the truck has to be parked on a slope, put blocks
275.0 kV 10 m 33 ft. behind all the wheels to prevent truck movement.
• When parking on public roads, provide fences
The following actions are effective in preventing and signs, such as flags or lights, on the truck to
accidents while working near high voltages: warn pedestrians and other vehicles. Make sure
that the truck, flags or lights do not obstruct
• Wear shoes with rubber or leather soles. traffic.
• Use a signalman to give warning if the truck • Before leaving the truck, lower the dump body
approaches an electric cable. fully, move the directional control lever to PARK,
• If the work equipment touches an electric cable, stop the engine and lock everything. Always take
the operator should not leave the cab. the key with you.
• When performing operations near high voltage
cables, do not allow anyone to approach the
truck.
• Check with the electrical maintenance
department about the voltage of the cables Do not activate the wheel brake lock when the
before starting operations. parking brake is activated. Bleed down of
hydraulic pressure may occur, causing the truck
When Dumping
to roll away.
• Before starting the dumping operation, make
sure that there are no persons or objects behind TOWING
the truck.
• Improper towing methods may lead to serious
• Stop the truck in the desired location. Check personal injury and/or damage.
again for persons or objects behind the truck.
Give the determined signal, then slowly operate • Use a towing device with ample strength for the
the dump body. If necessary, use blocks for the weight of this truck.
wheels or position a flagman. • Never tow a truck on a slope.
• When dumping on slopes, truck stability is poor • Inspect towing components, such as tow bars
and there is danger of tipping over. Always use and couplings, for any signs of damage. Never
extreme care when performing such operations. use damaged or worn components to tow a
• Never travel with the dump body raised. disabled vehicle.
• Keep a safe distance from the trucks and towing
Working On Loose Ground
apparatus while towing a vehicle.
• Avoid operating the truck near cliffs, overhangs • When connecting a truck that is to be towed, do
and deep ditches. If these areas collapse, the not allow anyone to go between the tow vehicle
truck could fall or tip over and result in serious and the disabled vehicle.
injury or death. Remember that ground surfaces
in these areas may be weakened after heavy rain • Set the coupling of the truck being towed in a
or blasting. straight line with the towing portion of the tow
truck, and secure it in position.
• Freshly laid soil and the soil near ditches is loose.
It can collapse under the weight or vibration of • For towing methods, refer to Operating
the truck. Avoid these areas whenever possible. Instructions - Section 30, Towing.

A3-8 General Safety & Operating Instructions 5/08 A03039


WORKING NEAR BATTERIES • Batteries generate hydrogen gas. Hydrogen gas
is very explosive and can easily be ignited with a
Battery Hazard Prevention small spark or flame.
• Battery electrolyte contains sulfuric acid, which • Before working with batteries, stop the engine
can quickly burn the skin and eat holes in and turn the key switch to the OFF position.
clothing. If you spill acid on yourself, immediately • Avoid short-circuiting the battery terminals
flush the area with water. through accidental contact with metallic objects,
• Battery acid can cause blindness if splashed into such as tools, across the terminals.
your eyes. If acid gets into your eyes, flush them • When removing or installing batteries, check
immediately with large quantities of water and which is the positive (+) terminal and the negative
see a doctor at once. (-) terminal.
• If you accidentally drink acid, drink a large • Tighten battery caps securely.
quantity of water, milk, beaten eggs or vegetable
oil. Call a doctor or poison prevention center • Tighten the battery terminals securely. Loose
immediately. terminals can generate sparks and lead to an
explosion.
• Always wear safety glasses or goggles when
working with batteries.

Starting With Booster Cables • If any tool touches between the positive (+)
terminal and the chassis, it will cause sparks.
• Always wear safety glasses or goggles when Always be cautious when using tools near the
starting the truck with booster cables. battery.
• When starting from another truck, do not allow • Connect the batteries in parallel: positive to
the two trucks to touch. positive and negative to negative.
• Connect the positive (+) cable first when • When connecting the ground cable to the frame
installing booster cables. Disconnect the ground of the truck to be started, connect it as far as
or negative (-) cable first during removal. possible from the battery.

INCORRECT

A03039 5/08 General Safety & Operating Instructions A3-9


BEFORE PERFORMING MAINTENANCE Securing The Dump Body

Warning Tag
Starting the engine or operating the controls while
other personnel are performing maintenance on the
truck can lead to serious injurty and/or death. Always To avoid serious personal injury or death, the
attach the warning tag to the control lever in the body-up retention cable must be installed
operator's cab to alert others that you are working on anytime personnel are required to perform
the truck. Attach additional warning tags around the maintenance on the vehicle with the dump body
truck, if necessary. in the raised position.
These tags are available from your Komatsu 1. To hold the dump body in the raised position,
distributor. Warning tag part number: 09963-03000 raise the body to its maximum height.

Stopping The Engine Before Service


• Before performing inspections or maintenance,
stop the truck on firm flat ground, lower the dump
body, move the directional control lever to PARK,
and stop the engine.
• If the engine must be run during service, such as
when cleaning the radiator, the directional control
lever must be in PARK. Always perform this work
with two people. One person must sit in the
operator's seat to stop the engine if necessary.
During these situations, never move any controls
that are not related to the task at hand.
• When servicing the truck, do not to touch any
moving parts. Never wear loose clothing or
jewelry.
FIGURE 3-1. BODY-UP RETENTION CABLE
• Put wheel blocks under the wheels to prevent
truck movement. INSTALLATION
1. Rear Body Ear
• When performing service with the dump body
2. Axle Housing Ear
raised, place the dump lever in the HOLD
position and apply the lock (if equipped). Install 3. Body-Up Retention Cable
the body-up safety pins or cable securely.
2. Install body-up retention cable (3, Figure 3-1)
Proper Tools between rear body ear (1) and axle housing ear
(4).
Only use tools that are suited to the task. Using
damaged, low quality, faulty or makeshift tools could 3. Secure the cable clevis pins with cotter pins.
cause personal injury. After service work is completed, reverse the
installation steps to remove the cable assembly.

A3-10 General Safety & Operating Instructions 5/08 A03039


WHILE PERFORMING MAINTENANCE Working Under The Truck
NOTE: Only authorized personnel should service • Always lower all movable work equipment to the
and repair the truck. ground or to their lowest position before
performing service or repairs under the truck.
Keep The Truck Clean • Always block the tires of the truck securely.
• Spilled oil, grease, scattered tools, etc., can • Never work under the truck if the truck is poorly
cause you to slip or trip. Always keep your truck supported.
clean and tidy.
• If water gets into the electrical system, there is
danger that the truck may may move
unexpectedly and/or damage to components may
occur. Do not use water or steam to clean any
sensors, connectors or the inside of the
operator's compartment.
• Use extreme care when washing the electrical
control cabinet. Do not allow water to enter the Rotating Fan And Belts
control cabinet around the doors or vents. Do not Stay away from all rotating parts such as the radiator
allow any water to enter the cooling air inlet duct
fan and fan belts. Serious bodily injury may result
above the electrical control cabinet. If water
enters the control cabinet through any opening or from direct or indirect contact with rotating parts and
crevice, major damage to the electrical flying objects.
components is possible.
• Never spray water into the rear wheel electric
motor covers. Damage to the wheel motor
armatures may occur.
• Do not spray water into the retarding grids.
Excess water in the retarding grids can cause a
ground fault, which will prevent propulsion.

Adding Fuel Or Oil


• Spilled fuel and oil may cause slipping. Always
clean up spills immediately.
• Always add fuel and oil in a well-ventilated area.
Attachments • When refueling, stop the engine and do not
smoke.
Place attachments that have been removed from the
truck in a safe place and manner to prevent them • Tighten the cap of the fuel and oil fillers securely.
from falling. • Never use fuel to wash parts.

A03039 5/08 General Safety & Operating Instructions A3-11


Radiator Water Level Precautions When Performing Maintenance Near
High Temperature Or High Pressure
If it is necessary to add coolant to the radiator, stop
the engine and allow the engine and radiator to cool Immediately after stopping operation, engine coolant
down before adding the coolant. Depress the and operating oils are at high temperature and under
pressure release button on the cap to vent cooling high pressure. If the cap is removed, the oil or water
system pressure. Slowly loosen the cap to relieve is drained, or the filters are replaced under these
any remaining pressure. conditions, it may result in burns or other injury. Wait
for the temperature to cool and pressure to subside
before performing the inspection and/or maintenance
as outlined in the shop manual.

Use Of Lighting
When checking fuel, oil, coolant or battery electrolyte, Precautions With High Pressure Oil
always use lighting with anti-explosion specifications.
If such lighting equipment is not used, there is danger • Work equipment circuits are always under
of an explosion. pressure. Do not add oil, drain oil or perform
maintenance or inspections before completely
releasing the internal pressure.
• Small, high-pressure pin hole leaks are extremely
dangerous. A jet of high-pressure oil can pierce
the skin and eyes. Always wear safety glasses
and thick gloves. Use a piece of cardboard or a
sheet of wood to check for oil leakage.
• If you are hit by a jet of high-pressure oil, consult
a doctor immediately for medical attention.
Precautions With The Battery
When repairing the electrical system or performing
electrical welding, remove the negative (-) terminal of
the battery to stop the flow of current.

Waste Materials
• Never dump oil into a sewer system, river, etc.
• Always put oil drained from your truck in
appropriate containers. Never drain oil directly
onto the ground.
• Obey appropriate laws and regulations when
Handling High Pressure Hoses disposing of harmful objects such as oil, fuel,
• Do not bend high pressure hoses or hit them with coolant, solvent, filters and batteries.
hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during
use.
• Always repair any loose or broken hoses. If fuel
or oil leaks, it may result in a fire.

A3-12 General Safety & Operating Instructions 5/08 A03039


TIRES
Handling Tires Storing Tires After Removal
If tires are not used under the specified conditions, • As a basic rule, store the tires in a warehouse in
they may overheat and burst, or be cut and burst by which unauthorized persons cannot enter. If the
sharp stones on rough road surfaces. This may lead tires are stored outside, always erect a fence
to serious injury or damage. around the tires and put up “No Entry” signs and
other warning signs that even young children can
To maintain tire safety, always use the specified tires. understand.
Inflate the tires to the specified pressure. An
• Stand the tire on level ground and block it
abnormal level of heat is generated when the inflation
securely so that it cannot roll or fall over.
pressure is too low.
• If the tire falls over, flee the area quickly. The tires
The tire inflation pressure and permissible speeds for dump trucks are extremely heavy. Never
are general values. The actual values may differ attempt to hold or support the tire. Attempting to
depending on the type of tire and the condition under hold or support a tire may lead to serious injury.
which they are used. For details, please consult the
tire manufacturer.
When tires become hot, a flammable gas is produced
and may ignite. It is particularly dangerous if the tires
become overheated while the tires are pressurized. If
the gas generated inside the tire ignites, the internal
pressure will suddenly rise and the tire will explode,
resulting in danger to personnel in the area.
Explosions differ from punctures or tire bursts
because the destructive force is extremely large.
Therefore, the following operations are strictly
prohibited when the tire is pressurized:
• Welding the rim
• Welding near the wheel or tire
• Smoking or creating open flames
If the proper procedure for performing maintenance
or replacement of the wheel or tire is not used, the
wheel or tire may burst and cause serious injury or
damage. When performing such maintenance,
consult your authorized regional Komatsu distributor
or the tire manufacturer.

A03039 5/08 General Safety & Operating Instructions A3-13


WHEN REPAIRS ARE NECESSARY
NOTE: Only qualified maintenance personnel who • Always fasten the welding machine ground (-)
understand the systems being repaired should lead to the piece being welded. The grounding
attempt repairs. clamp must be attached as near as possible to
the weld area. Never allow welding current to
• Many components on the Komatsu truck are pass through ball bearings, roller bearings,
large and heavy. Ensure that lifting equipment - suspensions or hydraulic cylinders. Always avoid
hoists, slings, chains, and lifting eyes - are of laying welding cables over or near the vehicle
adequate capacity to handle the lift. electrical harnesses. Welding voltage could be
• Do not work under a suspended load. Do not induced into the electrical harness and possibly
work under a raised body unless body safety cause damage to components.
cables, props or pins are in place to hold the • If the truck must be towed, use a rigid tow bar.
body in up position. Check the truck frame for a decal recommending
• Do not repair or service the truck while the engine special towing precautions. Also refer to
is running, except when adjustments can only be Operating Instructions - Section 30, Towing.
made under such conditions. Keep a safe • Drain, clean, and ventilate fuel tanks and
distance from moving parts. hydraulic tanks before making any welding
• When servicing any air conditioning system with repairs.
refrigerant, wear a face shield and cold resistant
gloves for protection against freezing. Follow all
current regulations for handling and recycling
refrigerants.
• Follow package directions carefully when using
cleaning solvents. Any operating fluid, such as hydraulic oil,
escaping under pressure can have sufficient
• If an auxiliary battery assist is needed, first use
force to enter a person's body by penetrating the
one cable to connect the 24V positive (+) post of
the disabled truck batteries to the 24V positive skin. Serious injury and possibly death may
(+) post of the auxiliary assist. Use a second result if proper medical treatment by a physician
cable to connect the 24V negative (-) post of the familiar with this injury is not received
auxiliary assist battery to a frame ground (-) on immediately.
the disabled truck away from the battery.
• Relieve pressure in lines or hoses before making
• Always disconnect the positive and negative any disconnects.
battery cables of the vehicle before doing any
• After adjustments or repairs, replace all shields,
welding on the unit. Failure to do so may
screens and clamps.
seriously damage the battery and electrical
equipment. Disconnect the battery charging • Only a qualified operator or maintenance
alternator lead wire and isolate the electronic personnel who are also qualified in truck
control components before making welding operation should move the truck under its own
repairs. (It is not necessary to disconnect or power in the repair facility or during road testing
remove any control circuit cards on electric drive after repairs are complete.
dump trucks or any of the AID circuit control
cards.)

A3-14 General Safety & Operating Instructions 5/08 A03039


SPECIAL PRECAUTIONS FOR WORKING Normal Engine Shutdown Procedure
ON AC DRIVE TRUCKS 1. Stop the truck out of the way of other traffic on a
dy, level surface (if possible) that is free of
Preliminary Procedures Before Welding overhead power lines or other obstructions in
or Performing Maintenance case the dump body should need to be raised.
Before welding or repairing an AC drive truck, a. Reduce engine speed to idle. Allow the
maintenance personnel should notify a Komatsu engine to cool gradually by running it at low
service representative. Only qualified personnel, idle for approximately 5 minutes.
specifically trained for servicing the AC drive system,
should perform this service. b. Place the directional control lever in PARK.
Make sure that the parking brake applied
If it is necessary to perform welding or repair to the indicator light in the overhead display panel
truck without the field engineer present, the following is illuminated.
procedures must be followed to ensure that the truck
is safe for maintenance personnel to work on and to 2. Place the rest switch in the ON position to put
reduce the chance for damage to equipment. the AC drive system in “rest” mode. Be sure the
“rest” indicator light in the overhead panel is
illuminated.
3. With the engine cooled down, turn the key
switch to the OFF position for normal engine
shutdown.
If the engine does not shutdown with the key
Anytime the engine is running, do not open any switch, use the engine shutdown switch on the
of the cabinet doors or remove any covers. Do operator cab center console. Pull this switch up
not use any of the power cables for hand holds or until the engine stops.
foot steps. Do not touch the retarding grid
elements. 4. With the key switch OFF and the engine
stopped, wait at least 90 seconds. Make sure
the steering circuit is completely bled down by
turning the steering wheel back and forth
several times. No front wheel movement will
occur when hydraulic pressure is relieved. If the
vehicle continues to steer after shutdown, notify
Before opening any cabinets or touching a maintenance personnel.
retarding grid element or a power cable, the
5. Verify that all the link voltage light in the control
engine must be shutdown and the red drive
cabinet is off. Notify maintenance personnel if
system warning lights must not be illuminated.
the light remains illuminated longer than five
minutes after engine shutdown.
6. Close and lock all windows, remove the key
from the key switch, and lock the cab to prevent
possible unauthorized truck operation.
Dismount the truck properly. Put wheel chocks
in place.

A03039 5/08 General Safety & Operating Instructions A3-15


Engine Shutdown Procedure Before Welding or 8. Power cables must be cleated in wood or other
Performing Maintenance non-ferrous materials. Do not repair cable
cleats by encircling the power cables with metal
Normal operation of the AC drive system at shutdown
clamps or hardware. Always inspect power
should leave the system safe to service. However, in
cable insulation before servicing the cables and
the event of a system failure, performing the following
returning the truck to service. Discard cables
procedure before any maintenance activities will
with broken insulation.
ensure that no hazardous voltages are present in the
AC drive system. 10. Power cables and wiring harnesses should be
protected from weld spatter and heat.
1. Before shutting down the engine, verify the
status of all the drive system warning lights on Always fasten the welding machine ground (-)
the overhead display panel. Use the lamp test lead to the piece being welded. The grounding
switch to verify that all lamps are functioning clamp must be attached as near as possible
properly. to the weld area.
If any of the red drive system warning lights Always avoid laying welding cables over or near
remain on, do not attempt to open any cabinets, the vehicle electrical harnesses. Welding
disconnect any cables, or reach inside the voltage could be induced into the electrical
retarding grid cabinet without a trained drive harness and cause damage to components.
system technician present, even if the engine is Before doing any welding on the truck,
off. Only qualified personnel, specifically trained disconnect the battery charging alternator lead
for servicing the AC drive system, should wire and isolate electronic control components.
perform this service. Also, always disconnect the negative and
positive battery cables of the vehicle. Failure to
2. If all red drive system warning lights are off,
do so may seriously damage the battery and
follow the Normal Engine Shutdown Procedure
electrical equipment.
on the previous page.
Never allow welding current to pass through ball
3. After the engine has been stopped for at least bearings, roller bearings, suspensions or
five minutes, inspect the link voltage lights on hydraulic cylinders.
the exterior of the main control cabinet and
back wall of the operator's cab (DID panel). If all 11. If the red lights on the exterior of the control
lights are off, it is safe to work on the retarding cabinet and/or the back wall of the operator's
grids, wheel motors, alternator and related cab continue to be illuminated after following
power cables. the above procedure, a fault has occurred.
Leave all cabinet doors in place. Do not touch
4. Locate the GF cut-out switch in the access
the retarding grid elements. Do not disconnect
panel on the left side of the main control
any power cables or use them as hand or foot
cabinet. Place the switch in the “alternator
holds.
cutout” position. This will prevent the alternator
from re-energizing and creating system voltage Notify your Komatsu service representative
until the switch is returned to its former position. immediately. Only qualified personnel,
specifically trained for servicing the AC drive
5. Before welding on the truck, disconnect all system, should perform this service.
electrical harnesses from the Engine Control
System (ECS) inside the electrical cabinet 12. Replace all covers and doors. Place the GF
behind the operator's cab. Also, disconnect the cutout switch and battery disconnect switches
ground strap from the ECS. in their original positions. Reconnect all
harnesses prior to starting the truck.
6. Do not weld on the rear of the control Leave the drive system in the rest mode until
cabinet! The metal panels on the back of the the truck is to be moved.
cabinet are part of capacitors and cannot be
heated.
7. Do not weld on the retarding grid exhaust
louvers! They are made of stainless steel.
Some power cable panels throughout the truck
are also made of aluminum or stainless steel.
They must be repaired with the same material
or the power cables may be damaged.

A3-16 General Safety & Operating Instructions 5/08 A03039


OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
The safest trucks are those which have been properly
prepared for operation. At the beginning of each shift,
a careful check of the truck should be made before
High voltage may be present on this truck! DO
attempting to start the engine.
NOT open any electrical cabinet doors on this
Safety is thinking ahead. Prevention is the best safety truck while the engine is running. Never climb on
program. Prevent a potential accident by knowing the any power cables or use power cables for
employer's safety requirements, all necessary job site handholds or footholds unless the engine has
regulations, and use and care of the safety been shut down and the system has been verified
equipment on the truck. Only qualified operators or to be at “rest”.
technicians should attempt to operate or maintain a
1. Start at left front of truck. Visually inspect all
Komatsu truck.
lights and safety equipment for damage. Make
Safe practices start before the operator gets to the sure that the lenses are clean and unbroken.
equipment. 2. Empty the dust collectors on the left side air
• Wear the proper clothing. Loose fitting clothing, cleaner assemblies. (A ladder may be
unbuttoned sleeves and jackets, jewelry, etc., necessary to reach the air cleaners.) Make sure
can catch on a protrusion and cause a potential that the battery box covers are in place and
hazard. secure.
• Always use the personal safety equipment 3. Move in front of the left front tire. Inspect the
provided for the operator such as hard hats, hub and brake assemblies for leaks and any
safety shoes, safety glasses or goggles. There abnormal conditions.
are some conditions when protective hearing
devices should also be worn for operator safety. 4. Make sure that all suspension mounting
hardware is secure. Inspect the mounting key
• When walking to and from the truck, maintain a
area for evidence of wear. Make sure that the
safe distance from all machines, even if the
operator is visible. suspension extension (exposed piston rod) is
correct and that there are no leaks.
WALK-AROUND INSPECTION 5. With the engine stopped, check the engine oil
level. Use the service light, if necessary.
At the beginning of each shift, a careful walk-around
inspection should be performed before attempting to 6. Inspect the air conditioner belts for correct
start the engine. A walk-around inspection is a tension, obvious wear, and tracking. Make sure
systematic ground level inspection of the truck and its that the fan guard is secure and in good
components to ensure that the truck is safe to condition. When leaving this point, turn off the
operate before entering the operator's cab. service light if used.
Start at the left front corner of the truck (see the 7. Make sure that the anchor end of the steering
illustration on the next page) and move in a cylinder is secure and properly greased.
counterclockwise direction. Move front-to-rear, 8. Move outside of the front wheel. Make sure that
across the rear, and continue forward up the opposite all of the mounting nuts/studs are in place and
side of the truck to the original starting point. tight. Check the tires for cuts, damage, or
If these steps are performed in sequence and are bubbles. Check for evidence of incorrect tire
repeated from the same point and in the same inflation.
direction before every shift, many potential problems 9. Move in behind the front wheel. Make sure that
may be avoided or scheduled for maintenance. the steering cylinder is properly greased and
Unscheduled downtime and loss of production can be the mounting hardware is tight. Check the
reduced as a result. suspension mounting hardware and suspension
Local work practices may prevent an operator from extension. Make sure that the suspension
performing all tasks suggested here. To the extent protective boot is in good condition. Inspect the
permitted, the operator should follow this routine. hub and brakes for any unusual conditions.
Check the entire area for leaks.

A03039 5/08 General Safety & Operating Instructions A3-17


START HERE

A3-18 General Safety & Operating Instructions 5/08 A03039


10. Inspect the sight glass on the hydraulic tank. 21. Make sure that all wheel nuts/studs are in place
With the engine stopped and the body down, and tight. Inspect the wheel for any oil that
the hydraulic oil level must be visible in the would indicate brake leakage or wheel motor
center of the upper sight glass. leakage.
11. Verify that all hydraulic tank shut-off valves are 22. Move in front of right dual tires. Inspect the hoist
locked in their fully open positions. cylinder in the same manner as the left side.
Make sure the body-up limit switch is secure
12. Move around the hydraulic tank and in front of
and in good condition. Remove any mud or dirt
the rear dual tires. Inspect the hoist cylinder for
accumulation from the switch.
any damage and leaks. Make sure that both
upper and lower hoist cylinder pins are secure 23. Move around the fuel tank. Make sure that the
and properly greased. fuel gauge agrees with the fuel gauge in the
cab. Inspect the mounting hardware for the fuel
13. Look under the lower edge of the chassis to
tank at the upper saddles and at the lower back
make sure that the flexible duct that carries the
side of the tank. Check the hoist filters for leaks.
air from the main blower to the final drive
housing is in good condition. Also, look up at 24. Move in behind the right front wheel. Make sure
the main hydraulic pumps to see if there is any that the steering cylinder is properly greased
leakage or any other unusual condition with the and the mounting hardware is secure. Check
pumps or pump drive shafts. the suspension mounting hardware and
suspension extension. Make sure that the
14. Move around the left side dual tires. Make sure
suspension protective boot is in good condition.
that all wheel nuts/studs are in place and tight.
Inspect the hub and brakes for any unusual
Inspect the wheel for any oil that would indicate
conditions. Check the entire area for leaks.
brake leakage or wheel motor leakage.
25. Move out and around the right front wheel.
15. Check the dual tires for cuts, damage, and
Make sure that all wheel nuts/studs are in place
bubbles. Verify that tire inflation is correct. If the
and tight.
truck has been run on a “flat”, the tire must be
cooled before moving the truck inside. Check 26. Move behind the front of the right front wheel.
for any rocks that might be lodged between the Check the hub and brakes for leaks and any
dual tires. unusual conditions. Make sure that the steering
cylinder is secure and properly greased. Inspect
16. Inspect the left rear suspension for damage,
the engine compartment for any leaks and
correct rod exposure, and leaks. Ensure that
unusual conditions. Inspect the fan guard and
the covers over the chrome piston rod are in
belts. Check for any debris behind the radiator.
good condition.
27. Move around to the right front of the truck.
17. Open the rear hatch cover. Inspect for leaks
Empty the dust collectors on the right side air
around the parking brakes. Make sure the
cleaner assemblies. (A ladder may be
cooling air exhaust ductwork is intact and there
necessary to reach the air cleaners.)
are no obstructions.
28. As you move in front of the radiator, remove any
18. While standing at the rear hatch, look up to
debris that is stuck in front of the radiator.
check that the rear lights and back-up horns are
Check for any coolant leaks. Inspect the
in good condition. Look up at panhard rod to
headlights and fog lights.
check that it is properly greased. Also check
both body hinge pins for proper greasing and 29. Inspect the auto lube system. See Section P3,
any abnormal condition. Check the hoist limit Automatic Lubrication System, for more
switch and clear any mud or debris from the information about the auto lube system.
contacts. 30. Before climbing the ladder to first level, make
19. Perform the same inspections on the right rear sure that the ground level engine shutdown
suspension. switch is ON. Inspect the fire control actuator.
Make sure that the safety pin and the plastic tie
20. Move around the right side dual tires. Inspect
that prevents accidental actuation are in place
between the tires for rocks. Inspect the tires for
and in good condition. Make sure that the
cuts, damage and proper inflation.
battery disconnect switches are activated.

A03039 5/08 General Safety & Operating Instructions A3-19


ENGINE START-UP

Always mount and dismount ladders facing the


truck. Never attempt to mount or dismount while Never attempt to start the engine by shorting
the truck is in motion. across the starter terminals. This may cause fire,
31. Always use handrails and ladders when or serious injury or death to anyone in the
mounting or dismounting the truck. Clean any machine’s path. Start the engine from the
foreign material such as ice, snow, oil or mud operator’s seat only.
from the ladders and handrails. If the truck is equipped with an auxiliary cold
weather heater system, do not attempt to start
the engine while the heaters are in operation.
Damage to the coolant heaters will result!

If the engine has been running, allow the coolant


to cool before removing the fill cap or draining
the radiator. Serious burns may result if skin
comes in contact with hot coolant.
32. Use the coolant level sight gauge to check the
coolant level in the radiator. If it is necessary to
remove the radiator cap, make sure that the
engine is off, then relieve the coolant pressure
by slowly removing the radiator cap.
33. Inspect the retarding grid covers. Make sure
that the latches are in place and secure. Inspect
the main air inlet to ensure that it is clear. Make
sure that all cabinet door latches are secure.
34. Move around to the rear of the cab. Open the
doors of the brake cabinet and check inside the
cabinet for leaks. 1. Make sure that all personnel are clear of the
truck before starting the engine. Always sound
35. Clean the cab windows and mirrors. Clean out the horn as a warning before moving any
the cab floor, if necessary. Make sure that the controls.
steering wheel, operator controls, and pedals
are free of any grease or mud. 2. If the truck is in an enclosure, make sure that
there is adequate ventilation before start-up.
36. Stow any personal gear in the cab so that it Exhaust fumes are dangerous!
does not interfere with any operation of the
truck. Dirt or trash buildup, specifically in the 3. Make sure that the directional control lever is in
operator's cab, should be cleared. Do not carry PARK before starting.
tools or supplies in the cab or on the deck. 4. Place the rest switch in the ON position to put
37. Adjust the seat and the steering wheel for the drive system in rest mode. For more
most operator comfort. information, refer to Section N5, Operator Cab
Controls.
38. Before operating the truck, read about and
understand the locations and functions of all
operator controls listed in Section N5, Operator
Cab Controls.

A3-20 General Safety & Operating Instructions 5/08 A03039


AFTER ENGINE HAS STARTED

Do not crank an electric starter for more than 30


seconds. Allow two minutes for cooling before
attempting to start the engine again. Severe Do not leave the truck unattended while the
damage to the starter motors can result from engine is running. Move the directional control
overheating. lever to PARK and turn off the engine before
leaving the truck.
5. The key switch is a three-position switch
(OFF, RUN, START). Become thoroughly familiar with the steering, braking
and emergency controls.
a. Turn the key switch one position clockwise to
the RUN (not START) position. All electrical 1. After the engine has been started and the low
circuits except the start circuit are activated. pressure warning systems are normal, test the
steering by turning the steering wheel fully to
b. Turn the key switch fully clockwise to the the left and right.
START position and hold this position until
If the steering system is not operating properly,
the engine starts. The START position is
turn the engine immediately. Determine the
spring-loaded and will return the switch to
steering system problem and have it repaired
the RUN position when the key is released.
before resuming operation.
NOTE: This truck is equipped with an engine prelube
2. Operate each of the truck's brake circuits at
system. With this feature, a noticeable time delay
least twice before operating and moving the
may occur before engine cranking begins as the
truck. These circuits include the service brake,
engine lube oil passages are being filled and
parking brake, and brake lock. With the engine
pressurized.
running and the hydraulic circuit fully charged,
6. After the engine has started, place the rest activate each circuit individually from the
switch in the OFF position to deactivate the rest operator's cab.
mode. Refer to Section N5, Operator Cab If any application or release of any brake circuit
Controls for more information on the rest switch. appears sluggish or improper, or if warning
alarms are activated, turn off the engine and
notify maintenance personnel immediately. Do
not operate the truck until the faulty brake circuit
is fully operational.
3. Check the gauges, warning lights, and
instruments before moving the truck to ensure
proper system operation and proper instrument
functioning. Pay special attention to the braking
and steering hydraulic circuit warning lights. If
warning lights come on, turn off the engine
immediately and determine the cause.
4. Make sure that the headlights, worklights, and
taillights are in proper working order. Check the
operation of windshield wiper. Good visibility
may help prevent an accident.

A03039 5/08 General Safety & Operating Instructions A3-21


EMERGENCY STEERING SYSTEM
Operation
This truck is equipped with an emergency steering b. Steering accumulator precharge: Verify that
system. This system is a backup in the event of loss the low accumulator precharge warning light
of oil supply to the main steering system. The is not illuminated and the warning buzzer is
emergency steering system was designed to meet or not sounding. If the warning light is
exceed SAE J1511 and ISO 5010 standards. illuminated and the buzzer is sounding,
immediately notify maintenance personnel.
If the low steering system pressure indicator light and Do not operate the truck until the problem is
alarm are activated, a failure in the hydraulic oil corrected.
supply to the steering and brake system exists. When
5. Start the engine and allow the steering
the alarm is activated, typically there is enough
accumulators to fully charge. Turn the steering
hydraulic pressure stored in the brake and steering
wheel so that the front wheels are straight.
accumulators to allow brief operation of the steering
and brake functions. However, this oil supply is 6. Check the hydraulic tank oil level while the
limited. Therefore, it is important to stop the truck as engine is on.
quickly and safely as possible after the alarm is first a. If the oil level is visible in center of the lower
activated. sight glass and does not cover the entire
If the oil supply pressure drops to a predetermined lower sight glass, the steering accumulators
level, the low brake pressure warning light will also are adequately charged. Proceed to Step 7.
illuminate. If the oil pressure continues to decrease, b. If the oil level is below the lower sight glass,
the brake auto-apply feature will activate the service the steering accumulators are not
brakes to stop the truck. adequately charged. Stop the engine and
turn the key switch to the OFF position.
Pre-Operation Testing
Immediately notify maintenance personnel.
NOTE: Komatsu recommends that operators perform Do not operate the truck until the problem is
this test to verify that the steering accumulator corrected.
precharge pressure is adequate at the beginning of 7. If the steering accumulators are adequately
each shift before operating the truck. charged, stop the engine by pulling up the
1. Park the empty truck on flat, level ground. engine shutdown switch. Leave the key switch
Lower the dump body onto the frame and stop in the ON position. This allows the steering
the engine. Make sure that the key switch is in accumulators to retain their hydraulic charge.
the OFF position. The low steering pressure warning light and the
low accumulator precharge warning light should
2. Wait at least 90 seconds to verify that all
not illuminate.
hydraulic pressure has been relieved from the
steering accumulators. Turn the steering wheel 8. Turn the steering wheel from stop to stop. The
from stop to stop. If the front wheels do not front wheels should turn fully to the left and to
move, there is no hydraulic pressure. the right. Also, the low steering pressure
warning light should illuminate and the warning
3. Check the hydraulic tank oil level. The oil level
buzzer should sound.
must be visible in the center of the upper sight
glass and must not cover the entire upper sight If the front wheels cannot be turned fully to the
glass. Add oil if necessary. Do not overfill. left and right, or if the warning light and buzzer
do not activate, immediately notify maintenance
4. Turn the key switch to the ON position, but do personnel. Do not operate the truck until the
not start the engine. problem is corrected.
a. Steering system pressure: Verify that the low If the truck passes this test, the emergency steering
steering pressure warning light is system is functioning properly.
illuminated. If it is not illuminated,
immediately notify maintenance personnel.
Do not operate the truck until the problem is
corrected.

A3-22 General Safety & Operating Instructions 5/08 A03039


MACHINE OPERATION SAFETY • Do not allow unauthorized personnel to ride in or
PRECAUTIONS on the truck. Do not allow anyone to ride on the
ladder of the truck.
After the engine is started and all systems are
• Check the gauges and instruments frequently
functioning properly, the operator must follow all local
during operation for proper readings.
safety rules to ensure safe machine operation.
• Observe all regulations pertaining to the job site's
traffic pattern. Be alert to any unusual traffic
pattern. Obey the spotter's signals.
• Match the truck speed to haul road conditions.
Slow down the truck in congested areas. Keep a
If any of the red warning lights come on or if any firm grip on the steering wheel at all times.
gauge reads in the red area during truck
• Do not allow the engine to run at idle for
operation, a malfunction is indicated. Stop the
extended periods of time.
truck as soon as possible and turn off the engine.
Have the problem corrected before resuming • When the truck body is in the dump position, do
truck operation. not allow anyone beneath it unless the body-up
retaining pin or cable is in place.

The truck is equipped with “slip/slide” control. If


Do not use the brake lock or the emergency
this function becomes inoperative, operating the
brake (if equipped) for parking. With the engine
truck with stalled or free spinning wheel motors
stopped, hydraulic pressure will bleed down,
may cause serious damage to the wheel motors.
allowing the brakes to release.
If the truck does not begin to move within 10
seconds after depressing the throttle pedal with • Check the brake lock performance periodically
the directional control lever in a F or R position, for safe loading and dump operation.
release the throttle pedal and allow the wheels to • Proceed slowly on rough terrain to avoid deep
regain traction before accelerating again. ruts or large obstacles. Avoid traveling close to
• Always look to the rear before backing the truck. soft edges or the edge of a fill area.
Watch for and obey the ground spotter's hand • Do not drive over unprotected power cables.
signals before making any reverse movements.
Sound the warning horn (three blasts). The • Truck operation requires concentrated effort by
spotter should have a clear view of the entire the driver. Avoid distractions of any kind while
area at the rear of the truck. operating the truck.

• Operate the truck only while properly seated with


seat belt fastened. Keep hands and feet inside
the cab while the truck is in operation.

A03039 5/08 General Safety & Operating Instructions A3-23


OPERATING ON THE HAUL ROAD 9. When operating the truck in darkness, or when
visibility is poor, do not move the truck unless all
1. Always stay alert! If you are unfamiliar with the
headlights, clearance lights, and tail lights are
road, drive with extreme caution. The cab doors
on. Do not back up the truck if the back-up horn
should remain closed at all times if the truck is
or lights are inoperative. Always dim the
in motion or unattended.
headlights when meeting oncoming vehicles.
2. Obey all road signs. Operate the truck so it is
10. If the emergency steering light and/or low brake
under control at all times. Govern the truck
pressure warning light illuminate during
speed by the road conditions, weather, and
operation, steer the truck immediately to a safe
visibility. Report poor haul road conditions
area away from other traffic, if possible, and
immediately. Muddy or icy roads, pot holes, or
stop the truck. Refer to Step 7.
other obstructions can present hazards.
11. Check the tires for proper inflation periodically
3. Initial propulsion with a loaded truck should during your shift. If the truck has been run on a
begin from a level surface whenever possible. If “flat”, or under-inflated tire, it must not be
there are circumstances where starting on a hill parked in a building until the tire cools.
or grade cannot be avoided, refer to Starting On
a Grade With a Loaded Truck.
4. When backing up the truck, give a back-up STARTING ON A GRADE WITH A
signal of three blasts on the horn. When starting
LOADED TRUCK
forward, give two blasts on the horn. These
signals must be given each time the truck is Initial propulsion with a loaded truck should begin
moved forward or backward. from a level surface whenever possible. If the truck
must be started on a hill or grade, use the following
5. Use extreme caution when approaching a haul procedure:
road intersection. Maintain a safe distance from
oncoming vehicles. 1. Fully depress the service brake pedal. Do not
use the retarder lever to hold the truck on the
6. Maintain a safe distance when following grade. With the service brakes fully applied,
another vehicle. Never follow another vehicle in move the directional control lever to a drive
the same lane closer than 15 m (50 ft). When position (FORWARD or REVERSE) and
driving on a downgrade, this distance should be increase the engine rpm with the throttle pedal.
at least 30 m (100 ft).
2. As the engine rpm approaches the maximum,
7. Do not stop or park on a haul road unless it is and the operator senses the propulsion effort
unavoidable. If you must stop, move the truck to working against the brakes, release the brakes
a safe place, move the directional control lever and let truck movement start. Completely
to PARK and turn off the engine before leaving release the service brake pedal. As the truck
the cab. Chock the wheels securely and notify speed increases above 5-8 kph (3-5 mph), the
maintenance personnel for assistance. propulsion system controller (PSC) will drop the
8. Before driving up or down a grade, maintain a propulsion if the retarder is still applied.
speed that will ensure safe driving and provide NOTE: Releasing and re-applying dynamic retarding
effective retarding under all conditions. Refer to during a hill start operation will result in loss of
Dynamic Retarding in Section N5, Operator propulsion.
Cab Controls. Refer to the grade/speed chart in
the operator's cab to determine the maximum
safe truck speeds for descending various
grades with a loaded truck.

A3-24 General Safety & Operating Instructions 5/08 A03039


PASSING 4. When the truck is stopped and in the dump
position, apply the brake lock and move the
1. Do not pass another truck on a hill or blind
directional control lever to NEUTRAL.
curve. Only use areas designated for passing.
2. Before passing, make sure that the road ahead
is clear. If a disabled truck is blocking your lane,
slow down and pass with extreme caution.

LOADING Dumping very large rocks (10% of payload or


greater) or sticky material (loads that do not flow
1. Pull into the loading area with caution. Remain
freely from the body) may allow the material to
at a safe distance while the truck ahead is being
move too fast and cause the body to move
loaded.
rapidly and suddenly. This sudden movement
2. When approaching or leaving a loading area, may jolt the truck violently and cause possible
watch out for other vehicles and personnel injury to the operator and/or damage to the hoist
working in the area. cylinders, frame, and/or body hinge pins.
3. When pulling in under a loader or shovel, follow
the spotter or shovel operator’s signals. The
truck operator may speed up loading operations
by observing the location and loading cycle of
the truck being loaded ahead, then follow a
similar pattern.
4. During loading, the operator must stay in the
cab with the engine running. Place the
directional control lever in NEUTRAL and apply
the brake lock.
5. When loaded, pull away from shovel as quickly
as possible but with extreme caution.
5. Pull the lever to the rear to actuate the hoist
DUMPING circuit. Releasing the lever anywhere during
“hoist up” will hold the body at that position.
Raising The Dump Body
6. Raise the engine rpm to accelerate the hoist
1. Pull into the dump area with extreme caution. speed.
Make sure the area is clear of persons and If dumping very large rocks or sticky material as
obstructions, including overhead utility lines. described in the WARNING above, slowly
Obey signals directed by the spotter, if present. accelerate the engine to raise the body. When
2. Avoid unstable areas. Stay a safe distance from the material starts to move, release the hoist
the edge of the dump area. lever to the HOLD position. If the material does
not continue moving and clear the body, repeat
this procedure until the material has cleared the
body.
7. Reduce the engine rpm as the last stage of the
To prevent tipping or rolling, position the truck hoist cylinder begins to extend. Let the engine
on a solid, level surface before dumping. As the go to low idle as the last stage reaches half-
body raises, the truck center of gravity will move. extension.

3. Carefully maneuver the truck into the dump 8. Release the hoist lever as the last stage of the
position. When backing the truck into the dump hoist cylinder reaches full extension.
position, use only the foot-operated brake pedal 9. After the material being dumped clears the
to stop and hold the truck. Do not rely on the body, lower the body to the frame.
wheel brake lock to stop the truck. This control
is not modulated and applies the rear service
brakes only.

A03039 5/08 General Safety & Operating Instructions A3-25


Lowering The Dump Body Lowering The Dump Body
(When dumping on flat ground): (When dumping over a berm or into a crusher):
It is very likely when dumping on flat ground that the 1. Move the hoist lever forward to the DOWN
dumped material will build up enough to prevent the position. Release the lever to place the hoist
body from lowering. In this case, the truck will have to control valve in the FLOAT position, which
be driven forward a short distance (just enough to allows the body to return to the frame.
clear the material) before the body can be lowered.
1. Move the directional control lever to If dumped material builds up at the rear of the
FORWARD, release the brake lock, depress the body and the body cannot be lowered, perform
override button, and drive just far enough the following steps:
forward for the body to clear the material. a. Move hoist lever back to the HOIST position
2. Stop, move the directional control lever to to fully raise the dump body. Release the
NEUTRAL, and apply the brake lock. hoist lever so it returns to the HOLD position.
3. Move the hoist lever forward to the DOWN NOTE: Do not drive forward if the tail of body will not
position. Release the lever to place the hoist clear the crusher wall in the fully raised position.
control valve in the FLOAT position, which b. Move the directional control lever to
allows the body to return to the frame. FORWARD, release the brake lock, depress
If dumped material builds up at the rear of the the Override button, and drive forward to
body and the body cannot be lowered, then clear the material.
perform the following steps:
c. Stop, move the directional control lever to
a. Move the hoist lever back to the RAISE NEUTRAL, apply the brake lock and lower
position to fully raise the dump body. Then the body.
release the hoist lever so it returns to the
NOTE: Failure to hoist the body after making an
HOLD position.
unsuccessful attempt at lowering the body may result
b. Move the directional control lever to in the dump body suddenly lowering after the truck
FORWARD, release the brake lock, depress has pulled ahead of the material that was previously
the override button, and drive forward to preventing the body from lowering.
clear the material.
c. Stop, move the directional control lever to
NEUTRAL, apply the brake lock, and lower
the body.
NOTE: Failure to hoist the body after making an
unsuccessful attempt at lowering the body may result
in the dump body suddenly lowering after the truck
has pulled ahead of the material that was previously
preventing the body from lowering. Do not move the truck with the dump body raised
except in an emergency. Failure to lower the
body before moving the truck may cause damage
to the hoist cylinders, frame and/or body hinge
pins.

2. With the body returned to the frame, move the


Do not move the truck with the dump body raised directional control lever to FORWARD, release
except in an emergency. Failure to lower body the brake lock, and leave the dump area
before moving truck may cause damage to hoist carefully.
cylinders, frame and/or body hinge pins.
4. With the body returned to frame, move the
directional control lever to FORWARD, release
the brake lock, and leave the dump area
carefully.

A3-26 General Safety & Operating Instructions 5/08 A03039


TOWING SAFE PARKING PROCEDURES
Before towing a truck, many factors must be carefully Continue to use safety precautions when preparing
considered. Serious personal injury and/or significant for parking and engine shutdown.
property damage may result if important safety
If the equipment is being used in consecutive shifts,
practices, procedures and preparation for moving
any questionable truck performance the operator
heavy equipment are not observed. Do not tow the
may have noticed must be checked by maintenance
truck any faster than 8 kph (5 mph).
personnel before the truck is released to another
Information about the towing attachments listed operator.
below is available from your Komatsu service
1. Park the truck on level ground, if possible. If the
representative:
truck must be parked on a grade, position the
Front Bumper Modification Kit - MK3941: This kit truck at a right angle to the grade.
contains the parts necessary to modify the front 2. The directional control lever must be in PARK
bumper for installation of towing bosses. One and chocks must be placed in front of and
MK3941 kit is required for each truck in the fleet. behind the wheels so the truck cannot roll. Each
Tow Adaptor Structure - MK3945: This structure truck should be parked at a reasonable distance
must be ordered (or designed) to mate with the from one another.
intended towing vehicle and is intended for towing an
unloaded vehicle only.
A disabled machine may be towed after the following
precautions have been taken.
1. Turn off the engine. Do not activate the wheel lock feature when the
2. If the truck is equipped, install hydraulic parking brake is activated. Bleed down of
connections for steering and dumping between hydraulic pressure may occur, causing the truck
towing and towed vehicles. Check the towed to roll away.
vehicle braking system. 3. Haul roads are not safe parking areas. In an
3. If the truck is loaded, dump the entire load. emergency, pick the safest spot that is most
Never pull or tow a loaded truck. Refer to visible to other machines in the area. If the truck
Disabled Truck Dumping Procedure. becomes disabled where traffic is heavy, mark
the truck with warning flags in daylight or flares
4. Make sure that the tow bar has adequate
at night.
strength (approximately 1.5 times the gross
vehicle weight of truck being towed).
5. Make sure that the towing vehicle has adequate
capacity to both move and stop the towed truck
under all conditions.
6. Chock the disabled truck’s wheels to prevent
movement while attaching the tow bar.
7. Release the disabled truck’s brakes and
remove the blocking.

Sudden movement may cause tow bar failure.


Smooth, gradual truck movement is preferred.
8. Minimize the tow angle at all times. Never
exceed 30 degrees. The towed truck must be
steered in the direction of the tow bar.

A03039 5/08 General Safety & Operating Instructions A3-27


NORMAL ENGINE SHUTDOWN DELAYED ENGINE SHUTDOWN
PROCEDURE PROCEDURE
Follow this procedure at each engine shutdown. 1. Stop the truck out of the way of other traffic on a
level surface and free of overhead power lines
1. Stop the truck out of the way of other traffic on a
or other obstructions in case dump body needs
level surface. Make sure that there are no
to be raised.
overhead power lines or other obstructions in
case the dump body must be raised. a. Reduce the engine speed to low idle.
a. Reduce the engine speed to idle. b. Place the directional control lever in PARK.
Make sure that the parking brake applied
b. Place the directional control lever in PARK.
indicator light in the overhead display panel
Make sure that the parking brake applied
is illuminated.
indicator light is illuminated.
2. Place the rest switch in the ON position to put
c. Allow the engine to cool gradually by running
the AC drive system in the rest mode. Make
at low idle for 3 to 5 minutes, or activate the
sure that the rest mode indicator light in the
5 minute shutdown delay timer as described
overhead panel is illuminated.
in “Delayed Engine Shutdown Procedure”.
3. Press the top of the engine
2. Place the rest switch in the ON position to put
shutdown timer switch to select
the AC drive system in the rest mode. Make
the ON (center) position. Press
sure that the rest mode indicator light in the
the top of the switch again to
overhead panel is illuminated.
activate the timer delay
3. With the engine cooled down, turn the key (MOMENTARY position). Release the switch
switch to the OFF position for normal engine and allow it to return to the ON position.
shutdown.
If the engine does not shutdown with the key When the engine shutdown timer
switch, use the engine shutdown switch on the has been activated, the timer
operator cab center console. Pull this switch up delay indicator light in the
until the engine stops. overhead panel will illuminate to
4. With the key switch OFF and engine stopped, indicate that the shutdown timing
wait at least 90 seconds. Make sure that the sequence has started. The engine will continue
steering circuit is completely bled down by to idle for approximately 5 minutes to allow for
turning the steering wheel back and forth proper engine cool-down before stopping.
several times. The front wheels should not turn
when the hydraulic pressure is relieved. If the
4. Turn the key switch to the OFF position. The
front wheels can still be turned, notify
engine will shutdown when the timing sequence
maintenance personnel.
is complete. When the engine stops, this will
5. Make sure that the link voltage light in the activate the hydraulic bleeddown timer and turn
control cabinet is off. Notify maintenance off the 24 VDC electric circuits that are
personnel if a light remains illuminated for controlled by the key switch.
longer than five minutes after the engine is shut
NOTE: To cancel the 5 minute idle timer sequence,
down.
press the engine shutdown timer switch to the OFF
6. Close and lock all windows. Remove the key (lower) position. If the key switch is in the OFF
from the key switch and lock the cab to prevent position, the engine will stop. If the key switch is in
unauthorized truck operation. Dismount the the ON position, the engine will continue to run.
truck properly. Put wheel chocks in place.

A3-28 General Safety & Operating Instructions 5/08 A03039


SUDDEN LOSS OF ENGINE POWER FUEL DEPLETION
If the engine suddenly stops, there is enough The high pressure injection (HPI) fuel system uses
hydraulic pressure stored in the brake and steering fuel to adjust fuel delivery timing by creating a
accumulators to allow the operation of the steering hydraulic link between the upper plunger and the tim-
and brake functions. However, this oil supply is ing plunger. Metered fuel is also used for lubricating
limited, so it is important to stop the truck as quickly the injector plunger and barrel. The maximum
and safely as possible after the loss of engine power. demand for metered fuel is required during high
speed / low load conditions.
If the brake supply pressure drops to a pre-
determined level, the low brake oil pressure warning
light will illuminate and sonalarm will sound. If the
brake pressure continues to decrease, the auto-apply
feature will activate and the service brakes will apply
automatically to stop the truck.
Operating the truck to fuel depletion forces the
1. Bring the truck to a safe stop as quickly as injector train into a no-follow condition. No fuel
possible by using the foot pedal to apply the flow between the plungers may cause damage to
service brakes. If possible, safely steer the the injectors and the overhead due to adhesive
truck to the side of the road while braking. wear, resulting in costly repairs and unnecessary
downtime.

Dynamic retarding will not be available. Do not


use the service brakes for continuous retarding Allowing the Komatsu truck to operate until fuel
purposes. depletion can lead to unsafe operating
2. Move the directional control lever to PARK as conditions possibly resulting in an
soon as the truck has stopped moving. uncontrollable vehicle and/or personal injury.
3. Turn the key switch to the OFF position and
notify maintenance personnel immediately.
4. If traffic is heavy near the disabled machine,
mark the truck with warning flags during
daylight hours or use flares at night. Adhere to
local regulations.

A03039 5/08 General Safety & Operating Instructions A3-29


DISABLED TRUCK DUMPING b. Remove the cap from the hoist pilot valve
PROCEDURE relief valve (2), located in the hydraulics
components cabinet behind the cab. While
Sometimes it is necessary to dump a load from the counting the number of turns, slowly turn the
body of a truck if the hoist system is inoperable. The relief valve adjustment screw clockwise until
following instructions describe the use of a “good” it bottoms. Repeat Step 2.
truck to provide the hydraulic power required to raise
the body of the “disabled” truck to dump the load.
In the following example, Figure 3-2 illustrates a
typical hookup from the good truck. The disabled
truck may be the same truck model or a different
Komatsu truck model.

Hookup
Make sure that there is an adequate, clear area to
dump the loaded body. When the good truck is in
position, turn off the engine and allow the hydraulic
system to bleed down. Make sure that the pressure
has bled off before connecting the hoses.
1. With the good truck parked as close as possible
to the disabled truck, attach a hose from the
power up quick disconnect (4, Figure 3-2) to FIGURE 3-2. PUMP MODULE, HOSE HOOKUP
the power down circuit of the disabled truck.
The hose must be rated to withstand 17,000 1. Hoist Valve
kPa (2500 psi) or greater pressure. 2. Tubes to LH Hoist Cylinder
3. Power Down Quick Disconnect (Connect to power
NOTE: The power down circuit will use a smaller up circuit of disabled truck.)
diameter hose (tube) than the power up circuit. 4. Power Up Quick Disconnect (Connect to power
down circuit of disabled truck.)
2. Connect another hose from the power down
5. Overcenter Manifold
quick disconnect (3) to the power up circuit of
the disabled truck.
Lowering the Body
NOTE: If both trucks are the same model, the hoses
1. Place the hoist lever of the good truck in FLOAT
will be installed at the quick disconnects shown in
to lower the body. If necessary, momentarily
Figure 30-1 and will be crossed when connected.
place the hoist control in POWER UP until the
Raising the Body body is able to descend in FLOAT. Do not
accelerate the engine.
1. On the disabled truck, move the hoist control
lever to power up and then release it to place 2. After the body is lowered, shut down the truck,
the hoist pilot valve in the HOLD position (leave bleed the hydraulic system, and disconnect the
in this position during entire procedure). hoses.

2. Start the engine on the good truck, place the 3. Reduce the power down relief valve pressure
hoist control in the POWER DOWN position and on the good truck to normal by turning the
increase the engine rpm to high idle to dump adjustment counterclockwise the same number
the disabled truck. If the body of the disabled of turns as required in Step 2b of “Raising the
truck fails to raise, increase the good truck Body.”
power down relief pressure as follows: 4. Check the power down relief pressure. Refer to
a. Shut down engine and allow the hydraulic Section L10, Hydraulic Check-Out Procedure.
system to bleed down. 5. Check the hydraulic tank oil level.

A3-30 General Safety & Operating Instructions 5/08 A03039


WARNINGS AND CAUTIONS
The following pages give an explanation of the KEY SWITCH
warning, caution, and service instruction plates and
A warning decal is below the key switch located to
decals attached to the truck. The plates and decals
the right of the steering column on the instrument
listed here are typical of this Komatsu model, but
panel. The warning stresses the importance of
because of customer options, individual trucks may
have plates and decals that are different from those reading the operator's manual before operation.
shown here.
The plates and decals must be kept clean and
legible. If any decal or plate becomes damaged or
illegible, replace it with a new one.

GRADE/SPEED CHART
A grade/speed retard chart is located on the left front
post of the operator's cab. It provides the
recommended maximum speeds to be used when
descending various grades with a loaded truck.
Always refer to the decal in operator's cab. This
decal may change with optional truck equipment
such as wheel motor drive train ratios, retarding
grids, tire sizes, etc.

ROPS/FOPS
A plate attached to the right rear corner of the cab
states that the Rollover Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS) meet
various SAE performance requirements.
The plate also contains a WARNING about making
modifications or repairs to the structure.
Unauthorized modifications or repairs will void the
certification.

A04061 Warnings and Cautions A4-1


BATTERIES CRUSHING HAZARD
Attached to the exterior of both battery Warning plates are mounted on the frame in front of
compartments is a danger decal which stresses the both front tires and to the rear of both front tires.
need to keep from making any sparks near the They warn that the clearances change when the
battery. When another battery or 24VDC power truck is steered and could cause serious injury.
source is used for auxiliary power, all switches must
be OFF before making any connections. When
connecting auxiliary power cables, positively
maintain correct polarity. Connect the positive (+)
posts together and then connect the negative (-) lead
of the auxiliary power cable to a good frame ground.
Do not connect to the negative posts of the truck
battery or near the battery box. This hookup
completes the circuit but minimizes the danger of
sparks near the batteries.
Sulfuric acid is corrosive and toxic. Use proper safety
gear, goggles, rubber gloves and a rubber apron
when handling and servicing batteries. If sulfuric acid Warning plates are attached to both the hydraulic
is swallowed, gets into your eyes or contacts your tank and fuel tank to alert technicians not to work on
skin, get proper medical help immediately. the truck with the body in the raised position unless
the body-up retention device (pins or cable) is in
position.

This decal is placed on both battery boxes and near


the battery disconnect switches to indicate that the
battery system (24VDC) is a negative (-) ground sys-
tem.

These decals are placed above the battery


disconnect switches on the right side of the front
bumper to indicate OFF and ON positions of the
switches.

A4-2 Warnings and Cautions A04061


CYLINDER PRESSURE FILLING THE HYDRAULIC TANK
These danger plates are mounted on the outside of A plate mounted on the side of the hydraulic tank
each frame rail to remind technicians to read the provides instructions for filling the hydraulic tank.
warning labels attached to the side of each of the
To lessen the chances of system contamination,
accumulators (see below) before releasing internal
keep the system open to the atmosphere only as
nitrogen pressure or disconnecting any hydraulic
long as absolutely necessary. Service the tank with
lines or hardware. There are similar decals mounted
clean Type C-4 hydraulic oil. All oil that is being put
on top of each of the accumulators (both steering
into the hydraulic tank should be filtered through 3
and brake) with the same danger message.
micron filters.

These warning decals 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 A caution decal is attached below the hydraulic tank
manual before performing any service. oil level sight gauge. Check the oil level with the body
down, engine stopped, and key switch OFF. Add oil
per filling instructions if the oil level is below the top
of the sight glass.

This danger plate is attached to all four suspensions.


It contains instructions for releasing internal pressure
before disconnecting any hardware. Serious injury
can occur if these directions are not followed.

A04061 Warnings and Cautions A4-3


HYDRAULIC OIL PRESSURE EMERGENCY DUMP PROCEDURE
A warning plate is attached to the hydraulic tank to A decal which provides the operator or technician
warn technicians that high pressure hydraulic oil is with the emergency procedure for dumping a loaded,
present during operation. When it is necessary to disabled truck by using a functional truck for
open the hydraulic system, be sure the engine is hydraulic power is located on the frame near the left
stopped and the key switch is OFF to bleed down hoist cylinder.
hydraulic pressure. There is always a chance of
Refer to Section L in the shop manual for additional
residual pressure being present. Open fittings slowly
information about using this procedure.
to allow all pressure to bleed off before removing any
connections.

WHEEL MOTOR OIL LEVEL


A wheel motor oil level decal is attached to the gear ACCUMULATOR DRAIN VALVES
cover on both electric wheel motors. This decal Warning decals are applied to both brake
stresses that the truck must be parked for 20 minutes accumulators located inside the brake system
prior to checking the oil level in order to get an cabinet behind the operator cab. These decals
accurate reading. remind servicing technicians to close the
accumulator drain valves after they have been
opened to bleed the brake pressure. It further warns
not to overtighten the drain valves in order to prevent
damage to the valve seat(s).

EMERGENCY TOWING PROCEDURE


A decal which provides the operator or technician
with the emergency procedure for towing a disabled
truck is located on the left frame rial near the steering
accumulators.
HOT EXHAUST
A caution decal is also attached to the door of the
rear hatch cover and around the retarding grid
cabinet to alert personnel that hot exhaust air is
present and may cause injury.

A4-4 Warnings and Cautions A04061


WELDING CAPACITORS
This caution decal is placed near the battery This caution decal is placed on the back of the
disconnect switches on the right side of the front control cabinet to alert service technicians that this
bumper to alert service technicians to always area contains capacitors and must not be disturbed
disconnect the battery charging alternator lead wire in any manner.
before making welding repairs.
In addition, always isolate electronic control
components and disconnect the positive and
negative battery cables of the vehicle. Failure to do
so may seriously damage the battery and electrical
equipment.

Always fasten the welding machine ground (-) lead to


the piece being welded. The grounding clamp
must be attached as near as possible to the weld
area. Never allow welding current to pass through
ball bearings, roller bearings, suspensions, or
hydraulic cylinders. Always avoid laying welding
cables over or near the vehicle electrical harnesses.
Welding voltage could be induced into the electrical
harness and possibly cause damage to components. This decal is placed near three different indicator
lights:
EMERGENCY SHUTDOWN • In the operator cab, on the D.I.D. panel on the
This decal is placed on the ground level engine rear wall.
shutdown switch, which is mounted on the right side • On the front of the control box, which is mounted
of the front bumper structure. It specifies that this on the right side of the main control cabinet.
switch is for emergency shutdown only.
• On the outside of the left control cabinet wall that
faces the right side of the operator cab.
When any of these indicator lights are on, high
voltage is present throughout the propulsion and
retarding system. Extreme care should be exercised!

A04061 Warnings and Cautions A4-5


INFORMATION DISPLAY HIGH VOLTAGE
This information decal is placed on the outside of the A high voltage danger plate is attached to the door of
door panel on the control cabinet wall that faces the the rear hatch cover.
right side of the operator cab.
High voltage may be present! Only authorized
personnel should access this rear housing.

These warning plates are mounted on all the AC


drive control housings and cabinets.
RADIATOR
High voltage may be present! Only authorized
A warning plate is mounted on top of the radiator
personnel should access this rear housing.
surge tank cover near the radiator cap. The engine
cooling system is pressurized. Always turn the key
switch OFF and allow the engine to cool before
removing the radiator cap. Unless the pressure is
first released, removing the radiator cap after the
engine has been running for a time will result in hot
coolant being expelled from the radiator. Serious
scalding and burning may result.

A4-6 Warnings and Cautions A04061


LIFTING INSTRUCTIONS
This page illustrates a variety of decals which are If any of these decals is damaged or defaced so it is
placed on deck mounted cabinets, housings, and no longer legible, it should be replaced immediately.
structures that must be lifted in a specific manner
Maintenance personnel must follow these lifting
and from specific points in order to safely move
instructions.
them.

A04061 Warnings and Cautions A4-7


PRODUCT IDENTIFICATION PLATE MDS - Character positions 4, 5, 6, 7 and 8 identify
the Machine Descriptor Section (MDS). The MDS
A product identification plate is located on the frame code identifies general information regarding
in front of the right side front wheel. It shows the machine specifications. The MDS is a code for the
Truck Model Number, Maximum GVW, and Product machine type and model.
Identification Number (PIN).
CL - Character position 9 identifies the Check Letter
(CL). The CL is used to verify the accuracy of the
individual PIN.
FC - Character positions 10 and 11 identify the
Factory Code (FC). The FC identifies the Komatsu
factory in charge of claims for the product. The FC for
electric drive trucks is 61.
SN - Character positions 12, 13, 14, 15, 16 and 17
identify the Serial Number (SN). The SN is a unique
sequential number.

The Product Identification Number (PIN) consists of a


total of 19 characters. The first and last characters
are tamper preventive symbols (*). The remaining 17
alpha/numeric characters are used to identify the
following five characteristics of the machine:
WMC - Character positions 1, 2 and 3 identify the
Worldwide Manufacturer Code (WMC). The WMC
designates the manufacturer of the product. Komatsu
brand products are identified with the letters KMT.

LUBRICATION CHART
The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P,
Lubrication and Service, in the shop manual for more complete lubrication instructions.

A4-8 Warnings and Cautions A04061


STANDARD TORQUE CHARTS AND CONVERSION TABLES
This manual provides U.S. standard and metric (SI) EFFECT OF SPECIAL LUBRICANTS
units for most specifications. On Fasteners and Standard Torque Values
References throughout the manual to standard torques Komatsu does not recommend the use of special
or other standard values will be to one of the following friction-reducing lubricants, such as Copper Coat,
charts or tables. For values not shown in these charts Never-Seez®, and other similar products, on the
or tables, standard conversion factors for most threads of standard fasteners where standard torque
commonly used measurements are provided in Table values are applied. The use of special friction-reducing
XIII. lubricants will significantly alter the clamping force
Standard torque values are not to be used when “turn- during the tightening process.
of-the-nut” tightening procedures are recommended. If special friction-reducing lubricants are used,
excessive stress and possible breakage of the
INDEX OF TABLES fasteners may result.
Table I . . . . . . . . Standard Torque Chart (SAE) . . A5-1
When the torque tables specify “lubricated threads” for
Table II . . . Standard Torque, 12-Point, Grade 9 . . A5-2
the standard torque values listed, these standard
Table III . . . Standard Metric Assembly Torque . . A5-2
torque values are to be used with simple lithium base
Table IV . . . . . . . JIC Swivel Nuts Torque Chart . . A5-3
chassis grease (multi-purpose EP NLGI) or a rust-
Table V. . . . . . . . . . .Pipe Thread Torque Chart . . A5-3
preventive grease (see list, page A5-2) on the threads
Table VI . . . . . . . . . O-Ring Boss Torque Chart . . A5-3
and seats unless specified otherwise.
Table VII. . . . . O-Ring Face Seal Torque Chart . . A5-3
Table VIII . . Torque Conversions (ft lbs to N•m) . . A5-4
Verify threads and tapped holes are free of burrs and
Table IX . . Torque Conversions (ft lbs to kg•m) . . A5-4
other imperfections before installing hardware.
Table X. . . . Pressure Conversions (psi to kPa) . . A5-4
Table XI . . Pressure Conversions (psi to MPa) . . A5-5
Table XII. . . . . . . . . .Temperature Conversions . . A5-5
Table XIII . . . . Common Conversion Multipliers . . A5-6

Grade 5 TABLE I. -STANDARD TORQUE CHART


Grade 8
SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS) - TOLERANCES ±10%
Cap- TORQUE - TORQUE - Cap- TORQUE - TORQUE -
screw GRADE 5 GRADE 8 screw GRADE 5 GRADE 8
Thread Thread
ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m
Size Size
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lbs = 0.138 kg•m = 1.356 N•m

A05001 11/05 Standard Torque Charts and Conversion Tables A5-1


STANDARD ASSEMBLY TORQUES STANDARD ASSEMBLY TORQUES
For 12-Point, Grade 9 Capscrews (SAE) For Class 10.9 Capscrews & Class 10 Nuts
The following specifications apply to required assembly The following specifications apply to required assembly
torques for all 12-point, grade 9 (170,000 psi minimum torques for all metric Class 10.9 finished hexagon head
tensile) capscrews. capscrews and Class 10 nuts.
• Capscrew threads and seats shall be lubricated • Capscrew threads and seats shall not be lubricated
when assembled. when assembled. These specifications are based
on all capscrews, nuts, and hardened washers
NOTE: Unless the instructions specifically recommend being phosphate and oil coated.
otherwise, these standard torque values are to be used
with simple lithium base chassis grease (multi-purpose NOTE: If zinc-plated hardware is used, each piece
EP NLGI) or a rust preventive grease (see list, this must be lubricated with simple lithium base chassis
page) on the threads. grease (multi-purpose EP NLGI) or a rust preventive
grease (see list, this page) to achieve the same
• Torques are calculated to give a clamping force of clamping forces provided below.
approximately 75% of proof load.
• Torques are calculated to give a clamping force of
• The maximum torque tolerance shall be ±10% of
approximately 75% of proof load.
the torque value shown.
• The maximum torque tolerance shall be within
±10% of the torque value shown.
TABLE II. STANDARD ASSEMBLY TORQUE
for 12-Point, Grade 9 Cap screws TABLE III. STANDARD ASSEMBLY TORQUE
for Metric Class 10.9 Cap screws & Class 10 Nuts
CAPSCREW TORQUE TORQUE TORQUE
SIZE* ft lbs N•m kg•m CAPSCREW TORQUE TORQUE TORQUE
0.250 - 20 12 16 1.7 SIZE* N•m ft lbs kg•m
0.312 - 18 24 33 3.3 M6 x1 12 9 1.22
0.375 - 16 42 57 5.8 M8 x 1.25 30 22 3.06
0.438 -14 70 95 9.7 M10 x 1.5 55 40 5.61
0.500 -13 105 142 14.5 M12 x 1.75 95 70 9.69
0.562 - 12 150 203 20.7 M14 x 2 155 114 15.81
0.625 - 11 205 278 28.3 M16 x 2 240 177 24.48
0.750 - 10 360 488 49.7 M20 x 2.25 465 343 47.43
0.875 - 9 575 780 79.4 M24 x 3 800 590 81.6
1.000 - 8 860 1166 119 M30 x 3.5 1600 1180 163.2
1.000 - 12 915 1240 126 M36 x 4 2750 2028 280.5
1.125 - 7 1230 1670 170 * Shank Diameter (mm) - Threads per millimeter
1.125 - 12 1330 1800 184 This table represents standard values only. Do not use these
1.250 - 7 1715 2325 237 values to replace torque values which are specified in assembly
1.250 - 12 1840 2495 254 instructions.
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342
Suggested* Sources for Rust Preventive Grease:
1.500 - 6 2980 4040 411 • American Anti-Rust Grease #3-X from Standard Oil
1.500 - 12 3225 4375 445 Company (also American Oil Co.)
* Shank Diameter (in.) - Threads per inch • Gulf Norust #3 from Gulf Oil Company.
This table represents standard values only. Do not use these
values to replace torque values which are specified in assembly
• Mobilarma 355, Product No. 66705 from Mobil Oil
instructions. Corporation.
• Rust Ban 326 from Humble Oil Company.
• Rustolene B Grease from Sinclair Oil Co.
• Rust Preventive Grease - Code 312 from the
Southwest Grease and Oil Company.
NOTE: This list represents the current engineering
approved sources for use in Komatsu manufacture. It is
not exclusive. Other products may meet the same
specifications of this list.

A5-2 Standard Torque Charts and Conversion Tables 11/05 A05001


TABLE IV. TABLE VI.
TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR
WITH OR WITHOUT O-RING SEALS O-RING BOSS FITTINGS

SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B ft lbs CODE (O.D.) UNF-2B ft lbs
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10

TABLE V. TABLE VII.


TORQUE CHART FOR TORQUE CHART FOR
PIPE THREAD FITTINGS O-RING FACE SEAL FITTINGS

PIPE WITH WITHOUT SIZE TUBE SIZE THREADS TORQUE ft


SIZE THREAD SEALANT SEALANT CODE (O.D.) UNF-2B lbs
CODE SIZE ft lbs ft lbs
–4 0.250 0.438 – 20 11 ±1
–2 0.125 – 27 15 ±3 20 ±5
–6 0.375 0.562 – 18 18 ±2
–4 0.250 – 18 20 ±5 25 ±5
–8 0.500 0.750 – 16 35 ±4
–6 0.375 – 18 25 ±5 35 ±5
– 10 0.625 0.875 – 14 51 ±5
–8 0.500 – 14 35 ±5 45 ±5
– 12 0.750 1.062 – 12 71 ±7
– 12 0.750 – 14 45 ±5 55 ±5
– 16 1.000 1.312 – 12 98 ±6
– 16 1.000 – 11.50 55 ±5 65 ±5
– 20 1.250 1.625 – 12 132 ±7
– 20 1.250 – 11.50 70 ±5 80 ±5
– 24 1.500 1.875 – 12 165 ±15
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10

A05001 11/05 Standard Torque Charts and Conversion Tables A5-3


TABLE VIII. TORQUE CONVERSIONS
Foot Pounds (ft lbs) to Newton-meters (N•m)

ft lbs 0 1 2 3 4 5 6 7 8 9
0 (N·m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage

TABLE IX. TORQUE CONVERSIONS


Foot Pounds (ft lbs) to kilogram-meters (kg•m)

ft lbs 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page A5-5 regarding Table usage

TABLE X. PRESSURE CONVERSIONS


Pounds/square inch (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
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page A5-5 regarding Table usage

A5-4 Standard Torque Charts and Conversion Tables 11/05 A05001


TABLE XI. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa

psi 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage

NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa). 3. Multiply by 10:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to psi row 0, column 5; read 34.475
2. Go to psi row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.

TABLE XII. TEMPERATURE CONVERSIONS


Formula: F° - 32 / 1.8 = C° or C° x 1.8 + 32 = F°

CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT


C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.

A05001 11/05 Standard Torque Charts and Conversion Tables A5-5


TABLE XIII
COMMON CONVERSION MULTIPLIERS

COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS


ENGLISH TO METRIC METRIC TO ENGLISH

To Convert Multiply Multiply


From TO By To Convert From TO By
inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394
inch – in. centimeter (cm) 2.54 centimeter (cm) inch – in. 0.3937
foot – ft meter (m) 0.3048 meter (m) foot – ft 3.2808
yard – yd meter (m) 0.914 meter (m) yard – yd 1.0936
mile – mi. kilometer (km) 1.61 kilometer (km) mile – mi. 0.6210

sq. in. – in. 2


sq. centimeters (cm ) 2 6.45 sq. centimeters (cm 2) sq. in. – in.2 0.1550

sq. ft. – ft2 sq. centimeters (cm2) 929 sq. centimeters (cm2) sq. ft. – ft2 0.001

cu. in. – in.3 cu. centimeters (cm3) 16.39 cu. centimeters (cm3) cu in – in.3 0.061

cu. in. – in.3 liters (l) 0.016 liters (l) cu in – in.3 61.02

cu. ft. – ft3 cu. meters (m3) 0.028 cu. meters (m3) cu ft – ft3 35.314

cu. ft. – ft3 liters (l) 28.3 liters (l) cu ft – ft3 0.0353

ounce – oz kilogram (kg) 0.028 grams (g) ounce – oz. 0.0353


fluid ounce – fl oz milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl oz. 0.0338
pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046
pound (force) – lbs Newton (N) 4.448 Newton (N) pound (force) – lbs 0.2248
in. lbs. (force) Newton meters (N•m) 0.113 Newton-meters (N•m) kilogram meters (kg•m) 0.102
ft lbs (force) Newton meters (N•m) 1.356 Newton-meters (N·m) ft lbs 0.7376
ft lbs (force) kilogram meters (kg•m) 0.138 kilogram-meters (kg•m) ft lbs 7.2329
psi (pressure) kilopascals (kPa) 6.895 kilogram-meters (kg•m) Newton meters (N•m) 9.807
psi (pressure) megapascals (MPa) 0.007 kilopascals (kPa) psi 0.1450
psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 megapascals (MPa) psi 145.038

ton (short) kilogram (kg) 907.2 kilograms/cm 2 (kg/cm2) psi 14.2231

ton (short) metric ton 0.0907 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
quart – qt liters (l) 0.946 kilogram (kg) ton 0.0011
gallon – gal liters (l) 3.785 metric ton ton 1.1023
HP (horsepower) Watts 745.7 liters (l) quart – qt 1.0567
HP (horsepower) kilowatts (kw) 0.745 liters (l) gallon – gal 0.2642
Watts Horsepower HP 0.00134
kilowatts (kw) Horsepower HP 1.3410

A5-6 Standard Torque Charts and Conversion Tables 11/05 A05001


STORAGE AND IDLE MACHINE PREPARATION
There may be periods when it is necessary for a SHORT TERM IDLE PERIODS
machine to be idle for an extended period of time. If
properly prepared, a stored machine may promptly There may be periods when a vehicle is idle from 30
and safely be put back into operation. Improper to 60 days, but must be ready for use at any time. To
preparation, or complete lack of preparation, can most effectively hande this type of situation, follow
make the job of getting the vehicle back to operating the procedure below to prevent any deterioration
status difficult. from the beginning of vehicle idle time.
1. Keep the vehicle fully serviced.
The following information outlines the essential steps
for preparing a unit for extended storage, and the 2. Perform a visual check of the vehicle every
necessary steps for bringing the unit back to week. Start and run the engine until it is at
operational status. Additional information is given to operating temperature. Move the vehicle
help restore machines that were not put into storage, around the yard for a few minutes to ensure that
but merely shut down and left idle for a long period of all internal gears and bearings are freshly
time. lubricated.
3. Operate all hydraulic functions through their
Much of this material is of a general nature since the
complete range to ensure that the cylinder rods
environment (where the machine has been standing
and seals are fully lubricated.
idle) will play a big part in its overall condition. A hot,
humid climate will affect vehicle components much 4. Check and operate all systems.
differently than a dry desert atmosphere or a cold 5. Once a month, perform the 10 Hour service
arctic environment. These climatic aspects must be items shown in the Operation and Maintenance
considered and appropriate actions taken when Manual. Keep batteries properly serviced.
restoring a long term idle vehicle.
These instructions are not intended to be all
inclusive, but are minimum guidelines. The final aim
should always be to provide the operator with a safe,
reliable, fully productive vehicle.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-1


PREPARATION FOR STORAGE
For long term idle periods, proper preparation will 6. The cooling system should be completely
pay large dividends in time and money when future drained, chemically flushed, and refilled with a
operation of the vehicle is scheduled. conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
1. The engine should be prepared for storage Section P, Lubrication and Service, for the
according to instructions found in the engine proper anti-freeze and conditioner
manufacturer's manual. concentrations. After refilling the system,
2. The vehicle should be in top operating condition always operate the engine until the thermostats
with all problems corrected. The paint should be open to circulate the solution through the
in good condition, with no rust or corrosion. All cooling system.
exposed, machined or unpainted surfaces
NOTE: NEVER store a vehicle with a dry cooling
should be coated with a good rust preventive
system.
grease.
3. After the vehicle has been parked in its storage
location, all hydraulic cylinders, including
Hydrair suspensions, should be retracted as
much as possible (steering cylinders centered).
Wipe the exposed portion of all cylinder rods Any operating fluid, such as hydraulic oil,
clean and coat them (including the seals on the escaping under pressure can have sufficient
end of the barrel) with a good preservative force to enter a person's body by pentrating the
grease. skin. Serious injury and possible death may
4. If long term storage is anticipated, the vehicle result if proper medical treatment by a physician
should be blocked up with the tires clear of the familiar with this injury is not received
ground to remove the vehicle weight from the immediately.
tires. Lower the tire pressure to 103 - 172 kPa 7. New hydraulic filters should be installed and the
(15 - 25 psi). Completely cover the tires with hydraulic tank fully serviced with Type C-4 oil as
tarpolins to minimize rubber oxidation and specified in Section P, Lubrication and Service.
deterioration.
8. Disconnect the batteries, if possible. Batteries
5. Clean the radiator. Refer to Section C, Cooling should be removed and stored in a battery shop
System, for the proper cleaning instructions. or a cool dry location on wooden blocks. Do not
store batteries on a concrete floor. Clean the
battery compartment. Remove all corrosion and
paint the compartment with an acid proof paint.
9. The wheel axle housings should be fully
serviced with recommended lubricants. Seal all
The cooling system is pressurized due to thermal
vents.
expansion of coolant. Do not remove the radiator
cap while the engine and coolant are hot. Severe 10. The exhaust openings and air cleaners should
burns may result. be covered tightly with moisture barrier paper
and sealing tape.

A7-2 Storage Procedures and Idle Machine Preparation 11/05 A07003


11. All lubrication points (grease fittings) should be REMOVAL FROM STORAGE
serviced with the recommended lubricants.
If the storage preparations were followed when
12. Relieve the tension from all drive belts. The placing the vehicle into storage, getting it back to
engine manufacturer recommends insertion of operational status is a matter of reversing those
heavy kraft paper between the belts and pulleys steps.
to prevent sticking.
NOTE: Before starting the job of restoring a vehicle
13. All vandalism covers and locks should be in to operation, obtain copies of the Operation and
place and secured. Maintenance Manual, Service Manual, Engine
14. All cab windows should be closed, locked and Manuals and Parts Book, if possible, and follow all
sealed, and the cab door should be locked to special instructions regarding servicing the vehicle
prevent vandalism and weather effects. and its components.
15. The fuel tank should be completely drained of In addition to removing the storage materials, the
fuel, fogged with preservative lubricant (NOX- following actions should be taken:
RUST MOTOR STOR., SAE10), and closed 1. Inspect the entire vehicle carefully for rust and
tightly. All fuel filters should be replaced. corrosion. Correct as necessary.
16. If possible, all available service publications 2. Service the engine according to the engine
(vehicle and engine) and a current parts catalog manufacturer's Operation and Maintenance
should be packaged in a moisture proof Manual.
package and placed in the cab to aid whomever
3. Clean the radiator. Refer to Section C, Cooling
will eventually place the unit back in operation.
System, for cleaning instructions.
17. Ensure that the water drain holes in the truck 4. The cooling system should be completely
body are open. drained, chemically flushed, and refilled with a
conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
Fluid Specifications in Section P, Lubrication
and Service, for the proper anti-freeze and
conditioner concentrations. After refilling the
system, always operate the engine until the
thermostats open to circulate the solution
through the cooling system.
5. Thoroughly inspect all drive belts and hydraulic
oil lines for damage, wear or deterioration.
Replace any suspected lines. Do not take
chances on possible ruptures or blow-outs.
6. New hydraulic filters should be installed and the
hydraulic tank checked and serviced with Type
C-4 oil as specified in Section P, Lubrication
and Service.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-3


7. Open the fuel tank drain valve to remove any 16. Refer to the Operation and Maintenance
moisture or sediment that may have Manual for engine startup and vehicle checkout
accumulated while in storage. Close the drain procedures. Check all hose and line
valve and fill the fuel tank with diesel fuel. connections for leaks when the engine is
running.
17. Before moving the vehicle, cycle all hydraulic
controls, steering controls, and braking systems
to verify proper operation. Check all
Never blend gasoline, gasohol and/or alcohol instruments and gauges to ensure that all
with diesel fuel. This creates an extreme fire systems are operational.
hazard and, under certain conditions, may cause
an explosion. 18. When all systems are operational and all known
problems are corrected, road test the vehicle in
8. Ensure that all hydraulic controls, steering a smooth, level, unobstructed area to check
linkage and throttle linkage points are lubricated steering response, service brake efficiency, and
and operate freely before starting the engine. hydraulic functions.
9. All electrical connections must be clean and
19. Recharge any fire protection equipment before
tight. Ensure that all ground straps and cables.
the vehicle is returned to service.
are secure
10. Install fully charged batteries in the vehicle.
Clean the connectors and connect the battery
cables. The battery compartment must be free
of corrosion. Secure the batteries with hold-
downs.
11. Check all electrical cables for deterioration,
cracks and other damage. Replace any
defective cables.

Air pressure must be released from tires with bad


cuts or wear that extends into the plies before
removal from the vehicle. Also, do not allow
personnel to stand in removal path of tires.
12. Check all tires carefully for damage. Inflate the
tires to the proper pressure.
13. If disconnected, reconnect the parking brake
linkage.
14. Completely service the vehicle as
recommended in Section P, Lubrication and
Service, for both 10 and 100 Hour inspections.
15. Adjust all drive belts to the specified tension.

A7-4 Storage Procedures and Idle Machine Preparation 11/05 A07003


RECONDITIONING AN IDLE VEHICLE
3. Inspect tires thoroughly for wear, cuts and
cracks on the treads and side walls.
a. Any tire suspected of being unserviceable
should be removed and thoroughly
inspected before being inflated.
Never attempt to operate a vehicle that has been
standing idle for a long period until all systems b. If the tires are removed, clean and inspect all
which affect steering, brakes, engine, wheel components. All rust and corrosion
transmission and running gears have been must be removed and parts repainted as
completely reconditioned. An unsafe vehicle can needed before mounting the tires.
cause serious injuries and/or major property c. Mount and inflate tires as shown in
damage. Operation and Maintenance Manual. Follow
Reconditioning a vehicle that has been subjected to all safety rules
long idle periods without being properly prepared for 4. Inspect the service brakes carefully. Before
storage - merely shut down and left to the elements - disabling the brake circuit, block all wheels to
may present a major expenditure of time and money prevent possible movement of the vehicle.
when it is to be put into operation.
a. All brake lines and connections must be
1. Remove all debris and thoroughly clean the clean and free of rust, corrosion and
vehicle before starting any inspection or damage.
maintenance.
b. When reconditioning the braking system, the
2. Remove the batteries and move them to a service brake hydraulic circuits should be
battery shop for service and charging, or checked out according to the instructions in
replace as necessary. Section J, Brake Circuit Check-Out
Procedure.
5. The engine should be inspected and serviced
according to the engine manufacturer's
Operation And Maintenance Manuals.
Do not disassemble an inflated tire. Remove the
valve core slowly and allow pressure to bleed off a. Ensure that the exhaust is clear and clean. If
before attempting to remove the lockring. Also, water entry is suspected, disconnect the air
eye protection must be worn during tire deflation tubes at the turbochargers to check for water
to protect against any foreign object being before attempting to start the ethe ngine.
projected into the eyes. b. Replace the fuel filters and fill filter cans with
fresh fuel for engine priming.

Do not mix rim parts of different rim


manufacturers. Rim parts may resemble those of
a different manufacturer, but the required Have a new safety filter (secondary) element on
tolerances may be wrong. Use of mismatched rim hand before removing the old one. Do not keep
parts is hazardous. the intake system open to the atmosphere any
longer than absolutely necessary.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-5


c. Replace both the primary and safety filter 7. Drain the hydraulic tank. If the oil is not
(secondary) elements in the air cleaners. contaminated and is stored in clean containers,
Check all intake lines between the air it may be reused if filtered through 3-micron
cleaners and the engine. All clamps must be filter elements when being pumped back into
tight. The plunger in the filter condition the tank. Do not attempt to use contaminated
indicators must move freey. hydraulic oil, especially if water entry into the
system is suspected.
d. Inspect the tubes in the precleaner section of
the air cleaner assembly. Use a light to NOTE: If filling is required, use clean hydraulic oil
inspect the tubes. The light should be visible only. Refer to the Lubrication Chart in Section P,
through the end of the tube. If clogging is Lubrication and Service, for proper oil specifications.
evident, the precleaner must be cleaned
a. Replace the hydraulic filter elements and
according to the instructions in Section C, Air
clean the suction strainer elements. While
Cleaners.
the suction strainers are removed, inspect
e. Drain and flush the engine cooling system. and clean the inside of the tank thoroughly to
Fill with coolant and inhibitors after checking remove all sediment and foreign material.
all lines, hoses and connections. Refer to
b. Inspect all hydraulic lines for deterioration
Section P, Lubrication and Service, for anti-
and damage. Replace any suspected lines.
freeze recommendations. Radiator cores
Do not risk possible hose ruptures or blow
must be clear of dirt and debris.
outs.
c. Check all hydraulic components (pumps,
valves and cylinders) for damage and
corrosion. Secure all mountings and
connections. The control valves must move
To prevent injuries, always release spring freely with no binding.
tension before replacing the fan belt. d. Check the exposed portions of all hydraulic
f. Check and tighten the engine fan drive belts. cylinder rods for rust, pitting and corrosion. If
If necessary, install a new belt set. the plating has deteriorated, the cylinder
should be removed and overhauled or
g. Check and tighten the engine mounts. replaced. Pitted or scored plating will cause
6. If fuel was left in the tanks, it must be removed. leakage at the cylinder seals.
Do not attempt to use old diesel fuel. 8. Check the front wheel hub, final drive and wheel
a. With the tanks empty, remove the inspection axle lubricant. If contamination is suspected,
plates and thoroughly check the interior of the oil should be drained completely and the
the tanks. Remove any sediment and component serviced with clean recommended
contamination. If the fuel was contaminated, lubricant. If major contamination is present,
the lines should be disconnected and blown disassembly and overhaul will be necessary.
clear. 9. Check the parking brake. Since it is spring
b. Check all fuel lines for deterioration or applied, the brake pads may be stuck tightly to
damage. Replace lines as necessary. the disc. It may be necessary to remove and
overhaul the parking brake assembly.
c. Install the inspection covers with new
gaskets.
d. Fill the tanks with the specified diesel fuel.
e. Replace the fuel filters.

A7-6 Storage Procedures and Idle Machine Preparation 11/05 A07003


10. Lubricate all grease fittings that are not part of ENGINE OPERATION
the automatic lubrication system with the
recommended lubricants. Pay special attention After all reconditioning procedures have been
to the steering linkage connections. All pivot completed, a static check of engine operation,
points must move freely with no binding. systems operations, and verification of the braking
and steering functions must be done before the
11. Check the battery charging alternator for vehicle is moved.
corrosion or deterioration. The alternator rotor
must move freely with no binding or roughness. .
Inspect, install and properly tension the
alternator drive belts.
12. Ensure that the steering cylinder ball joints link
and hydraulic connections are secure. Before starting the engine, clear the immediate
13. Examine the Hydrair suspensions for damage. area of personnel and obstructions. Ensure that
all tools and loose equipment have been
a. Discharge the nitrogen from the suspensions
removed from the vehicle. Always sound the
as outlined in Section H, Hydrair II
horn as a warning before starting the engine or
Suspensions.
actuating any operational controls.
b. Check the conditon of the suspension oil and Never start the engine in a building unless the
cylinder wipers. If the wipers are cracked or doors and windows are open and ventilation is
hardened, the suspension must be rebuilt. adequate.
Recharge the suspension with new oil if the
1. Turn the key switch ON. The warning lights for
old oil is deteriorated.
low brake and steering pressure should
c. Check the exposed chrome portions of illuminate and the horn should sound. If it does
cylinder for rust, pitting and corrosion. If the not, check all components in the circuit and
plating is deteriorated, the suspension correct the problem before continuing.
should be removed and overhauled or 2. Turn the key switch to the START position to
replaced. Pitted or scored plating will rapidly crank the engine. Release the key when the
cause leakage at the seals. engine starts. Watch the engine oil pressure
d. Recharge the suspensions as outlined in gauge. If the pressure does not show within 10 -
Section H, Hydrair II Suspensions. 15 seconds, turn off the engine and locate the
problem.
14. If not done previously, install fully-charged
batteries and ensure that the hook-up is correct. 3. While the engine is warming up, inspect the
coolant, oil and fuel lines for leaks. Check the
hydraulic pump and hydraulic lines for leaks.
4. When the engine is at operating temperature,
check the operation of the throttle circuit.
Acceleration should be smooth. Watch the
gauges for any abnormal activity. Proper
temperatures and pressures are shown in the
Operation and Maintenance Manual.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-7


After The Engine Has Started
Any machine which is unsafe and/or not in top 5. After all known problems have been corrected,
operating condition should not be assigned to an the vehicle is ready for a road test. This test
operator for production use. should be performed only by a capable and
experienced operator in a large open area
1. Become thoroughly familiar with the steering where plenty of maneuvering room is available.
and emergency controls. Test the steering in
the extreme right and left directions. If the One of the road test items that should be
steering system is not operating properly, turn performed is the repeated test of braking
off the engine immediately. Determine the efficiency at progressively higher speeds. Start
steering system problem and have repairs at slow speeds. Do not operate at higher
made before resuming operation. speeds until the machine is determined to be
operating safely.
2. Operate each of the brake circuits at least twice
prior to operating and moving the machine. 6. When the vehicle is ready for production use, it
should be visually rechecked and fully serviced
a. Activate each circuit individually using the according to Section P, Lubrication and
controls in the cab with the engine running Service.
and the hydraulic circuit fully charged.
A few of the conditions which might be encountered
b. If any application or release of any brake
after a machine has been exposed to the elements
circuit does not appear proper or if
for a long period of time include:
sluggishness is apparent, turn off the engine
and notify maintenance personnel. Do not • increased corrosion and fungus growth on
operate the machine until the brake circuit in electrical components in humid/tropical areas.
question is fully operational. • accelerated rust formation in humid climates.
3. Check all gauges, warning lights and
• increased sand and dust infiltration in windy, dry
instruments before moving the machine to dusty areas.
ensure proper system operation and gauge
function. Pay special attention to the braking • deterioration of rubber products in extreme cold
and steering circuit warning lights. If any areas. Cables, hoses, O-rings, seals and tires
warning lights come on, turn off the engine may become weather checked and brittle.
immediately and determine the cause. • animal or bird's nests in unsealed openings.
4. Cycle the hoist controls and steering several
times to remove any trapped air. Complete the
steering cycles in both directions to verify
steering response, smoothness and reliability.
Check the seals and lines for leaks.

A7-8 Storage Procedures and Idle Machine Preparation 11/05 A07003


ENGINE STORAGE
When an engine is to be stored or removed from 6. Seal all engine openings. The material used for
operation for a period of time, special precautions this purpose must be waterproof, vaporproof
should be taken to protect the interior and exterior of and possess sufficient physical strength to
the engine and other parts from rust and corrosion. resist puncture and damage from the expansion
of entrapped air.
All rust and corrosion must be completely removed
from any exposed part before applying a rust An engine prepared in this manner can be returned
preventive compound. Therefore, it is recommended to service in a short period of time by removing the
that the engine be processed for storage as soon as seals at the engine openings, checking the engine
possible after removal from operation. coolant, fuel oil, lubricating oil, transmission oil, and
priming the raw water pump (if used).
The engine should be stored in a building which is
dry and can be heated during the winter months.
Moisture absorbing chemicals are commercially
Extended Storage (More Than 30 Days)
available for use when excessive moisture is
prevalent in the storage area. 1. Drain the cooling system and flush with clean,
softened water. Refill the system with clean,
Temporary Storage (30 Days Or Less) softened water and add a rust inhibitor.
1. Drain the oil from the crankcase. Fill the 2. Remove, check and recondition the injectors, if
crankcase to the proper level with the necessary, to ensure that they will be ready to
recommended viscosity and grade of new oil. operate when the engine is restored to service.
2. Fill the fuel tank with the recommended grade Reinstall the injectors. Time them and adjust
of fuel oil. Operate the engine for two minutes at the exhaust valve clearance.
1200 rpm with no load. Turn off the engine. Do 3. Circulate the coolant by operating the engine
not drain the fuel system or the crankcase. until the normal operating temperature of 71° -
3. Check the air cleaner and service it, if 85° C (160° - 185° F) is reached.
necessary. 4. Stop the engine.
4. If freezing weather is expected during the 5. Drain the oil from the crankcase, then reinstall
storage period, add an ethylene glycol base and tighten the drain plug. Install new
antifreeze solution in accordance with the lubricating oil filter elements and gaskets.
manufacturer's recommendations. 6. Fill the crankcase to the proper level with a 30-
5. Clean the entire exterior of the engine (except weight preservative lubricating oil (MIL-L-
the electrical system) with fuel oil and dry it with 21260C, Grade 2).
compressed air.

To prevent possible personal injury, wear


adequate eye protection and do not exceed a
compressed air pressure of 276 kPa (40 psi).

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-9


7. Drain the fuel tank. Refill with enough No. 1 16. Remove and clean the batteries and battery
diesel fuel or pure kerosene to allow the engine cables with a baking soda/water solution and
to operate for about ten minutes. If it is not rinse them with fresh water. Do not allow the
convenient to drain the fuel tank, use a soda solution to enter the battery. Add distilled
separate portable supply of the recommended water to the electrolyte, if necessary. Store the
fuel. battery in a cool - never below 0° C (32° F) -
dry place. Keep the battery fully charged and
NOTE: If the engine is stored where condensation of
check the level and the specific gravity of the
water in the fuel tank may be a problem, add pure,
electrolyte regularly. Never set batteries on a
waterless isopropyl alcohol (isopropanol) to the fuel
concrete floor. Place them on wooded blocks.
at a ratio of one pint to 125 gallons(473 L) of fuel, or
0.010% by volume. Where biological contamination 17. Insert heavy paper strips between the pulleys
of fuel may be a problem, add a biocide, such as and belts to prevent sticking.
Biobor JF or an equivalent, to the fuel. When using a 18. Seal all engine openings, including the exhaust
biocide, follow the manufacturer's concentration outlet, with moisture resistant tape. Use
recommendations and all cautions and warnings. cardboard, plywood or metal covers where
8. Drain and disassemble the fuel filter and practical.
strainer. Discard the used elements and
19. Clean and dry the exterior painted surfaces of
gaskets. Fill the cavity between the element and
the engine and spray with a suitable liquid
shell with No. 1 diesel fuel or pure kerosene,
automotive body wax, a synthetic resin varnish
and install on the engine. If spin-on fuel filters
or a rust preventive compound.
and strainers are used, discard the used
cartridges, fill the new ones with No. 1 diesel 20. Protect the engine with a weather-resistant
fuel or pure kerosene, and install on the engine. tarpaulin and store it under cover, preferably in
a dry building with temperatures above 0° C
10. Operate the engine for five minutes to circulate
(32° F).
the clean fuel oil throughout the fuel system.
11. Service the air cleaner.
12. Turbocharger bearings are pressure lubricated
through the external oil line leading from the
engine cylinder block while the engine is
operating. However, the turbocharger air inlet Outdoor storage of engines is not recommended.
and turbine outlet connections should be sealed However, if an engine must be kept outdoors,
off with moisture resistant tape. follow the preparation and storage instructions
above. Do not use plastic sheeting for outdoor
13. Apply a rust preventive compound to all
storage. Plastic may be used for indoor storage.
exposed, non-painted surfaces.
However, when used outdoors, moisture can
14. Drain the cooling system. condense on the inside of the plastic and cause
15. Drain the preservative oil from the engine ferrous metal surfaces to rust and/or pit
crankcase. Reinstall and tighten the drain plug. aluminum surfaces. If a unit is stored outside for
any extended period of time, severe corrosion
damage can result.

A7-10 Storage Procedures and Idle Machine Preparation 11/05 A07003


21. Inspect the stored engine periodically. If there RESTORING AN ENGINE AFTER
are any indications of rust or corrosion, EXTENDED STORAGE
corrective steps must be taken to prevent
damage to the engine parts. Perform a 1. Remove the covers and tape from all of the
complete inspection at the end of one year and openings of the engine, fuel tank and electrical
apply additional treatment, as required. equipment. Do not overlook the exhaust
outlet or the intake system.
2. Wash the exterior of the engine and flywheel
with fuel oil to remove the rust preventive
compound.
3. Remove the paper strips from between the
pulleys and the belts.
4. Remove the drain plug and drain the
preservative oil from the crankcase. Reinstall
the drain plug. Then, refer to Lubrication and
Service, Section P, and fill the crankcase with
the recommended grade of lubricating oil to
proper level using a pressure prelubricator.
5. Fill the fuel tank with the engine manufacturer's
specified fuel.
6. Close all of the drain cocks and fill the engine
cooling system with clean, softened water and a
rust inhibitor. If the engine is to be exposed to
freezing temperatures, fill the cooling system
with an ethylene glycol base antifreeze solution.
Refer to the coolant specifications in Section P,
Lubrication and Service.
7. Install and connect the fully charged batteries.
8. Service the air cleaner as outlined in Section C,
Air Cleaners.
10. Remove the covers from the turbocharger air
inlet and turbine outlet connections.
11. After all of the preparations have been
completed, start the engine. The small amount
of rust preventive compound which remains in
the fuel system will cause a smoky exhaust for
a few minutes.
NOTE: Before subjecting the engine to a load or high
speed, it is advisable to check the engine tune-up.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-11


ELECTRIC DRIVE TRUCKS
These instructions provide the recommended It is also important to note that these instructions
procedures for protecting equipment from damage cannot possibly anticipate every type of storage
during both short term and long-term storage condition and, therefore, cannot prevent all
periods. Also included are instructions for placing this equipment deterioration problems caused by
equipment into service after having been stored. inadequate storage. These instructions are not
intended to be all inclusive, but are minimum
For the purposes of this instruction, a short term guidelines for achieving the best possible equipment
storage period is considered to be less than three life and the lowest operating cost when the
months; a long-term storage period is considered to equipment is returned to service.
be three months or longer.
NOTE: Local conditions and/or experience may
General Electric recommends a maximum storage require additional procedures and/or additional
period of three years, with these storage procedures storage precautions.
being repeated after each year. After a storage
period of three years or more, the motorized wheels
should be removed and sent to an overhaul facility
for teardown and inspection of seals and bearings. Storing A Truck That Is Operational
These should be replaced if necessary. When a fully operational truck is being placed into
Periodic (every three months) inspections should be storage for less than three months, the best
made to determine the lasting qualities of long-term protective measure which can be taken is to drive the
storage protection measures. Such inspections will truck once a week for at least 30 minutes. Prior to
indicate the need for renewing protective measures driving the truck, the rotating equipment should be
when necessary to prevent equipment deterioration. Meggered and:

Proper storage of this equipment is vital to equipment • If greater than 2 megohms, run normally.
life. Bearings, gears, and insulation may deteriorate • If less than 2 megohms, isolate the condition and
unless adequate protective measures are taken to correct it before running.
protect against the elements. For example, bearings
Driving the truck circulates oil in the gearcase to
and gears in the motorized wheel gear case are
keep gears and bearings lubricated and free from
susceptible to the formation of rust, insulation in
rust. It also prevents deterioration of the brushes,
rotating electrical equipment can accumulate
commutators and slip rings.
moisture, and bearings may become pitted.
When a fully operational truck is being placed into
storage for three months or longer, and the truck
cannot be operated weekly throughout the storage
Never apply any spray, coating, or other period as indicated above, perform the following:
protective materials to areas not specifically 1. Drain the oil from the gearcase and install rust
recommended. preventive 4161 (a product of Van Straaten
Chemical Co.) or equivalent. Fill per General
Electric Motorized Wheel Service Manual.

A7-12 Storage Procedures and Idle Machine Preparation 11/05 A07003


2. Megger the wheels as indicated in the 9. Install a 500 watt heat source inside all control
instructions above. Operate the truck for at least groups which house electronic control
30 minutes to ensure that the rust preventive equipment. These heat sources are to be
compound has been thoroughly circulated energized below 0° C (32° F) and de-energized
throughout the gearcase. Stop the truck and above 5° C (41° F).
drain the rust preventive compound. 10. Install a 500 watt heat source inside the
NOTE: Do not run a loaded truck with rust preventive commutator chamber of both motorized wheels
compound in the wheel motor gearcases. and inside the alternator slip ring chamber. This
will minimize the accumulation of moisture. A
hole in the bottom of the hubcap will
accommodate the electrical cord for the heat
source in the motorized wheels. These heat
sources are to be energized continuously.
Do not operate trucks without oil in the wheel
11. Seal the compartment doors with a
motor gearcases.
weatherproof tape to prevent entry of rain, snow
3. Perform a megohmmeter test. Refer to the and dirt (allow breathing).
truck's Vehicle Test instructions for the correct
procedure. Record the Megger readings for
future reference. They will be helpful in
Storing A Truck That Is Not Operational
determining if deterioration is being
experienced when additional Megger tests are When a truck which is not fully operational is being
made as part of the periodic inspection. stored for any period of time, perform the following:
4. Lift all brushes in the motorized wheels, blowers 1. Drain the oil from the gearcase and install rust
and the alternator. They must be removed from preventive compound 4161 (or equivalent). Fill
the brushholder. Disconnecting brush pigtails is per General Electric Motorized Wheel Service
not required. Manual.
5. Cover any open ductwork with screening 2. Jack up each side of the truck (one side at a
material to prevent rodents from entering. Then time) enough to rotate the tires.
tape over the screen to prevent the entry of
3. Connect a D-C welder as described in the
water and dirt (allow breathing).
Vehicle Test Instructions (Wheel Motor inst.
6. Examine all exposed machined surfaces for 400A, arm & field in stress 900- 1000 rpm arm).
rust or dirt accumulation. Remove all
4. Rotate each motorized wheel (one at a time) for
contamination as necessary. Remove rust by
at least 30 minutes to ensure that the rust
using a fine abrasive paper. Old flushing
preventive compound has been thoroughly
compound can be removed with mineral spirits
circulated throughout the gearcase. Disconnect
(GE-D5B8). Methanol should be used to
the welder. Remove the jacks. Drain the
remove all residue. When clean, coat with Tarp
gearcase.
B rust preventive. Refer to General Electric
Motorized Wheel Service Manual for
specifications.
7. Loosen exciter drive belts (where applicable).
8. Open all switches in the control compartment.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-13


5. If the truck is partially dismantled, pay close 2. Check all other weatherproofing tape. Replace
attention to ductwork, blower shrouds, etc., any that has become loose or is missing.
which may be exposed to weather conditions. 3. Check all heat sources. Replace or repair any
These areas will require the same sealing that have become inoperative.
measures as in Step 5 above which deals with
4. Check all machine surfaces that were coated
protecting ductwork. Cover exposed blower
with flushing compound when storage began. If
housings to prevent entry of water and dirt.
the compound appears to be deteriorating, it
6. Perform Steps 3 through 11 in “Storing A Truck must be cleaned off and renewed.
That Is Operational” in this section.

Placing Equipment Into Service After Storage


Storing A Major Component
If a truck has been operated weekly throughout the
When storing a motorized wheel, alternator, blower storage period, perform a complete visual inspection
or control group for any period of time, always store it of the motorized wheels, blowers, alternator and
inside a warm, climate-controlled environment. Do control compartments. Repair any defects that are
not attempt to store individual components where found, then place the truck directly into service.
they would be exposed to inclement weather,
climatic changes, high humidity and/or temperature If the truck was not operated weekly throughout the
extremes. storage period, perform the following procedures:
1. Remove all weatherproofing tape from control
compartment doors and ductworks.
Periodic Inspections 2. Remove all screening material from the
ductwork.
It is important that periodic inspections (every three
months) of stored equipment be performed to ensure 3. Remove all heat sources from the motorized
the continued serviceability of all protective wheels, control compartments and the
measures initially taken when the storage period alternator.
began. The following items should be checked at 4. Fill with recommended oil. Refer to the
each inspection interval: Motorized Wheel Service Manual for the type
1. Remove the weatherproof tape from the and amount oil to be used. This oil should be
compartment doors and perform a Megger test drained and new oil should be added after 500
as described in the Vehicle Test Instructions. hours of operation.
Record the test results and compare them with 5. Clean all motorized wheel grease fittings in the
the recorded Megger readings taken when axle box. Ensure that all grease lines are
storage first began, and those taken throughout completely full of grease, then add the
the storage period. Remove all test equipment recommended amount of grease to all fittings.
and close the compartment. Reseal the 6. Install brushes in the motorized wheels, blowers
compartment doors with new weatherproof and alternator. Make sure that the brushes
tape. If Megger readings indicate a move freely in their carbonways and that they
deterioration of insulation quality (to below 2.0 have enough length to serve until the truck's
megohms), more protection may need to be next inspection period. Install new brushes if
provided. necessary. Ensure that all brush pigtail screws
are tight.

A7-14 Storage Procedures and Idle Machine Preparation 11/05 A07003


7. Perform a megohmmeter test. Refer to the 10. Check the retarding grids and insulators for
truck's Vehicle Test Instructions for the correct loose connections and dirt accumulation. Clean
procedure. If Megger readings are less than 2.0 and tighten connections as necessary.
megohms, the problem could be an 11. Where applicable, check exciter drive belts for
accumulation of moisture in the motor or cracks and deterioration. If acceptable, set the
alternator. If this is the case, the faulty belt tension to specification.
component will have to be isolated and dried
out using procedures outlined in the G.E. 12. Before starting the engine, turn on the control
Service Manual. power. Check that the contactors and relays
pick up and drop out normally.
8. Perform a thorough inspection of the motorized
wheels, alternator, blowers and control 13. Perform a startup procedure on the complete
compartments. Look for: system to ensure maximum performance during
service. Refer to the truck's Vehicle Test
•Rust or dirt accumulation on machine
Instructions for the complete test procedure.
surfaces
•Damaged insulation
•Any accumulation of moisture or debris, After all storage protection has been removed, the
especially in the ductwork truck has been cleaned and inspected, all repairs
have been made, the motorized wheel gearcase has
•Loose wiring and cables been filled with new oil, the dirt seals have been
•Any rust on electrical connectors in the control completely purged with new grease, and the system
compartment has been completely checked, the truck can be
•Any loose cards in the card panels placed into service. However, it is recommended that
the truck be driven unloaded at a low speed of no
9. Clean and make repairs as necessary.
more than 16 km/h (10 mph) for the first hour of
operation.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-15


NOTES

A7-16 Storage Procedures and Idle Machine Preparation 11/05 A07003


SECTION B
STRUCTURES
INDEX

STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1

DUMP BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1

B01016 Index B1-1


NOTES

B1-2 Index B01016


SECTION B2
STRUCTURAL COMPONENTS
INDEX

PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3

GRILLE, HOOD AND LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

RIGHT DECK AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

LEFT DECK AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6

CENTER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

B02028 Structural Components B2-1


NOTES

B2-2 Structural Components B02028


STRUCTURAL COMPONENTS
PREPARATION After the truck is parked for repairs, the truck must be
shut down properly to ensure the safety of those
The deck components are removable in sections as working in the areas of the deck, electrical cabinet
shown in Figure 2-1. The following removal and and retarding grids. The following procedures will
installation instructions detail the steps to be taken ensure the electrical system is properly discharged
before the decks and hood can be removed. before repairs are started.
Additional steps may be required before the deck or
other major structure is removed, depending on 1. Reduce the engine speed to idle. Place the
optional equipment installed on the truck. directional control lever in PARK. The parking
brake applied indicator lamp in the overhead
Prior to removal or repair procedures, it may be panel should be illuminated.
necessary to remove the body to provide clearance
2. Place the drive system in the rest mode by
for any lifting equipment. If body removal is not
turning on the rest switch on the instrument
required, the body should be raised and the safety
panel. The rest warning lamp should be
cables installed at the rear of the truck.
illuminated.
3. Turn the key switch to OFF. If the engine does
not stop, use the emergency shutdown switch
on the center console.
4. Verify that the link voltage lights are off. If they
remain on longer than five minutes after
• Do not attempt to work in deck area until body shutdown, notify the electrical department.
safety cables have been installed.
5. Verify that the steering accumulators have bled
• Do not step on or use any power cable as a down by attempting to steer.
handhold when the engine is running. 6. Bleed down the brake accumulators by using
• Do not open any electrical cabinet covers or the manual bleed valves on the brake manifold.
touch the retarding grid elements until all 7. Activate the battery disconnect switches.
shutdown procedures have been followed.
8. Inspect and maintain the anti-slip material on
• All removal, repairs and installation of the decks.
propulsion system electrical components
9. If weld repairs are necessary, disconnect all
and cables must be performed by an
electrical maintenance technician who is electrical harnesses and remove the ground
properly trained to service the system. strap from the engine control system (governor)
located in the auxillary control cabinet behind
• In the event of a propulsion system the cab.
malfunction, a qualified technician should
inspect the truck and verify that the 10. All hoses and mating fittings should be capped
propulsion system does not have dangerous as they are removed to prevent possible system
voltage levels present before repairs are contamination.
started.
11. Tag and verify that all cables, harnesses, and
hoses have been removed before the structure
is lifted off the truck.

B02028 Structural Components B2-3


GRILLE, HOOD AND LADDER
Removal
1. Remove the hardware that attaches diagonal
ladder (4, Figure 2-1) to the front bumper.
2. Attach an appropriate lifting device to the ladder
and lift the structure off the truck.
3. Disconnect the wiring harnesses and remove
the cable clamps as necessary to allow
rremoval of the hood.
4. Attach an appropriate lifting device to hood and
grille assembly (1, Figure 2-2).
5. Remove all side mounting capscrews and
lockwashers (2, Figure 2-2).
6. Loosen the radiator bumpers on both decks.
7. Lift the hood and grille assembly from the truck
and move it to a work area.

FIGURE 2-2. HOOD AND GRILLE REMOVAL

1. Hood & Grille 2. Capscrews and


Assembly Lockwashers

Installation
1. Move hood and grille assembly (1, Figure 2-2)
from the work area to the truck. Use an
appropriate lifting device to lift it into place.
2. Align the mounting holes with the brackets
attached to the radiator assembly. Install side
mounting capscrews (2, Figure 2-2).
3. Adjust and tighten both radiator bumpers.
4. Use an appropriate lifting device to lift diagonal
FIGURE 2-1. DECK COMPONENTS ladder (4, Figure 2-1) into position over the
mounting pads on the front bumper. Align the
1. L.H. Deck 5. Center Deck mounting holes and install the hardware.
2. Electrical Cabinet 6. R.H. Deck Tighten the capscrews to the standard torque.
3. Cab 7. Retarding Grids
5. Connect all cables, harnesses, hoses and
4. Diagonal Ladder
clamps that were removed previously.

B2-4 Structural Components B02028


RIGHT DECK AND COMPONENTS 5. Install an appropriate lifting device to the lifting
eyes at each corner of the deck and take up any
Removal slack. Do not attach the lifting device to the
1. Remove the access covers from retarding grids handrails.
(7, Figure 2-1). Tag and disconnect all electrical 6. Remove deck mounting hardware (2, Figure 2-
leads in preparation for removal. Attach an 3) at the deck support and the front upright.
appropriate lifting device to the lifting eyes on 7. Loosen the radiator bumpers on both decks.
the grids. 8. Ensure that all wiring harnesses, cables and
2. Remove retarding grid mounting hardware (3, hoses have been removed. Carefully lift the
Figure 2-3) at six locations. deck from the deck supports.
3. Lift the retarding grids clear of deck structure (1,
Figure 2-3) and move it to a work area. Installation

NOTE: If repairs to the grid assembly or cooling Repeat the removal procedure in reverse order to
blower are required, refer to the applicable G.E. install the right deck and components. Clean all
publication for service and maintenance procedures. mount mating surfaces and tighten all attaching
hardware to standard torque specifications listed in
4. Disconnect deck lighting harness (4, Figure 2-
Section A, Standard Torque Charts and Conversion
3). Inspect the underside of the deck and, if
Tables.
necessary, remove any hoses or cables that
remain. The lighting harness and clamps do not Ensure that all electrical harnesses and clamps are
require removal. undamaged and reinstalled securely. Replace any
components as necessary.

FIGURE 2-3. R.H. DECK STRUCTURE MOUNTING


1. Deck Structure 3. Retarding Grid Mounting Hardware
2. Deck Mounting Hardware 4. Deck Lighting Harness

B02028 Structural Components B2-5


LEFT DECK AND COMPONENTS 2. Install an appropriate lifting device to the lifting
eyes at each corner of the deck and take up any
slack. Do not attach the lifting device to the
handrails.
3. Remove deck mounting hardware (2, Figure 2-
4) at the deck support and the front upright.
If air conditioning system components must be 4. Loosen the radiator bumpers on both decks.
removed, refer to Section N, Operator Comfort,
for instructions on discharging the air 5. Ensure that all wiring harnesses, cables and
conditioning system befoe disconnecting any air hoses have been removed. Carefully lift the
conditioning lines and servicing the air deck from the deck supports.
conditioning system after installation.
Installation
NOTE: Refer to Section N, Truck Cab, for cab
Repeat the removal procedure in reverse order to
removal and installation instructions.
install the right deck and components. Clean all
Removal mount mating surfaces and tighten all attaching
hardware to standard torque specifications listed in
1. Disconnect deck lighting harness (3, Figure 2- Section A, Standard Torque Charts and Conversion
4). Inspect the underside of the deck and, if Tables.
necessary, remove any hoses or cables that
remain. The lighting harness and clamps do not Ensure that all electrical harnesses and clamps are
require removal. undamaged and reinstalled securely. Replace any
components as necessary.

FIGURE 2-4. L.H. DECK STRUCTURE MOUNTING


1. Deck Structure 3. Deck Lighting Harness
2. Deck Mounting Hardware

B2-6 Structural Components B02028


CENTER DECK
Removal Installation
1. Install an appropriate lifting device to the deck Repeat the removal procedure in reverse order to
and take up any slack. install the right deck and components. Clean all
2. Remove deck mounting hardware (2, Figure 2- mount mating surfaces and tighten all attaching
5). hardware to standard torque specifications listed in
Section A, Standard Torque Charts and Conversion
3. Ensure that all wiring harnesses, cables and
Tables.
hoses have been removed. Carefully lift the
deck from the truck. Ensure that all electrical harnesses and clamps are
undamaged and reinstalled securely. Replace any
components as necessary.

FIGURE 2-5. CENTER DECK STRUCTURE


MOUNTING
1. Deck Structure 2. Deck Mounting
Hardware

B02028 Structural Components B2-7


NOTES

B2-8 Structural Components B02028


SECTION B3
DUMP BODY
INDEX

DUMP BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4

BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5

BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6

HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6

BODY-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6

BODY-UP RETENTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6

ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7

B03020 1/08 Dump Body B3-1


NOTES

B3-2 Dump Body 1/08 B03020


DUMP BODY
DUMP BODY Removal
1. Park truck on a hard, level surface and block all
the wheels. Attach cables and a lifting device to
the dump body and take up the slack as shown
in Figure 3-1.
2. Remove the mud flaps from both sides of the
Inspect the condition and rating of all lifting body. Remove any electrical wiring and hoses
devices, slings, chains, and cables. Refer to the that are attached to the body.
manufacturer's manual for correct capacities and
3. Attach chains around the upper end of the hoist
safety procedures when lifting components.
cylinders to support them after the mounting
Replace any questionable items.
pins are removed.
Ensure that the lifting device is rated for at least a
4. Remove retaining capscrew and locknut (4,
45 ton capacity. Slings, chains, and cables used
Figure 3-2) from each of the upper hoist
for lifting components must be rated to supply a
cylinder mounting eyes. Remove each pivot pin
safety factor of approximately 2X the weight
(2).
being lifted. When in doubt as to the weight of
components or any service procedure, contact
the Komatsu area representative for further
information.
Lifting eyes and hooks should be fabricated from
the proper materials and rated to lift the load
being placed on them.
Never stand beneath a suspended load. Use of
guy ropes are recommended for guiding and
positioning a suspended load.
Before raising or lifting the body, ensure there is
adequate clearance between the body and
overhead structures or electric power lines.

FIGURE 3-2. HOIST CYLINDER MOUNT (UPPER)


1. Dump Body 3. Hoist Cylinder
2. Pivot Pin 4. Retaining Capscrew
and Locknut

FIGURE 3-1. DUMP BODY REMOVAL


1. Lifting Cables 2. Guide Rope

B03020 1/08 Dump Body B3-3


5. Remove capscrews (1, Figure 3-3) and locknuts Installation
(2) from each body pivot pin. 1. Park truck on a hard, level surface and block all
6. Attach a body pivot pin support fixture to the the wheels. Attach cables and a lifting device to
bracket on the underside of the dump body to the dump body and take up the slack as shown
aid in supporting the pin as it is removed. in Figure 3-1. Lower the body over the truck
7. Remove body pivot pins (3) far enough to allow frame and align the body pivots with the frame
shims (6) to drop out. Complete removal of pins pivot holes.
is not necessary unless new pins are being 2. Install shims (6, Figure 3-3) in both body pivots,
installed. as required, to fill the outside gaps and center
NOTE: To prevent the pivot pins from falling while the body on the frame pivot. Do not install
removing the dump body, use chains to secure them shims on the inside. A minimum of one shim is
to the truck. required at the outside end of both frame pivots.
8. Lift the dump body clear of the chassis and 3. Align the hole in pivot pin (3) with the capscrew
move it to a work area. Block the body to hole in the pin retainer - part of body pivot ear
prevent damage to the body guide. (4). Push the pivot pin through shims (6), frame
pivot (7), and into pivot bushings (5) and (9) in
9. Inspect bushings (5), (8), and (9), body ear (4), each side of the body pivot.
and frame pivot (7) for excessive wear or
damage. 4. Install capscrew (1) through each pin and
tighten nuts (2) to 203 N•m (150 ft lbs). Use
washers, as necessary, on the nut side only to
ensure the capscrew does not run out of
threads when tightening.
5. Align the hoist cylinder upper mounting eye
bushings with the hole through the body. Align
the pin retaining capscrew hole and install the
pin.
6. Install retaining capscrews and locknuts (4,
Figure 3-2). Tighten the locknuts to 203 N•m
(150 ft lbs).
7. Install all mud flaps, electrical wiring and hoses
to the body.

FIGURE 3-3. DUMP BODY PIVOT PIN


1. Capscrew 6. Shim
2. Locknut 7. Frame Pivot
3. Body Pivot Pin 8. Pivot Bushing
4. Body Ear 9. Body Pivot Bushing
5. Body Pivot Bushing

B3-4 Dump Body 1/08 B03020


BODY PADS
NOTE: It is not necessary to remove the dump body 6. Remove the blocks from the frame. Lower the
to replace the body pads. Body pads should be body onto the frame.
inspected during scheduled maintenance inspections
and replaced if worn excessively. Adjustment
1. Raise the unloaded dump body to a height that 1. Park the truck on a flat, level surface.
is sufficient to allow access to all of the body 2. All pads (except the rear pad on each side)
pads. Place blocks between the body and should contact the frame with approximately
frame. Secure the blocks in place. equal compression of the rubber.
2. Remove pad mounting hardware (2, Figure 3- 3. A gap of approximately 1.9 mm (0.075 in.) is
4). required at each rear pad. This can be
3. Remove body pad (4) and shims (5). Note the accomplished by using one less shim at each
number of shims installed at each pad location. rear pad.
The rear pad on each side should have one less 4. If pad contact appears to be unequal, repeat the
shim than the other pads. adjustment procedure.
4. Install new body pads with the same number of NOTE: Proper contact between the body pad and
shims that were removed in step 3. frame is required to assure maximum pad life.
5. Install pad mounting hardware (2) and torque to
88 N•m (65 ft lbs).

FIGURE 3-4. BODY PAD INSTALLATION


1. Dump Body 3. Frame 5. Shim
2. Pad Mounting Hardware 4. Body Pad 6. Mounting Pad

B03020 1/08 Dump Body B3-5


BODY GUIDE HOIST LIMIT SWITCH
1. Inspect the body guide wear points each time a Refer to Section D, Electrical System (24VDC), for
body pad inspection is performed. Body guide the hoist limit switch adjustment procedure.
(2, Figure 3-5) should be centered between
wear plates (3) with a maximum gap of 4.8 mm
(0.19 in.) at each side (new wear plates).
BODY-UP SWITCH
2. If the gap becomes excessive, install new parts.
Refer to Section D, Electrical System (24VDC), for
the body up switch adjustment procedure.

BODY-UP RETENTION CABLE

To avoid serious personal injury or death, the


body-up retention cable must be installed
anytime personnel are required to perform
maintenance on the vehicle with the dump body
in the raised position.
Refer to Section A3, General Safety & Operating
Instructions - Securing The Body, for the body-up
retention cable installation procedure.

FIGURE 3-5. BODY GUIDE

1. Dump Body 3. Body Guide Wear


2. Body Guide Plates

B3-6 Dump Body 1/08 B03020


ROCK EJECTORS 3. If rock ejector arm (1) becomes bent, it must be
removed and straightened.
Rock ejectors are placed between the rear dual
wheels to keep rocks or other material from lodging 4. At each shift change, inspect mounting brackets
between the tires. Failure to maintain the rock (4, Figure 3-7), pins (2) and stops (3) for wear
ejectors could allow debris to build up between the and damage. Repair as necessary.
dual wheels and cause damage to the tires.

Inspection
1. The rock ejectors must be positioned on the
center line between the rear tires within 6.0 mm
(0.25 in.).
2. With the truck parked on a level surface, the
arm structure should be approximately 454.5
mm (17.9 in.) from wheel housing (2). Refer to
Figure 3-8.
NOTE: With rock ejector arm (1, Figure 3-7) hanging
vertical as shown in Figure 3-8, there must be no gap
at stop block (3, Figure 3-7).

FIGURE 3-7. ROCK EJECTOR INSTALLATION

FIGURE 3-6. ROCK EJECTOR MOUNTING 1. Rock Ejector Arm 2. Wheel Housing
BRACKET
1. Rock Ejector 3. Stop Block
2. Pin 4. Mounting Bracket

B03020 1/08 Dump Body B3-7


NOTES

B3-8 Dump Body 1/08 B03020


SECTION B4
FUEL TANK
INDEX

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4

FUEL GAUGE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

FUEL TANK BREATHER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

FUEL RECEIVERS (WIGGINS QUICK FILL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6

B04025 Fuel Tank B4-1


NOTES

B4-2 Fuel Tank B04025


FIGURE 4-1. FUEL TANK INSTALLATION
1. Fuel Tank 8. Fuel Supply Hose 15. Flat Washer
2. Fuel Receiver Assembly 9. Fuel Gauge Sender 16. Rubber Dampener
3. Mounting Cap 10. Drain Cock 17. Ground Wire
4. Upper Mounting Hardware 11. Hoist Circuit Filter Assemblies 18. Terminals
5. Filler Cap 12. Steering Circuit Filter Assembly 19. Sender Mounting Hardware
6. Fuel Return Hose 13. Wire Harness
7. Breather 14. Lower Mounting Hardware

B04025 Fuel Tank B4-3


FUEL TANK Cleaning
The fuel tank has drain cock (10, Figure 4-1) and a
Removal
cleaning port in the side that allows steam or solvent
1. Raise the truck body and install the body up to be used for cleaning tanks that have accumulated
retention cable. foreign material.
2. Loosen filler cap (5, Figure 4-1) and open drain It is not necessary to remove the tank from the truck
cock (10) to drain the fuel from the tank into for cleaning of sediment. However, rust and scale on
clean containers. Tighten the filler cap when the the walls and baffles may require complete tank
fuel is completely drained. removal. This allows cleaning solutions to be in
3. Disconnect wire harness (13) and remove the contact with all interior surfaces by rotating the tank
clamps attached to the fuel tank. Remove in various positions.
ground wire (17).
Before a cleaning procedure of this type, all vents,
4. If equipped, close the inline shutoff valves. the fuel gauge sender, and hose connections should
Remove fuel return hose (6) and fuel supply be removed and temporarily sealed. After cleaning is
hose (8). Cap the hoses and tank fittings to complete, the temporary plugs can be removed.
prevent contamination.
5. Remove hoist circuit filter assemblies (11) and If the tank is to remain out of service, a small amount
steering circuit filter assembly (12) from the of light oil should be sprayed into the tank to prevent
frame side of the tank. Support the filter rust. All openings should be sealed for rust
assembly by placing a chain over the frame rail. prevention.
It is not necessary to remove the hydraulic
Installation
hoses.
1. Thoroughly clean the frame mounting brackets
NOTE: The weight of the empty fuel tank is and the mounting hardware holes. Re-tap the
approximately 1690 kg (3725 lbs). Use lifting devices threads if damaged.
with adequate capacity to remove the fuel tank.
6. Attach a lifting device to the lifting eyes on each NOTE: The weight of the empty fuel tank is
side of the tank. approximately 1690 kg (3725 lbs). Use lifting devices
with adequate capacity to remove the fuel tank.
7. Remove lower mounting hardware (14), flat
washer (15) and rubber dampeners (16). 2. Lift the fuel tank into position over the frame
Remove upper mounting hardware (3) and trunnion mounts and lower it into position.
mounting caps (4). Install mounting caps (4, Figure 4-1) and upper
mounting hardware (3). Do not tighten the
8. Lift the fuel tank from the brackets and move it hardware at this time.
to a work area.
3. Install rubber dampeners (16), flat washers (15)
9. Remove fuel gauge sender (9), breather (5), and lower mounting hardware (14) in the lower
and other fittings as required to perform interior mounts. Tighten the lower mounting hardware
cleaning. See “Fuel Gauge Sender” in this to 420 ± 42 N•m (310 ± 31 ft lbs).
section for removal of the fuel gauge sender.
4. Tighten upper mounting hardware (3) to 711 ±
Repair 72 N•m (525 ± 53 ft lbs).
5. Install hoist circuit filter assemblies (11) and
If a tank has been damaged and requires structural
steering circuit filter assembly (12) on the frame
repair, perform such repairs before final cleaning.
side of the tank.
6. Connect fuel return hose (6) and fuel supply
hose (8). Install wire harness (13) and all
clamps. Open the inline shutoff valves, if
equipped.
If a tank is to be weld repaired, special
precautions are necessary to prevent fire or
explosion. Consult local authorities for safety
regulations before proceeding.

B4-4 Fuel Tank B04025


FUEL GAUGE SENDER
Fuel gauge sender (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 the fuel below the level of the fuel gauge
sender.
2. Disconnect the wires from terminals (18).
3. Remove sender mounting hardware (19).
Carefully remove the sender and gasket.

Installation
1. Clean the mating surfaces. Install a new gasket.
2. Install the fuel gauge sender in the tank. Ensure
the float is oriented properly and moves freely.
3. Install sender mounting hardware (19) and
tighten the capscrews to the standard torque.
4. Connect the wires to terminals (18).
5. Fill the fuel tank and check for leaks.

FUEL TANK BREATHER VALVE


NOTE: The relief pressure of the fuel tank breather
valve is 70 - 89 kPa (10 - 13 psi).

Disassembly FIGURE 4-2. BREATHER VALVE


1. Remove clamp (3, Figure 4-2), cover (2) and
screen (1). 1. Screen 7. End Fitting
2. Cover 8. Stem
2. Remove ball cage (10), solid ball (11) and float 3. Clamp 9. O-Ring
balls (12). 4. Body 10. Ball Cage
3. Unscrew end fitting (7) from body (4). 5. Valve Spring 11. Solid Ball
4. Remove stem (8) and valve spring (5). 6. O-Ring 12. Float Ball

Assembly
1. Clean and inspect all parts. If any parts are
damaged, replace the entire assembly.
2. Place valve spring (5) into position in body (4).
3. Insert stem (8) into end fitting (7).
4. Screw end fitting (7) into body (4). Ensure the
components are properly aligned and seated.
5. Place screen (1) and cover (2) into position on
the breather. Install clamp (3).
6. Insert the balls into ball cage (10) with solid ball
(11) on top.
7. Insert the ball cage onto the stem. A minimum
of two cage coils must be seated in the groove
on the stem. Ensure the solid ball is able to seat
properly on the stem. If not, adjust the cage
accordingly.

B04025 Fuel Tank B4-5


FUEL RECEIVERS (WIGGINS QUICK FILL)
Fuel receiver assembly (2, Figure 4-1) is mounted on If fuel spills from the fuel tank breather valve, or if the
the front of the fuel tank. Fuel receiver assembly (6, tank does not completely fill, check the breather
Figure 4-3) is mounted on the left hand frame rail. valve to see whether the float balls are in place and
the outlet screen is clean. If the breather valve is
Keep the cap on each fuel receiver to prevent dirt
operating properly, the problem will most likely be in
build up in valve area and nozzle grooves.
the fuel supply system.

FIGURE 4-3. LEFT SIDE QUICK FILL


1. Refueling Box 3. Capscrew 5. Filler Cap 7. Fuel Tank
2. Filler Hose 4. Tapped Bar 6. Receiver Assembly 8. Frame Rail

B4-6 Fuel Tank B04025


SECTION C
ENGINE
INDEX

POWER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-1

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1

POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1

AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1

FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-1

C01014 Index C1-1


NOTES

C1-2 Index C01014


SECTION C2
POWER MODULE
INDEX

POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3

SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3

PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-4

REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-9

HOOKUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-10

C02028 Power Module C2-1


NOTES

C2-2 Power Module C02028


POWER MODULE
The radiator, engine and alternator assemblies are SHUTDOWN PRODEURE
mounted on a roller-equipped subframe which is
contained within the truck's main frame. It is referred The truck must be shut down properly to ensure the
to as a “power module”. This arrangement permits safety of those working in the areas of the deck,
removal and installation of these components with a control cabinet and retarding grids. The following
minimum amount of disconnect and by utilizing the procedure will ensure that the electrical system is
unique “roll in/roll out” feature. properly discharged before repairs are started.
1. Stop the truck in position for repairs. Place the
Although the instructions in this section are primarily
directional control lever in PARK. Make sure
based upon the “roll out” method for major
that the parking brake indicator lamp in the
component removal, the radiator and fan may be
overhead panel is illuminated. Make sure that
removed as separate items. Instructions for radiator
the engine speed is reduced to low idle.
and fan removal are included later in this section. If
any optional equipment is installed on the truck, 2. Place the drive system in the rest mode by
additional removal and installation steps that are not turning the rest switch on the instrument panel
listed may be required. to ON. Make sure that the rest mode indicator
lamp in the overhead panel is illuminated.
The procedures outlined in this section of the manual
3. Turn off the engine by using the key switch. If
are general instructions for power module removal
the engine does not turn off, use the engine
and installation. It may be necessary to perform
shutdown switch on the center console.
some procedures in a different order or use different
methods for component removal and installation, 4. Verify that the link voltage lights are off. If they
depending on the lifting equipment available at the remain on longer than 5 minutes after
mine site. Prior to removal or repair procedures, it shutdown, notify the electrical department.
may be necessary to remove the body to provide 5. Place the GF cutout switch in the CUTOUT
clearance for lifting equipment to be used. If body position. For switch location, see Figure 3-1 in
removal is not required, raise the body and install the Section E, Propulsion System.
safety cable at the rear of the truck. 6. Verify that the steering accumulators have bled
Read and observe the following instructions before down by attempting to steer.
attempting any repairs. 7. Bleed down the brake accumulators by using
the manual bleed valves on the brake manifold.
8. Open the battery disconnect switches.
9. Tag or mark all hydraulic lines, fuel lines and
electrical connections to ensure correct hookup
during installation of the power module. Plug all
• Do not attempt to work in the deck area until
ports and cover all hose fittings and
body safety cables have been installed.
connections when disconnected to prevent
• Do not step on or use any power cable as a contamination.
handhold when the engine is running.
NOTE: It is not necessary to remove the radiator
• Do not open any control cabinet covers or before removing the power module. However, the
touch the retarding grid elements until all
coolant must be drained and the piping connected to
shutdown procedures have been followed.
the brake cooling heat exchanger must be removed.
• All removal, repairs and installation of If radiator removal is needed or only radiator repair is
propulsion system electrical components necessary, refer to Section C, Cooling System.
must be performed by an electrical
maintenance technician properly trained to
service the system.
• In the event of a propulsion system
malfunction, a qualified technician should
inspect the truck and verify the propulsion
system does not have dangerous voltage
levels present before repairs are started.

C02028 Power Module C2-3


PREPARATION FOR REMOVAL
1. If radiator removal is required, refer to Section
B, Structural Components, for hood and grille
removal instructions. The power module may
be removed with the hood installed if desired.
2. Remove bottom drive shaft cover (2, Figure 2-
1). Disconnect pump drive shaft (3) at drive
shaft U-joint companion flange (4) mounted on
the alternator.

FIGURE 2-1. HYDRAULIC PUMP DRIVE SHAFT


1. Hydraulic Pump 3. Pump Drive Shaft
2. Bottom Drive Shaft 4. Companion Flange
Cover
FIGURE 2-2. MAIN ALTERNATOR BLOWER DUCT

3. Remove the main alternator blower ducts to 1. Control Cabinet 6. Wheel Motor Duct
provide clearance to raise the engine off the 2. Intake Duct 7. Main Alternator
subframe mounts. Refer to Figure 2-2. 3. Alternator Inlet Duct 8. Alternator Inlet
4. Blower Assembly Transition Structure
a. Disconnect cables and hoses as required. 5. Wheel Motor Duct
b. Remove alternator inlet transition structure Transition Structure
(8) and the gasket.
5. Attach an overhead hoist to the center deck
c. Remove wheel motor duct transition structure. Remove the deck mounting
structure (5). hardware. Lift the deck from the truck and move
d. Cover all openings to prevent foreign it to a storage area.
material from entering the system. 6. Disconnect the air cleaner restriction indicator
nylon tubes at the inlet ducts.
4. Remove engine air intake duct support rods (9, 7. Loosen clamps (5) on hump hoses (4) between
Figure 2-3). Remove any hoses or electrical the four engine air inlet ducts and air cleaner
cables attached to center deck structure. outlet ducts.
8. Disconnect the inlet ducts at each of the four
turbochargers. Remove the inlet ducts from
truck. Cover the openings at the turbochargers.

C2-4 Power Module C02028


FIGURE 2-3. ENGINE AIR INLET PIPING

1. Air Cleaner Assemblies 7. Reducer Elbow


2. Left Rear Intake Duct 8. T-Bolt Clamp
3. Left Front Intake Duct 9. Duct Support Rod
4. Hump Hose 10. Right Front Intake Duct
5. T-Bolt Clamp 11. Right Rear Intake Duct
6. T-Bolt Clamp

C02028 Power Module C2-5


15. Remove the mounting hardware from the
diagonal ladder mounting pads. Lift the ladder
from truck and move it to a storage area.
16. Refer to Section N4, Heater/Air Conditioner, for
the procedures required to properly remove the
refrigerant. After the system has been
discharged, disconnect the refrigerant hoses
that are routed to the cab at the compressor
and receiver/drier (10).
NOTE: The system contains HFC-134A refrigerant.

Federal regulations prohibit venting air


FIGURE 2-4. ENGINE EXHAUST PIPING conditioning system refrigerants into the
atmosphere. An approved recovery/recycle
1. Capscrew 4. Front Exhaust Pipe
station must be used to remove the refrigerant
2. Lockwasher 5. Rear Exhaust Pipe
from the air conditioning system.
3. Nut 6. Clamp Bands

REMOVAL
9. Remove exhaust duct clamps (6, Figure 2-4).
Remove capscrews (1), lock washers (2) and 1. Remove capscrews, nuts and washers (8,
nuts (3) retaining the exhaust pipes to the Figure 2-5) that secure the front subframe
turbocharger outlet flange. Remove exhaust support to the main frame.
ducts (4) and (5). Cover the opening on the 2. Install a safety chain around the engine
engine exhaust outlets. subframe cross member and the main frame to
prevent the power module from rolling when the
10. Remove the alternator power cable protective
subframe rollers are installed.
cover. Disconnect all electrical cables, oil and
fuel lines that would interfere with power 3. Remove the capscrews and caps that secure
module removal (see Figure 2-5). Cover or plug the subframe mounting bushings to subframe
all lines and their connections to prevent support bracket (3) at the rear of the subframe.
entrance of dirt or foreign material. To simplify 4. Check the engine and the alternator to ensure
this procedure, most connections utilize quick that all cables, wires, hoses, tubing and
disconnects. linkages have been disconnected.
11. Close the cab heater shutoff water valves,
disconnect the water lines and drain the water
from the heater core. Secure the water lines
away from engine compartment to prevent
interference with power module removal.
12. Drain the engine coolant into clean containers
for re-use after engine installation. Coolant
capacity is approximately 738 L (195 gal).
13. Disconnect and remove heat exchanger piping
(6, Figure 2-5) from the engine water pump and
the radiator.
14. Remove upper radiator support rod (11) at each
side of radiator.

C2-6 Power Module C02028


FIGURE 2-5. POWER MODULE REMOVAL & INSTALLATION
1. Alternator 5. Power Module Subframe 8. Front Frame/Subframe Mount
2. Rear Power Module Lift Eye 6. Heat Exchanger Piping 9. Front Power Module Lift Eye
3. Rear Frame/Subframe Mount 7. Heat Exchanger 10. Receiver/Drier
4. Engine/Alternator Cradle 11. Upper Radiator Support Rod
Structure

C02028 Power Module C2-7


FIGURE 2-7. POWER MODULE LIFTING POINTS
1. Module Lifting Tool 4. Engine
2. Alternator 5. Power Module
3. Lifting Points Subframe

FIGURE 2-6. SUBFRAME ROLLERS 7. Roll the power module forward so that
1. Roller Assembly adequate clearance is provided in front of the
2. Subframe control cabinet for the lifting device to be
3. Capscrews attached to engine/alternator cradle structure
(2, Figure 2-5) and front subframe lifting points
5. Place a jack under the rear of the power (9). Place stands or blocks under the front of the
module. Raise the rear portion of engine subframe and lower the hoist until the front of
subframe and install the subframe rollers (see the subframe is supported. Install a safety chain
Figure 2-6). Lower the rear portion of the to prevent the subframe from rolling.
subframe carefully until the rollers rest on the 8. Attach lifting device (1, Figure 2-7) to the hoist
main frame guide rail. and attach it to the engine/alternator cradle
structure and the front subframe lifting points as
NOTE: Subframe rollers are supplied in the truck tool
shown in Figure 2-7. Remove the safety chain.
group and can be installed in the storage position
after use as shown in Figure 2-6. 9. Raise the power module slightly to determine
whether it is on an even plane. Move the power
module straight out of the truck to a clean work
area for disassembly.
For further disassembly of the engine, alternator, and
radiator, refer to the appropriate section of this
The complete power module, including the hood manual.
and grille, weighs approximately 17,000 kg
(37,500 lbs). Make sure that the lifting device to
be used has adequate capacity.
Lift the power module only at the lifting points on
the subframe and engine/alternator cradle
structure. Refer to Figure 2-5 and 2-7.

6. Position the hoist to front subframe lifting points


(9, Figure 2-5). Raise the engine subframe until
the engine is on a level plane. Remove the
safety chain.

C2-8 Power Module C02028


INSTALLATION 6. Lower the power module to the subframe guide
rails, relax the hoist slightly, and roll the power
1. Inspect the main frame guide rails. Remove any
module into truck frame as far as possible
debris which would interfere with power module
before the lifting chains contact the control
installation.
cabinet.
2. Clean the main frame rear support brackets.
7. Place stands or blocks under the front of the
Apply a light film of soap solution to each rubber
subframe to support the assembly while
bushing (3, Figure 2-5) located at the rear of the
repositioning the hoist.
subframe.
8. Install a safety chain around the truck frame
3. Check the subframe rollers making sure they
and the subframe to prevent the power module
roll freely and are in the “roll out” position (see
from rolling forward.
Figure 2-6).
9. Place a small block behind each rear subframe
4. Attach a lifting device to engine/alternator
roller to prevent rolling.
cradle structure and front subframe lifting points
(Figure 2-7). 10. Lower the hoist to allow the subframe to rest on
the stands and rollers. Remove the lifting
device.
11. Attach the hoist to the front lifting eyes on the
subframe.
The complete power module, including the hood
and grille, weighs approximately 17,000 kg 12. Remove the small blocks behind the subframe
(37,500 lbs). Make sure that the lifting device to rollers. Remove the safety chain and slowly roll
be used has adequate capacity. the power module into position over the main
frame mounts. Lower the hoist until the front
subframe mounts are aligned and seated on the
5. Raise the power module and align the subframe front main frame mounts. Install the safety
rollers within the main frame guide rails. chain.
13. Place a jack under the rear of the subframe to
support the power module. Raise the power
module just enough to permit removal of the
subframe rollers.
14. Lower the rear portion of the subframe until the
subframe rubber bushings are seated in
mounting brackets (3, Figure 2-5) on the main
frame of the truck.
15. After the subframe is seated in the frame
mounts, the safety chain may be removed from
the front subframe member.
16. Install the rubber bushings, capscrews, washers
and nuts in front mounts (8, Figure 2-5). Tighten
the capscrews to 1017 ± 72 N•m (750 ± 53 ft
lbs).
17. Install the rear subframe mounting caps and
secure caps in place with lubricated capscrews.
Tighten capscrews to 552 ± 20 N•m (407 ± 15 ft
FIGURE 2-8. POWER MODULE INSTALLATION
lbs). Refer to Figure 2-5.

C02028 Power Module C2-9


HOOKUP 7. Install piping (6, Figure 2-5) between heat
exchanger (7) and the engine water pump and
1. Install all ground straps between the frame and
radiator.
subframe. Reconnect the electrical harnesses
at the power module subframe connectors. 8. Inspect the alternator/wheel motor cooling duct
gaskets and replace them if damaged. Install
2. Install the diagonal ladder on the front platform.
alternator inlet transition structure (8, Figure 2-
3. Attach a hoist to the front center deck and lift it 2) and wheel motor duct transition structure (5).
into position. Install the capscrews, flat
9. Connect hydraulic pump drive shaft companion
washers, lockwashers and nuts at each
flange (4, Figure 2-1) to alternator (5). Tighten
mounting bracket. Tighten the capscrews to the
the capscrews to the standard torque. Install
standard torque.
driveshaft guard (2).
4. Install the engine air intake duct supports.
Install the intake ducts between the 10. Connect all remaining electrical, oil, and fuel
turbochargers and air cleaner outlet ducts (see lines. Connect the air filter restriction indicator
Figure 2-3). Clamp them securely to ensure that hoses.
a positive seal is made. Refer to Figures 2-3 11. Close the battery disconnect switches.
and 2-9 for correct installation and alignment
12. Connect the hoses routed from the cab to the
examples.
receiver/drier and air conditioning compressor.
5. Install exhaust ducts (4) and (5, Figure 2-4) on
the turbocharger outlet flanges and pipes at the 13. Refill the radiator and service the engine with
frame crossmember. appropriate fluids. Refer to Section P,
Lubrication and Service, for capacity and fluid
6. Connect the cab heater inlet and outlet hoses, specifications.
then open both valves.
14. Recharge the air conditioner system. Refer to
Section N4, Heater/Air Conditioner.

FIGURE 2-9. AIR INLET PIPING CONNECTIONS

C2-10 Power Module C02028


SECTION C3
COOLING SYSTEM
INDEX

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5

Filling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

REPAIRING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8

Pressure Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9

COOLANT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9

C03034 7/07 Cooling System C3-1


NOTES

C3-2 Cooling System 7/07 C03034


COOLING SYSTEM
RADIATOR 3. Refer to Section N4, Heater / Air Conditioner,
for the procedures required to properly remove
Removal the refrigerant from the air conditioning system.
1. Drain the coolant into clean containers for NOTE: The system is charged with HFC-134A
possible reuse after engine installation. Refer to refrigerant.
Section P, Lubrication and Service, for the
a. Remove the refrigerant hose clamps and
cooling system capacity.
receiver/drier (3, Figure 3-1) from the front
2. If the radiator is being removed without the left side of the radiator shroud. Disconnect
complete power module, remove the grille and the harness from the low pressure switch on
hood according to the removal instructions in the receiver/drier.
Section B, Structural Components.
b. Remove the clamps and disconnect inlet
hose (4, Figure 3-2) and outlet hose (5) at
the condenser. Remove mounting hardware
(3) and remove condenser (2) from radiator
assembly (1).
Federal regulations prohibit venting air
c. Cap all hoses to prevent contamination.
conditioning system refrigerants into the
Remove any remaining clamps attaching the
atmosphere. An approved recovery/recycle
hoses and wiring to the radiator shroud.
station must be used to remove the refrigerant
Reposition the hoses and wiring to allow
from the air conditioning system.
removal of the radiator and shroud
assembly.
4. Disconnect the lines at the fuel cooler. Remove
all clamps that secure the lines to the radiator.

FIGURE 3-1. RECEIVER/DRIER LOCATION


1. Condenser 3. Receiver/Drier
2. Accumulator

FIGURE 3-2. AIR CONDITIONER CONDENSER


1. Radiator Assembly 4. Inlet Hose
2. Condenser 5. Outlet Hose
3. Mounting Hardware

C03034 7/07 Cooling System C3-3


FIGURE 3-4. FAN GUARDS
1. Fan Guard (LH) 3. Radiator Shroud
2. Fan Guard (RH)
FIGURE 3-3. RADIATOR PIPING, BOTTOM VIEW 9. Attach the hoist to the radiator and take up any
1. Drain Cock 4. Outlet Elbow (Rear) slack.
2. Outlet Elbow (Front) 5. Heat Exchanger
NOTE: The radiator and shroud assembly weighs
3. Radiator Mounting 6. Engine Subframe
approximately 2600 kg (5730 lbs).
Hardware
10. Remove upper support rods (2, Figure 3-5) and
stabilizer bars (3), if equipped.
5. Unclamp and separate all upper hoses between
the radiator and the engine. 11. Remove radiator mounting hardware (4, Figure
6. Remove outlet elbows (2, Figure 3-3) and (4) at 3-3) that secures the radiator and to the power
the bottom tanks. Cap all coolant lines to module subframe.
prevent contamination. 12. Loosen the radiator bumpers on both decks.
7. Remove and cap the hoses from the radiator 13. Ensure that all hoses and wiring harnesses
top tank and surge tank. have been removed. Lift the radiator slightly
8. Remove the capscrews and lockwashers to free with the hoist and move the radiator forward
fan guards (1, Figure 3-4) and (2) from radiator until it is clear of the engine fan. Move the
shroud (3). The two halves of the fan guard may radiator to a work area for service.
be disassembled and removed or the complete
guard may be moved to the rear to clear the
shroud during removal of the radiator.

C3-4 Cooling System 7/07 C03034


6. Tighten radiator mounting hardware (4) at the
lower radiator mounting brackets to the
standard torque.
7. For added stability, stabilizer bars (3) may be
installed. Install the stablizer bars at the radiator
brackets and subframe as shown, then tighten
the mounting hardware to the standard torque.
8. Install fan guards (1, Figure 3-4) and (2) using
the original mounting hardware.
10. Install the upper hoses between the radiator
and the engine. Seat the hoses fully and tighten
the clamps securely.
11. Install outlet elbows (2, Figure 3-3) and (4) with
new gaskets.
12. Route the lines to the fuel cooler and clamp
them in place. Attach the lines to the fuel cooler
fittings.
13. Install the air conditioning system components.
a. Install condenser (2, Figure 3-2), hoses (4)
and (5), and all clamps.
b. Install receiver/drier (3, Figure 3-1) and
clamp the hoses. Attach the harness to the
low pressure switch.
c. Clamp all hoses and wiring to the studs
FIGURE 3-5. RADIATOR MOUNTING using the original clamps. Refer to Section N,
1. Radiator 4. Radiator Mounting Heater / Air Conditioner, for complete
2. Upper Support Rod Hardware instructions on evacuating and recharging
3. Stabilizer Bar the air conditioning system.
14. Install the grille and hood according to the
instructions in Section B, Structural
Installation Components. Make sure that both radiator
bumpers are adjusted and secured.
1. Attach a hoist to the radiator and lift it into
position on the power module subframe. 15. Make sure that all coolant drains are closed, all
2. Install radiator mounting hardware (4, Figure 3- pipe plugs are installed, and all hoses are
5) at the lower radiator mounting brackets. Do connected securely. Service the cooling system
not tighten at this time. with the proper mixture of antifreeze as
recommended in Section P, Lubrication and
3. Inspect the rubber bushings for upper support Service. Check for leaks and correct as needed.
rods (2) and replace them if worn or damaged.
16. Start and operate the engine until the cooling
4. Install upper support rods (2) and the mounting
system reaches normal operating temperature.
hardware at both ends. Do not tighten at this
Recheck for leaks during engine operation.
time.
Turn off the engine and correct any leaks.
5. Adjust the upper support rods until the radiator
is positioned perpendicular to the subframe
within ± 3.0 mm (0.12 in.) measured at top of
radiator. When the position is established,
tighten the upper support rod locknuts and
recheck the perpendicularity of the radiator.

C03034 7/07 Cooling System C3-5


Filling Procedure REPAIRING THE RADIATOR
Internal Inspection
If desired, an internal inspection can be performed on
the radiator before complete disassembly. The
inspection involves removing tubes from the radiator
core and cutting them open. This type of inspection
The cooling system is pressurized due to thermal can indicate overall radiator condition, as well as
expansion of coolant. DO NOT remove the coolant and additive breakdown.
radiator cap while the engine and coolant are hot. To perform this inspection, remove four random
Severe burns may result. tubes from the air inlet side of the radiator. Remove
1. With engine and coolant at ambient tubes from both the top and bottom cores, and near
temperature, remove the radiator cap. each end of the radiator. Refer to Disassembly and
Assembly in this section for the proper instructions
Note: If coolant is added using the Wiggins quick fill for removing and installing tubes. Analyze any
system, the radiator cap must be removed before contaminant residue inside the tube to determine the
adding coolant. cause of contamination. Flush the system before
2. Fill the radiator with the proper coolant mixture returning the truck to service. Contact your nearest
(as specified by the engine manufacturer) until L&M Radiator facility for further instructions or visit
coolant is visible in the sight gauge. the L&M website at www.mesabi.com.
3. Install the radiator cap.
4. Operate the engine for five minutes, then check
the coolant level. External Cleaning
5. If coolant is not visible in the sight gauge, Many radiator shops use a hot alkaline soap, caustic
repeat steps 1 through 4 of this procedure. Any soda or chemical additives in their boil-out tanks,
excess coolant will be discharged through the which can attack solders. These tanks are generally
vent hose after the engine reaches normal not recommended. Before such tanks are used for
operating temperature. cleaning, ensure that the cleaning solutions are
NOTE: Engine coolant must always be visible in the not harmful to solder. Otherwise, damage to the
sight gauge before truck operation. radiator will result. Completely rinse the cleaned
tube or core in clean water after removing it from the
boil-out tank.
As an alternative to boil-out tanks, radiators can be
cleaned externally with a high pressure washer and
soap. In most cases, it may be best to blow out any
dry dirt with a high pressure air gun prior to washing
the core with the high pressure washer.
Pressure washers should not exceed 8275 kPa
(1200 psi). Unlike conventional cores, the spray
nozzle can be used right up next to the core. Starting
from the air exit side, place the high pressure washer
nozzle next to the fins. Concentrate on a small area,
slowly working from the top down. Spray straight into
the core, not at an angle. Continue washing until the
exit water is free of dirt. Repeat from the opposite
side.

C3-6 Cooling System 7/07 C03034


Disassembly

To aid in removal of the tubes, clean the radiator


prior to disassembly. Heating the seals with hot
water helps to loosen the grip on the tubes.
Cleaning the radiator prior to disassembly also
reduces the risk of internal contamination. After
cleaning, spray lubricating oil at the top end of
the tubes.
FIGURE 3-7. INSTALLATION TOOL (VJ6567)

2. After the tube is loose, position the installation


tool (VJ6567) at the bottom of the tube to be
removed. Refer to Figure 3-8. The upper jaw of
the installation tool should be positioned just
below the rectangular section of the tube. The
bottom jaw should rest on the seal. Squeeze
the installation tool just enough to allow the
bottom of the tube to be removed from the
bottom seal.
NOTE: To ease in the removal of tubes, use the
breaker tool and installation tool simultaneously.
FIGURE 3-6. BREAKER TOOL (XA2307)

1. Start at the top row of tubes. Use the breaker


tool (XA2307) to loosen the tube to be removed.
When using the breaker tool, position it at the
top or bottom of the tube. Never position it in the
middle of the tube or damage may result. Use
the breaker tool to lightly twist the tube back
and forth within the seals to loosen the grip.
Refer to Figure 3-7.

FIGURE 3-8. ANGLING TUBE DURING REMOVAL

3. Pull the tube from the top seal while


simultaneously twisting the tube. Angle the tube
only far enough to clear the radiator. Refer to
Figure 3-9. Removing the tube at an excessive
angle may cause damage to the tube.
4. Remove all the top tubes before removing the
bottom tubes. After all of the tubes are
removed, use pliers to remove the seals from
the tanks. Discard all seals. New seals must be
used for assembly.

C03034 7/07 Cooling System C3-7


Cleaning and Inspection
1. Use a drill with a 19 mm (3/4 in.) wire brush to
remove any foreign material from the tube
holes, then wipe the holes clean.
2. Clean the inside of the tanks and tubes. In most
cases, just flushing the inside with soap and a
high pressure hot water washer will be
sufficient. If not, contact an L&M manufacturing
facility for further instructions or visit the L&M
website at www.mesabi.com.
3. Check for signs of internal blockage in the tubes
and tanks. If desired, you may cut open tubes
for inspection. If contamination is present, the
tube should be analyzed. The radiator must be FIGURE 3-9. PROPER SEAL INSTALLATION
properly flushed of all contaminants and
corrective action must be taken to prevent such
contamination from occurring in the future.
Refer to Internal Inspection in this section. 2. Use a 13 mm (1/2 in.) diameter brush to
lubricate the seals with lube/release agent
4. Buff the tube ends with a polishing wheel and a (XA2308).
copper polishing compound. If any debris can
not be removed by buffing, using an emery 3. Use a spray bottle to lubricate the tube ends
cloth, steel wool or a wire wheel with a wire size with the lube/release agent.
of 0.15 - 0.20 mm (0.006 - 0.008 in.) is 4. When installing tubes, start at one end and
acceptable. Be careful not to mar the tube ends. work toward the center. After you reach the
center, move to the opposite end, and again
Assembly work toward the center. If any of the tubes are
difficult to install, do not force the tube. Remove
NOTE: For easier installation, soak the seals in hot
the tube and determine the problem. Possible
water before installing.
causes may be:
1. Install new tube seals onto the bottom tank and
the bottom side of the center tank. Do not install •adequate seal/tube lubrication
seals in the top core at this time. Seals for the •improperly installed seal
top of the tubes do not have locking grooves;
•damaged seal or tube end
bottom tube seals do. Ensure the correct seals
are installed in the proper position. •tube angle excessive during installation and/or
tube not centered in seal.
The seal holes must be dry during installation.
Use a rubber mallet and a flat metal plate to
lightly tap the seals into place. Using excessive Inspect the seals and tube ends for damage
force will drive the seals in too far. When before trying to reinstall a tube. Replace as
installed properly, the seals should be slightly necessary.
convex. Improperly installed seals are concave
with a smaller diameter hole. Refer to Figure 3-
10.

C3-8 Cooling System 7/07 C03034


5. Working from the front of the radiator (opposite Pressure Testing
of fan side), install the bottom row of tubes
The radiator should be pressure tested at 103 kPa
starting with the fan side row.
(15 psi) for 30 minutes. Various methods of pressure
When installing the tubes, center the top of the testing include the following:
tube in the top seal while angling the tube only
as much as necessary. Twist the tube while • Pressurize the radiator and submerge into a test
applying upward force. Push the tube into the tank. Watch for leaks.
seal until enough clearance is available to • Lay the front side of the radiator on the floor. Cap
install the bottom end of the tube into the off ports, and fill the radiator with hot water.
bottom seal. Pressurize the radiator and check for leaks.
6. Center the bottom end of the tube in the bottom • Cap off radiator ports. Install an air pressure
seal. Push the tube downward until the formed gauge and pressurize to 103 kPa (15 psi).
bead on the tube is seated inside the lock ring Remove the air source and monitor the pressure
groove in the seal. If necessary, use the gauge.
installation tool (VJ6567) to pull the tube • Pressurize the radiator with air, and spray sealed
downward into the seal. The tool has a hooking joints with soapy water.
device on the end of one of the handles for
aiding in installation. Refer to Figure 3-11.
Additional service information can be found on
the L&M Radiator website at www.mesabi.com.

COOLANT SYSTEM
TROUBLESHOOTING
If abnormal coolant temperatures are experienced,
perform the following visual inspections and tests:
1. Check the coolant level and thoroughly inspect
the system for leaks.
a. Check for proper coolant/antifreeze mixture.
b. Follow the recommendations of the engine
FIGURE 3-10. USING INSTALLATION TOOL TO manufacturer regarding use of cooling
INSTALL TUBE system additives.
2. Inspect the radiator fins for restrictions. Ensure
7. Ensure that all tube beads are seated in their the air flow through the radiator is not restricted
respective bottom seals. Align and straighten all by debris or bent radiator fins.
tubes during the installation of each row to allow 3. Inspect the fan blades for damage.
maximum air flow through the radiator. 4. Check the radiator cap sealing surfaces.
8. Install tube stay ends. Install the felt air baffles 5. If equipped with a fan clutch, refer to Section N,
behind the front and back rows while Operator Comfort, for complete instructions for
completing tube installation. testing and repairs, if required.
6. Refer to the engine manufacturer's Service
Manual for information about testing and
replacing the cooling system thermostats.

C03034 7/07 Cooling System C3-9


NOTES

C3-10 Cooling System 7/07 C03034


SECTION C4
POWER TRAIN
INDEX

ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3

ALTERNATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5

Measuring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5

Joining the Alternator and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-7

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

C04027 5/08 Power Train C4-1


NOTES

C4-2 Power Train 5/08 C04027


POWER TRAIN
ALTERNATOR REMOVAL
The following instructions cover the removal of the
main alternator from the engine after the power
module has been removed from the truck.

The alternator weighs approximately 3720 kg


(8200 lbs). Ensure the lifting device to be used
has adequate capacity. Lift the alternator only at
the lifting eyes on the alternator.
1. Attach a hoist with two lifting chains to both
lifting eyes (8, Figure 4-2) on top of alternator
(1).
2. Block up the rear of the engine.
3. Loosen cradle adjustment setscrews (3, Figure
4-1). FIGURE 4-1. CRADLE STRUCTURE
4. Loosen engine-to-cradle capscrews (5, Figure 1. Cradle Structure 4. Subframe
4-2). 2. Jam Nut 5. Gap
3. Adjustment Setscrew

FIGURE 4-2. ENGINE AND ALTERNATOR


1. Alternator 4. Flywheel Housing 7. Subframe
2. Mounting Hardware 5. Capscrews 8. Alternator Lifting Eyes
3. Cradle Structure 6. Engine

C04027 5/08 Power Train C4-3


5. Remove the access cover at the front, right side
of engine flywheel housing (4). Reach through
the access openings and remove 12 capscrews
(6, Figure 4-3) that join engine drive ring (7) to
alternator rotor (8). Rotate the crankshaft to
align each capscrew with the access hole.
NOTE: Ensure that all 12 capscrews have been
removed.
6. Remove 16 capscrews (3) that secure flywheel
housing adapter (2) to alternator housing (1).
NOTE: The clearance between the head of capscrew
(3) and flywheel housing (4) will not permit complete
removal of the capscrews at all locations. Ensure that
all of the capscrew threads are completely
disengaged from alternator housing (1).
7. Take up any slack in the hoist. Remove
mounting hardware (2, Figure 4-2) that secures
the alternator to the cradle structures.
8. Keep the alternator as level as possible and
move away from engine.
9. Note the location and quantity of the shims.
Keep the shims for possible reuse during
installation.
NOTE: For further disassembly instructions for the
alternator, refer to the GE Service Manual. FIGURE 4-3. ALTERNATOR TO ENGINE
MOUNTING
1. Alternator Housing 5. Capscrew
2. Flywheel Housing 6. Capscrews
Adapter 7. Engine Drive Ring
3. Capscrews 8. Alternator Rotor
4. Flywheel Housing

C4-4 Power Train 5/08 C04027


ALTERNATOR INSTALLATION Measuring Procedure
1. Thoroughly clean the alternator housing
mounting surface, rotor drive adapter mounting
surface and flywheel housing adapter mounting
surfaces.
2. Mount a magnetic base on the front of the
The following instructions must be followed to engine and a dial indicator on the front of the
ensure proper alignment and engine crankshaft crankshaft. Measure total crankshaft endplay.
endplay. Failure to follow these instructions can
Verify end play is within 0.13 - 0.38 mm (0.005 -
result in serious damage to the engine and/or
0.015 in.).
alternator.
Total Crankshaft Endplay_________________
• Never pry on the engine crankshaft damper.
3. Refer to Figure 4-4. Move the engine crankshaft
• Loosen or remove fan belts before measuring to the rear of its end travel.
crankshaft endplay to ensure that the crankshaft
moves easily and completely. a. Carefully measure Dimension “C” at four
locations, 90° apart:
• When taking measurements, always take four
equally spaced readings and average them. 1st measurement:___________________
2nd measurement:__________________
• Always measure from mating surface to mating 3rd measurement:___________________
surface. 4th measurement:___________________
• A reference to crankshaft rotation - clockwise Dimension “Cavg”:______________
(CW) or counterclockwise (CCW) - is the b. Add 1/2 (one-half) of Total Crankshaft
direction of rotation when looking at the front
Endplay from step 2 to Dimension “Cavg”.
(damper end) of engine.
c. Record (Step 3a + Step 3b) as
• Crankshaft end play: 0.13 - 0.38 mm
(0.005 - 0.015 in.) Measurement “C”:___________________

SERVICE DATA - Eccentricity & Runout Limits


Description T.I.R
Maximum Eccentricity of Flywheel 0.66 mm
Housing Bore (0.026 in.)
Maximum Face Runout of Flywheel 0.25 mm
Housing (0.010 in.)
Maximum Eccentricity of Flywheel 0.18 mm
(Coupling Assembly) (0.007 in.)
Maximum Axial Runout of Flywheel 0.25 mm
Face (Coupling Assembly) (0.010 in.)

FIGURE 4-4. SHIM LOCATION


1. Alternator Housing “A” - Dimension “A”
2. Alternator Rotor “B” - Drive Shims
3. Flywheel Housing “C” - Dimension “C”
Adapter “D” - Housing Shims
4. Engine Flywheel
Housing
5. Engine Drive Ring

C04027 5/08 Power Train C4-5


4. Refer to Figure 4-5 to determine alternator
endplay:
a. Using flat steel bar (3) bolted rigidly to
alternator rotor (2), install 5/8" - 11NC
capscrew (4) finger tight at each end into
alternator housing (1).
b. Move alternator rotor (2) axially toward the
rear (slip ring end) by alternately tightening
capscrews (4) one-half turn at a time. Do not
exceed 16 N•m (12.0 ft lbs) on each
capscrew. This establishes the maximum
permissIble rear travel for the alternator
rotor.
c. Alternately loosen capscrews (4) one turn at
a time until all torque is released. Carefully
remove steel bar (3).
Refer to Figure 4-4.
d. Carefully measure Dimension “A” at four
locations, 90° apart, and average the
measurements. Do not move the alternator
rotor.
1st measurement:___________________
2nd measurement:___________________
3rd measurement:___________________
4th measurement:___________________
Dimension “Aavg”:____________ FIGURE 4-5. ALTERNATOR END-PLAY
e. Add 0.25 mm (0.010 in.) to Dimension
“Aavg”. 1. Alternator Housing 3. Steel Bar
2. Alternator Rotor 4. Capscrew
f. Record (Step 4d + Step 4e) as
Measurement “A”:___________________
5. To determine the correct shims to use,
compare Measurement “C” (Step 3c) with
Measurement “A” (Step 4f). b. If A is greater than C, subtract: (A - C) = D
a. If C is greater than A, subtract: (C - A) = B D = ________________Shim pack thickness
B = ______________Shim pack thickness to be installed at location D, Figure 4-4.
to be installed at location B, Figure 4-4.

Alternator-to-Flywheel Housing Adapter


Rotor-to-Drive Ring Location “D”
Location “B” Shim Part Number Shim Thickness
Shim Part Number Shim Thickness 0.10 mm
TM3466
0.10 mm (0.004 in.)
TM3467
(0.004 in.) 0.18 mm
TM3468
0.18 mm (0.007 in.)
TM3469
(0.007 in.)

C4-6 Power Train 5/08 C04027


Joining the Alternator and Engine

The alternator weighs approximately 3720 kg


(8200 lbs). Ensure the lifting device to be used
has adequate capacity. Lift the alternator only at
the lifting eyes.
1. Use two lifting eyes (8, Figure 4-2) provided on
the alternator. The top front lifting eye should be
equipped with some method of adjusting the
alternator to keep it horizontal.
2. Carefully move the alternator into place and
engage engine drive ring (6, Figure 4-6) into
alternator rotor drive (7) using shims “B”, if
required. Refer to step 5a. in Measuring
Procedure.
3. Install flywheel housing adapter capscrews (2)
into alternator housing (1). Tighten to 237 N•m
(175 ft lbs).
4. Install capscrews (5) through engine drive ring
(6) into alternator rotor adapter (7). Rotate the
crankshaft to access and align holes. Tighten
capscrews (5) to 237 N•m (175 ft lbs). FIGURE 4-6. ALTERNATOR TO ENGINE
5. Install alternator-to-cradle mounting hardware MOUNTING
(2, Figure 4-2). Tighten to 712 N•m (525 ft lbs).
1. Alternator Housing 5. Capscrew
6. Tighten engine-to-cradle capscrews (5) to 465 2. Point Capscrew 6. Engine Drive Ring
N•m (345 ft lbs). 3. Flywheel Housing 7. Alternator Rotor
Adapter “B” - Drive Shims
4. Engine Flywheel “D” - Housing Shims
Housing

The total engine crankshaft endplay (step 7) must


equal the original measurement or 0.51 mm
Never pry on the engine crankshaft damper. (0.020 in.), whichever is smaller.
Severe engine damage can result.
If the endplay after the alternator and engine are
7. Mount a magnetic base on the front of the assembled is less than 0.51 mm (0.020 in.), and
engine and a dial indicator on the front of the less than the original engine crankshaft endplay,
crankshaft. Measure total crankshaft endplay. reshimming is required.
9. Rotate the crankshaft one full revolution and
Total Crankshaft Endplay:________________ listen for any unusual noise caused by moving
components contacting stationary parts.
8. Compare the value above to the measurement 10. Install the engine side cover, if removed. Install
taken before the alternator was installed on the the lockwire on all alternator mounting
engine. capscrews.
11. Install the access cover on the flywheel housing.

C04027 5/08 Power Train C4-7


ENGINE Service
Complete instructions for the disassembly, assembly
Removal
and maintenance of the engine and its components
NOTE: Refer to previous sections for removal can be found in the engine manufacturer's service
procedures for the power module, alternator, and manual.
radiator assembly.
Installation
1. Align the engine with subframe (7, Figure 4-2)
and install the capscrews at the front engine
mounts.
The engine weighs approximately 9,300 kg 2. Align and install capscrews (2) through the rear
(20,515 lbs). Ensure that the lifting device to be engine mounts and into cradle structure (3), but
used has adequate capacity. do not tighten at this time.
1. Disconnect any remaining wiring or hoses 3. Install the alternator on the engine. Refer to
between engine (6, Figure 4-2) and subframe Alternator Installation in this section.
(7). 4. Adjust setscrew (3, Figure 4-1) to equalize gap
2. Remove the capscrews at the front engine (5) between cradle structure (1) and subframe
mounts. (4) at the left side and right side. Lock the
setscrew with jam nut (2).
3. To ensure that the engine stays level while
lifting, attach a spreader bar with lifting straps to
the engine lifting eyes. Remove engine-to-
cradle structure mounting capscrews (5).
4. Lift the engine from the subframe and move to
clean work area for further disassembly.

C4-8 Power Train 5/08 C04027


SECTION C5
AIR CLEANERS
INDEX

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

SERVICING THE AIR CLEANERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

Replacing The Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

Cleaning The Main Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5

Servicing The Precleaner Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-6

AIR INTAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7

C05013 11/05 Air Cleaners C5-1


NOTES

C5-2 Air Cleaners 11/05 C05013


AIR CLEANERS
OPERATION SERVICING THE AIR CLEANERS
Air required by the diesel engine passes through the
air cleaner assemblies mounted on each side of the
radiator. These air cleaners discharge heavy
particles of dust and dirt by centrifugal action and
then remove finer particles by passing air through
The engine must be turned off before servicing
filter cartridges.
the air cleaner assemblies or opening the engine
The engine demand for air creates a vacuum in the air intake system. Never start the engine with the
air cleaners and causes outside air to be drawn in filter elements removed. Serious engine damage
through air inlets on the air cleaners. Dirty air can result.
entering here is drawn through a series of tubes that
• Inspect and empty dust collector cups at regular
are designed to produce a cyclonic action. As the air
intervals. Daily inspection is recommended.
passes through the outer portion of the tubes, a Never allow the dust level to build up to the tube
circular motion is set up causing dust and dirt (precleaner) chamber.
particles to be thrown from the air stream into dust
collectors (1, Figure 5-1). At the same time, the air • During operation or after the engine has been
stream turns and is directed up through the center of turned off, observe the air filter restriction gauges
mounted on the overhead panel in the cab.
the tubes into the filter chamber. Here the air passes
When a gauge shows maximum restriction, filter
through the main filter element and safety filter service is required.
element and out the clean air outlet to the engine's
air intake system. The function of the safety filter is to • Check all engine air inlet tubes, hoses and
increase overall reliability and engine protection. clamps. All connections must be air tight to
prevent dirt from entering.
• Air cleaner housing fasteners and mountings
must be tight.
• After the filters have been serviced, reset the air
filter restriction gauges by pressing the reset
button on the face of the gauge.

Replacing The Filter Element


1. Turn off the engine. Clean any dirt and dust
from the area around air cleaner element cover
(4, Figure 5-1).
2. Loosen large wing nut (5, Figure 5-2) on the air
cleaner cover to free main filter element (10).
Pull the main filter element from the assembly.
3. Inspect the main filter element carefully for
damage, holes or breaks which might affect
reuse of the element. If the element appears
serviceable, proceed with the cleaning
procedure. If defects are found in the element,
wing nut (5) must be removed from the
assembly and installed on the new element.
4. Check safety filter indicator (7). If the solid red
FIGURE 5-1. ENGINE AIR CLEANERS area is showing, replacement of the safety filter
1. Dust Collectors 3. Air Intake Cover is required. If the center is green, the safety
2. Precleaner Section 4. Element Cover filter does not require replacement.

C05013 11/05 Air Cleaners C5-3


6. Reset the safety filter indicator from red to
green by gently blowing air into the threaded
hole from gasket side of the indicator nut.
7. Install the new safety filter element. Tighten the
wing nut to 13 N•m (10 ft lbs).
Have a new safety (secondary) filter element on 8. Install main filter element (10) into the air
hand before removing the used filter element. Do cleaner and secure it with wing nut (5). Tighten
not keep the intake system open to the the wing nut hand tight. Do not use a wrench or
atmosphere any longer than necessary. pliers. If the original filter element is being
5. If the safety filter element must be replaced, reused, ensure the sealing gasket is not
remove the indicator and remove the safety damaged. The gasket must seal completely.
filter element. Discard the filter element. Do not 9. Close and latch the dust collectors on the
clean the damaged filter element. bottom of the air cleaner assembly.

FIGURE 5-2. AIR CLEANER ASSEMBLY

1. Dust Collector 5. Wing Nut 9. Safety Filter Element 13. Precleaner Gasket
2. Dust Collector Gasket 6. Wing Nut Gasket 10. Main Filter Element 14. Safety Filter Element
3. Tube 7. Safety Filter Indicator 11. Main Element Gasket Gasket
4. Unfiltered Air Inlet 8. End Cover 12. Clean Air Outlet

C5-4 Air Cleaners 11/05 C05013


Cleaning The Main Filter Element

Only the main filter elements may be cleaned,


and then only if they are structurally intact. Do
not reuse an element that is damaged. Do not
clean and reuse the safety (secondary) filter
elements. Replace them with new parts.
After inspection, determine the condition of the main
filter element and choose either the washing method FIGURE 5-3. INSPECTING FILTER ELEMENT
or compressed air method for cleaning the element.
If the element is clogged with carbon, soot, oil and/or
dust, the complete washing procedure will produce Clean dust loaded elements with dry filtered
the best results. compressed air as follows:
1. Maximum nozzle pressure must not exceed
207 kPa (30 psi). The distance from the nozzle
Wash elements with water and detergent as follows:
to the surface of the filter element must be at
1. Soak the element in a solution of detergent and least 25 mm (1 in.) to prevent damage to the
water for at least 15 minutes. Rotate the filter material.
element back and forth in the solution to loosen 2. As shown in Figure 5-4, direct the stream of air
dirt deposits. Do not soak elements for more from the nozzle against the inside of the filter
than 24 hours. element. This is the clean air side of the
2. Rinse the element with a stream of fresh water element and air flow should be opposite of
in the opposite direction of normal air flow until normal air flow.
rinse water runs clear. Maximum permissible 3. Move the air flow up and down vertically with
water pressure is 276 kPa (40 psi). A complete the pleats in the filter material while slowly
and thorough rinse is essential. rotating the filter element.
3. Dry the element thoroughly. If drying is done 4. When cleaning is complete, inspect the filter
with heated air, the maximum temperature must element as shown in Figure 5-3. If holes or
not exceed 60°C (140°F) and must be ruptures are noted, discard the element and
circulated continually. Do not use a light bulb to replace with a new element.
dry elements.
4. After cleaning, inspect the element thoroughly
for the slightest ruptures and damaged gaskets.
A good method for detecting paper ruptures is
to place a light inside the filter element, as
shown in Figure 5-3, and inspect the outer
surface of the filter element. If holes or ruptures
are found, do not reuse the element. Discard
and replace with a new element.

FIGURE 5-4. CLEANING FILTER ELEMENT


WITH COMPRESSED AIR

C05013 11/05 Air Cleaners C5-5


Servicing The Precleaner Section NOTE: The precleaner section may be separated
from the air cleaner assembly without removing the
The tubes in precleaner section (2, Figure 5-1)
entire air cleaner from the truck.
should be cleaned at least once per year and at each
engine overhaul. More frequent cleaning may be 1. Remove air intake cover (3, Figure 5-1).
necessary depending upon operating conditions and Remove the mounting hardware that secures
and the local environment. the precleaner section to the air cleaner
assembly. Remove the precleaner section. The
To inspect the tubes in the precleaner section, safety filter element must remain in place to
remove the main filter element. Do not remove the protect the engine intake.
safety filter element. Loosen the clamps and remove
dust collector (1, Figure 5-2). Use a light to inspect 2. Loosen the clamps and remove dust collector
the tubes. All tubes should be clear and the light (1) from the precleaner section. Wash the dust
should be visible. collector with a water and liquid soap solution.
3. Submerge the precleaner section in a solution
NOTE: Both the main and safety elements must be of Donaldson D-1400 and warm water (see
installed in the air cleaner while Steps 1 and 2 are Figure 5-6). Mix the solution according to the
being accomplished to prevent any possibility of dirt directions on the package. The tube section
being forced into the engine intake area. must be down. Soak for 30 minutes, then
Dust can be removed with a stiff fiber brush (see remove the precleaner section from the
Figure 5-5). Do not use a wire brush. Dust may also solution. Rinse thoroughly with fresh water and
be removed effectively using compressed air. blow dry.
Heavy plugging of the tubes may require soaking and Severe plugging may require the use of an
washing the entire precleaner section. Refer to the Oakite 202 and water solution instead. The
following procedure. solution should be 50% Oakite 202 and 50%
fresh water.
4. Check the precleaner gaskets carefully for any
evidence of air leaks. Replace if necessary.
5. Install the precleaner section and gaskets on
the air cleaner assembly. Install all mounting
hardware that was removed.
6. Install the dust collector and gasket on the
precleaner section. Secure the dust collector
with mounting clamps.

FIGURE 5-5. REMOVING DUST FROM


PRECLEANER TUBES

FIGURE 5-6. WASHING AND SOAKING


PRECLEANER SECTION

C5-6 Air Cleaners 11/05 C05013


AIR INTAKE TROUBLESHOOTING
To ensure maximum engine protection, all
connections between the air cleaners and the engine
intake are tight and sealed. If air leaks are
suspected, check the following:
1. Check all intake lines, tubes and hump hoses
for breaks, cracks, and holes which could allow
an intake air leak.
2. Check that all air cleaner gaskets are sealing
properly.
3. Check the main and safety filter elements for
ruptures, holes or cracks.
4. Check the air cleaner assembly for structural
damage, cracks, breaks or other defects which
could allow air leakage. Check that all mounting
hardware is tightened properly.

C05013 11/05 Air Cleaners C5-7


NOTES

C5-8 Air Cleaners 11/05 C05013


SECTION C7
FAN CLUTCH
INDEX

REMOVAL & INSTALLATION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-3

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-6

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-16

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-20

TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-34

C07001 Fan Clutch C7-1


NOTES

C7-2 Fan Clutch C07001


FAN CLUTCH

REMOVAL & INSTALLATION TOOLING

TOOL A - FRONT SLEEVE BEARING

TOOL B - REAR SLEEVE BEARING

C07001 Fan Clutch C7-3


TOOL C - FRONT AND REAR SLEEVE BEARING REMOVER

TOOL D - WEAR SLEEVE AND RETAINER/SEAL ASSEMBLY INSTALLER;


BEARING REMOVER; ASSEMBLY PUSHER TOOL

C7-4 Fan Clutch C07001


TOOL E - BEARING INSTALLER

TOOL F - BEARING INSTALLER

C07001 Fan Clutch C7-5


DISASSEMBLY

FIGURE 7-1. FAN CLUTCH EXPLODED VIEW

1. Orifice Fitting 16. External Snap Ring (Spacer) 32. Internal Snap Ring
2. Dowel Pin (Rear) 17. Seal Ring (Hook-Type) 33. Main Bearing (Front)
3. Pitot Tube 18. Bolt 34. O-Ring Seal
4. Wear Sleeve 19. Washer 35. Bearing Retainer (Front)
5. Retainer/Seal Assembly 20. Pulley 36. Oil Seal
6. Shaft Assembly 21. Pulley Adapter 37. Washer
7. Name Plate Kit 22. Seal Ring (Large) 38. Bolt
8. Washer 23. Piston 39. Wear Sleeve
9. Bolt 24. Seal Ring (Small) 40. Retainer/Seal Assembly
10. Oil Seal 25. Spring Washer 41. Sleeve Bearing (Rear, Short)
11. Bearing Retainer (Rear) 26. Shim 42. Fan Mounting Hub
12. Bearing Spacer 27. External Snap Ring 43. Dowel Pin (Front)
(External Snap Ring) 28. External Snap Ring 44. Sleeve Bearing (Front, Long)
13. O-Ring Seal 29. Clutch Hub 45. End Cap
14. Main Bearing (Rear) 30. Facing Plate
15. Internal Snap Ring 31. Steel Clutch Plate

C7-6 Fan Clutch C07001


FIGURE 7-1. FAN CLUTCH CUTAWAY (Typical)
3. Pitot Tube 14. Main Bearing 27. External Snap Ring 37. Washer
4. Wear Sleeve 15. Internal Snap Ring 28. External Snap Ring 38. Bolt
5. Retainer/Seal 16. External Snap Ring 29. Clutch Hub 39. Wear Sleeve
Assembly 17. Seal Ring (Hook-Type) 30. Facing Plate 40. Retainer/Seal Assembly
6. Shaft Assembly 20. Pulley 31. Steel Clutch Plate 41. Sleeve Bearing
8. Washer 22. Seal Ring (Large) 32. Internal Snap Ring (Rear, Short)
9. Bolt 23. Piston 33. Main Bearing 42. Fan Mounting Hub
10. Oil Seal 24. Seal Ring (Small) 34. O-Ring Seal 44. Sleeve Bearing
11. Bearing Retainer 25. Spring Washer 35. Bearing Retainer (Front, Long)
13. O-Ring Seal 26. Shim 36. Oil Seal 45. End Cap

C07001 Fan Clutch C7-7


FIGURE 7-4.
FIGURE 7-2.

1. Support the fan clutch on a bench with fan 3. Remove O-ring seal (34).
mounting hub (42) facing upward. Support the
assembly beneath the pulley. Remove bolts
(38) and washers (37).

FIGURE 7-3. FIGURE 7-5.

2. Install lifting eyes, and attach a hoist and chains


to front bearing retainer (35). Use a small 4. Position the bearing retainer and hub assembly
screwdriver to separate the front bearing on the bench with clutch hub (29) up. Remove
retainer from pulley adapter (21), and set it external snap ring (28).
aside on a bench.

C7-8 Fan Clutch C07001


FIGURE 7-8.

FIGURE 7-6.
7. Remove front oil seal (36).

5. Remove clutch hub (29).

FIGURE 7-9.

FIGURE 7-7.
8. Remove internal snap ring (32).
6. Position the sub-assembly beneath the ram of a
press. Support the assembly beneath the
bearing retainer as close as possible to fan
mounting hub (42). Press the fan mounting hub
out of the front bearing using tooling (B).

C07001 Fan Clutch C7-9


FIGURE 7-10.
FIGURE 7-12.

11. Remove front retainer/seal assembly (40).


9. Turn bearing retainer (35) over on the press Wedge a large chisel or other appropriate tool
bed. Press front bearing (33) out of the bearing behind the retainer to force it off fan mounting
retainer using tooling (D). hub (42).

FIGURE 7-13.

FIGURE 7-11. Use a chisel to make three indentations in wear


sleeve (39) in order to loosen the sleeve. The
indentations should be approximately 120
10. Support beneath the fan mounting hub with end degrees apart from one another. Remove the
cap (45) down, but approximately 50 mm (2 in.) wear sleeve.
above the press bed. Using a solid steel bar or
NOTE: Use caution when using the chisel. Do not cut
equivalent, press the end cap from the fan
through the sleeve. Damage to the shaft can cause
mounting hub.
future leaks.

C7-10 Fan Clutch C07001


FIGURE 7-14.

12. Inspect sleeve bearing (44) and sleeve bearing FIGURE 7-16.
(41). Compare the color of each bearing to the
chart above. The lighter the appearance of the 14. Remove the stack of facing plates (30) and
bearing, the more worn it is. If either bearing steel clutch plates (31) from inside the pulley.
needs replacing, proceed to the next step. If the
bearings are in good condition, skip the next
step.

FIGURE 7-17.

FIGURE 7-15. 15. Remove external snap ring (27), shim (26), and
spring washer (25).
13. Position tooling (C) against sleeve bearing (41).
Press the front sleeve bearing downward to
press it out of the fan mounting hub. Rear
sleeve bearing (44) will be pressed out
simultaneously.

C07001 Fan Clutch C7-11


FIGURE 7-20.

FIGURE 7-18.
18. Support beneath the pulley to prevent it from
dropping to the bench. Remove bolts (9) and
16. Attach wire lifting hooks to piston (23). Use the lockwashers (8).
lifting hooks to pull the piston from pulley
adapter (21).

FIGURE 7-19.

FIGURE 7-21.
17. Remove seal rings (22) and (24) from the
piston. 19. Install lifting eyebolts to the shaft and bearing
retainer assembly. Use a suitable lifting device
to lift the assembly from the pulley. Remove O-
ring seal (13).
NOTE: It may be necessary to use a soft rubber
mallet to separate the shaft and bearing retainer from
the pulley.

C7-12 Fan Clutch C07001


FIGURE 7-22.

20. Position the shaft as shown. Insert a phillips-


FIGURE 7-24.
head screwdriver into pitot tubes (3) to loosen
and remove them from the shaft. Rotate the
pitot tube until the sealant holding it tight is
broken loose. Then grip the pitot tube with a
pair of pliers and gently tap on the pliers to 22. Remove external snap ring (16).
remove the pitot tubes from the hole in the
shaft.

FIGURE 7-25.
FIGURE 7-23.

21. Remove both seal rings (17). 23. Remove internal snap ring (15).

C07001 Fan Clutch C7-13


FIGURE 7-28.

FIGURE 7-26. 26. Use tooling (E) to press rear bearing (14) out of
rear bearing retainer (11).

24. Support the bearing retainer as close as


possible to the bearing bore. Be careful not to
damage the retainer/seal assembly. Press the
shaft out of bearing (14) using tooling (E).

FIGURE 7-29.

27. Use a chisel to make three indentations in wear


sleeve (4). The indentations should be
approximately 120 degrees apart from one
FIGURE 7-27. another. Remove the wear sleeve.
NOTE: Use caution when using the chisel. Do not cut
25. Remove oil seal (10) from bearing retainer (11). through the sleeve. Damage to the shaft can cause
future leaks.

C7-14 Fan Clutch C07001


FIGURE 7-30.

28. Remove rear retainer/seal assembly (5). Drive


the assembly off the shaft or wedge a large
chisel or other appropriate tool behind the
retainer to force it off.

C07001 Fan Clutch C7-15


CLEANING AND INSPECTION
Thoroughly clean all components before inspection.
Check each of the following components, and follow the guidelines for reuse:
• Ball bearings - Replace at time of rebuild.
• Internal snap rings - Must not be damaged or worn. Must be flat and have square edges at outer diameter.
• External snap rings - Must not be damaged or worn. Must be flat and have square edges at inner diameter.
• Seal rings - Replace during rebuild.
• Oil seals - Replace during rebuild.
• Bolts and washers - Reuse unless damaged or worn.
• Retainer/Seal assemblies - Replace if damaged or worn.
• Wear sleeves - Replace during rebuild.
• Sleeve bearings - Inspect color of surface. Refer to Figure 7-14.

FIGURE 7-31. SHAFT ASSEMBLY WEAR DIMENSIONS

1. Check the shaft assembly for wear or damage. Refer to Figure 7-31 for dimensions.
NOTE: Some shafts were manufactured as two-piece assemblies. Do not attempt to separate the shaft assembly.

2. Inspect and clean the pitot tube holes in the shaft. Use a standard reamer (straight flute, 0.3770 in. diameter).
Remove pipe plugs in the shaft for cleaning and reinstall using Loctite® Primer N and #242.

C7-16 Fan Clutch C07001


FIGURE 7-32.

3. Check pulley and adapter dimensions.

FIGURE 7-34.

5. Check piston (23) dimensions.

FIGURE 7-33.

4. Check rear bearing retainer (11) dimensions.

C07001 Fan Clutch C7-17


FIGURE 7-35. PISTON REWORK
(For earlier pistons with the drilled orifice.)

6. Check the piston for a drilled orifice at the inside


face. If the piston contains the orifice, modify
the piston as shown in Figure 7-35.
7. Inspect clutch hub (29) for wear. Wear marks
that may be present on the teeth must not
restrict plate movement. If they have smooth
entry and exit ramps, the notches will not
restrict plate movement and the clutch hub may
be reused.
8. Check steel plates (31) for wear. The plates
must be smooth and free of grooves or heat
related damage. The plates are 3.07 mm (0.121
in.) minimum thickness when new and must be
flat within 0.13 mm (0.005 in.).
9. Inspect facing plates (30). Minimum thickness
for new facing plates is 2.77 mm (0.109 in.).
Grooves are 0.15 mm (0.006 in.) deep. The
plates must be flat within 0.13 mm (0.005 in.).
Check the teeth for excessive wear. When new,
the space between the teeth is approximately
7.11 mm (0.280 in.).
FIGURE 7-36.

10. Inspect fan mounting hub (42).

C7-18 Fan Clutch C07001


FIGURE 7-37.

11. Inspect front bearing retainer (35).


12. Inspect end cap (45) for any wear or raised
nicks.

C07001 Fan Clutch C7-19


ASSEMBLY
NOTE: The fan clutch is reassembled using Loctite ® 2. If removed, install dowel pin (43) into fan
(or equivalent) sealants. Follow manufacturer's mounting hub assembly (42). Refer to Figure 7-
recommendations regarding minimum cure time to 38. Press the pin into the hub, leaving 2.3 mm
prevent oil from washing the sealant from the sealing (0.090 in.) exposed.
surfaces.
If the shaft did not originally come with
pinned bearings, install the dowel per
1. Place end cap (45) in a freezer or on dry ice to instructions in Figures 7-38 and 7-39.
prepare for installation in the following steps.

FIGURE 7-39.

FIGURE 7-38.

C7-20 Fan Clutch C07001


FIGURE 7-40.

FIGURE 7-42.

4. Turn the hub over on the bed of the press.


Using tooling (B), press rear sleeve bearing (41)
into the fan mounting hub until the tool contacts
the shoulder of the hub.

FIGURE 7-41.

3. Using tooling (A), press front (long) sleeve


bearing (44) into the fan mounting hub until the
tool contacts the shoulder of the hub. Ensure
the correct bearing is installed. There are two
sleeve bearings, and each one must be
installed in the proper area of the hub to ensure
the lube passage is not restricted. Refer to
Figure 7-40.

C07001 Fan Clutch C7-21


FIGURE 7-44.

FIGURE 7-43.

5. Press front retainer/seal assembly (40) onto the


fan mounting hub (42) using tooling (D). The
inner race of the retainer should be recessed
1.0 mm (0.040 in.) below the shoulder.
Check carefully to ensure that the retainer/seal
assembly is installed straight and is not bent or
damaged in any way which will cause
interference between it and the bearing retainer
after assembly.

• Front wear sleeve (39) is NOT


interchangeable with rear (notched) wear
sleeve (4). The inside diameter of the front
wear sleeve is color coded red. FIGURE 7-45.
• Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from 6. Coat the inside diameter of front wear sleeve
occurring. (39) and the wear sleeve diameter of the shaft
with Loctite Primer N and #242 (or equivalent).
• Use extreme care when handling the wear Using tooling (D), press the wear sleeve onto
sleeve. The slightest nicks or scratches may
the shaft until it is flush with the shoulder.
cause leakage.
NOTE: Some fan hubs may have a small hole on the
wear sleeve mounting journal. This hole is not used
and will be covered by the wear sleeve.

C7-22 Fan Clutch C07001


FIGURE 7-46.
FIGURE 7-48.
7. Coat the bore of the fan mounting hub (42) with
a thin coating of Loctite Primer N and #242. 9. Install internal snap ring (32).
Remove frozen end cap (45) from the freezer.
Do not apply Loctite to the end cap. Press the
end cap into the hub until the cap bottoms out.

FIGURE 7-47.
FIGURE 7-49.

8. Apply Loctite Primer N and #609 to the mating 10. Turn the retainer over on the press bed. Coat
surfaces of front bearing (33) and front bearing the outside diameter of front oil seal (36) and
retainer (35). Place the bearing into position on the mating surface on the bearing retainer with
the retainer with the notch for the bearing pin Loctite Primer N and #242 (or equivalent).
facing downward.
Use tooling (E) to press the oil seal into the front
Press the front bearing into the bearing retainer bearing retainer until it is flush with the front
using tooling (E) or equivalent. Press ONLY on face. Ensure that the lip of the seal is dry.
the outer race of the bearing until it seats at the Wipe any excess Loctite from the seal area and
bottom of the bore. remove any rubber strings from the seal.

C07001 Fan Clutch C7-23


FIGURE 7-50.

11. Coat the inside diameter of the bearing and the


fan mounting hub bearing journal with Loctite
Primer N and #609 (or equivalent). Place the FIGURE 7-51.
front bearing retainer sub-assembly into
position on the fan mounting hub. Ensure the
notch in the bearing is aligned with the bearing 12. Install clutch hub (29) on the fan mounting hub
dowel pin. Do not allow the seal lip to come in assembly (42) with the open end down. (No
contact with the Loctite. Press the bearing onto special timing is necessary.)
the hub using tooling (D) until it contacts the
wear sleeve.
Wipe any lubricant or sealer from the seal
lip. The seal lip is teflon and must remain
dry for proper sealing to occur.
Spin the bearing retainer at least 25 revolutions
to ensure proper rotation of the bearing and to
burnish the seal.

FIGURE 7-52.

13. Install external snap ring (28) to hold the clutch


hub in place.

C7-24 Fan Clutch C07001


FIGURE 7-53.

FIGURE 7-55.

15. Use tooling (D) to press rear retainer/seal


assembly (5) onto shaft (6). The inner race of
the retainer should be recessed 1.0 mm (0.040
in.) below the shoulder.
Check carefully to ensure that the retainer/seal
assembly is installed straight and not bent or
damaged in any way which will cause
interference between it and the bearing retainer
FIGURE 7-54. after assembly.

14. If removed, install rear dowel pin (2) in shaft


assembly (6). Press the pin until 2.0 mm (0.080
in.) is left exposed above the surface.
If the shaft did not originally come with
pinned bearings, install the dowel per
instructions in Figures 7-53 &7-54.

C07001 Fan Clutch C7-25


FIGURE 7-57.

FIGURE 7-56. 17. Coat the outside diameter of rear bearing (14)
and the mating surface of bearing retainer (11)
with Loctite Primer N and #609 or equivalent.
The end of the bearing with the notch is
installed first. Using tooling (F) or equivalent,
press the bearing into the bearing retainer.
Press ONLY on the outer race of the bearing
until the bearing bottoms out in the bore.
• Rear (notched) wear sleeve (4) is NOT
interchangeable with front wear sleeve (39).
The inside diameter of the rear wear sleeve is
color coded blue.
• Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from
occurring.
• Use extreme care when handling the wear
sleeve. The slightest nicks or scratches may
cause leakage.

16. Coat the inside diameter of rear (notched) wear


sleeve (4) and the wear sleeve diameter of the
fan mounting hub with Loctite Primer N and
#242 (or equivalent). Locate the sleeve so the
notch in the sleeve will be aligned with the small FIGURE 7-58.
lube hole in the shoulder. Using tooling (D),
press the wear sleeve onto the fan mounting
hub until it is flush with the shoulder.
18. Install internal snap ring (15).

C7-26 Fan Clutch C07001


FIGURE 7-59.

19. Some fan clutches were assembled with an external snap ring that is used as a spacer between the bearing
and the oil seal. Newer models were assembled using a notched spacer. If an external snap ring was used,
place snap ring (12) on top of the bearing (oil seal side). If a notched spacer was used, the spacer will be
installed in a later step. Proceed to the next step.

FIGURE 7-60.
FIGURE 7-61.

20. Coat the outside diameter of rear oil seal (10) 21. If a bearing spacer is used instead of a snap
with Loctite Primer N and #242 (or equivalent). ring (as explained in Step 19), place the spacer
Use tooling (E) or an equivalent to install the oil into position in the groove on shaft assembly
seal in the rear bearing retainer until it is flush (6). Note the location of the spacer in Figure 7-
with the rear face. 61.
Do not lubricate the seal. The seal is made of
teflon and must be installed dry.

C07001 Fan Clutch C7-27


FIGURE 7-62.
FIGURE 7-63.

23. Install external snap ring (16). Ensure that the


22. Place the shaft sub-assembly on the press bed. snap ring is fully seated in the groove. It may be
Coat the inside diameter of the bearing and the necessary to tap on the snap ring with a
bearing journal on the shaft with Loctite Primer screwdriver to fully seat it.
N and #609 (or equivalent).
Carefully, lower the rear bearing retainer sub-
assembly in place on the shaft. Do not allow the
seal lip to come in contact with the Loctite.
Ensure the notch in the bearing and the dowel
pin are aligned. If external snap ring (16) was
installed in the bearing retainer, ensure the
opening is aligned with the dowel pin.
Press the bearing onto the shaft until it reaches
the shoulder of the wear sleeve. Wipe any
excess Loctite from the assembly.
Ensure the seal lip is dry. The seal must
remain dry for proper sealing.
Spin the bearing retainer approximately 25
times to burnish the teflon seal on the wear
sleeve. Check for abnormal sounds or other
indications of contact between the retainer/seal
assembly and the bearing retainer. If FIGURE 7-64.
interference is found, remove the bearing
retainer and eliminate the point of interference.
24. Ensure that the pitot tube holes in the shaft are
clean and free of burrs and staking material to
allow the pitot tubes to fit into the holes and seat
completely to the bottom. Apply a thin coating of
Loctite Primer N and #609 (or equivalent) on
the straight end of one pitot tube (3). Coat the
tube to approximately 20 mm (0.75 in.) from the
end.

C7-28 Fan Clutch C07001


Push the pitot tubes to the bottom of the hole.
The outer end of the tube should be located well
within the pulley-locating shoulder of the
bearing retainer. Rotate the tube so the open,
bent end faces in a counterclockwise direction
and is exactly parallel to the surface of the
bearing retainer. (A large phillips-head
screwdriver inserted in the end of the tube can
be used as an alignment gage).
Install the second pitot tube in the same manner
as the first. Stake each pitot tube in three places
(at the 9, 12, and 3 o'clock positions) to prevent
the tubes from rotating in operation.

FIGURE 7-66.

26. Lubricate the seal ring grooves of piston (23)


with an oil-soluble lubricant such as engine
assembly grease. Install small seal ring (24) in
the inside groove and large seal ring (22) in the
outside groove. Refer to Figure 7-66 for proper
orientation.

FIGURE 7-65.

25. Install both hook-type seal rings (17) in the


grooves in the shaft. Rotate the rings so the slits
in the rings are 180 degrees apart from one FIGURE 7-67.
another.

27. Lubricate the external surfaces of seal rings


(22) and (24) with an oil-soluble lubricant such
as engine assembly grease. Also lubricate the
seal mating surfaces in the pulley adapter.

C07001 Fan Clutch C7-29


Do not push the piston in place. Forcing the
piston will usually cause the seal rings to be cut.
28. Carefully place the piston in the pulley. Without
pressing down on the piston, rotate it slowly
back and forth until it falls into place.

FIGURE 7-69.

30. Install spring washer (25), shim (26), and


spirolock ring (27). It will be necessary to press
downward to compress the spring washer while
forcing the spirolock to properly seat in the
groove. The shim must then be centered on the
spring washer to prevent it from interfering with
the movement of the piston.

FIGURE 7-68.

29. Align the tangs of the piston for final assembly


of the fan clutch. Lift the front bearing retainer
sub-assembly in place on the pulley. While
doing so, the slots of the front bearing retainer
will engage the tangs of the piston, and the
retainer will rest against the pulley. FIGURE 7-70.
Then, rotate the bearing retainer (and piston) 31. Place the front bearing retainer sub-assembly
until the bolt holes align in the bearing retainer on the bench with the clutch hub up. Install one
and pulley. Carefully remove the bearing steel clutch plate (31) in place in the bearing
retainer sub-assembly. retainer. Dip one facing plate (30) in new engine
oil. Allow the excess oil to drain off, then place
the facing plate on top of the steel plate.
Repeat this step until all 16 plates have been
installed.

C7-30 Fan Clutch C07001


32. Turn the pulley adapter assembly over and
install two lifting eyes 180 degrees apart. Install
a guide bolt in one bolt hole of the pulley. Refer
to Figure 7-71.
Coat front O-ring seal (34) with petroleum jelly
or an oil-soluble grease. Place the seal in the
groove in the pulley. The grease should secure
the seal in the groove during installation.
Carefully lower the pulley. Ensure that the guide
bolt is aligned with a bolt hole in the bearing
retainer assembly and the O-ring seal is still
securely in place. Lower the pulley until it rests
on the front bearing retainer.

FIGURE 7-71.

FIGURE 7-73.

33. Install at least four bolts (38) with lockwashers


(37) 90 degrees apart. Snug them down.

FIGURE 7-72.

C07001 Fan Clutch C7-31


FIGURE 7-76.

FIGURE 7-74.
36. Install bolts (9) with lockwashers (8). Tighten
each bolt to 49 - 58 N•m (36 - 43 ft lbs).
34. Lubricate O-ring seal (13) with petroleum jelly or
an oil-soluble grease and install it in the pulley
groove.

FIGURE 7-77.
FIGURE 7-75.

35. Lubricate hook-type seal rings (17) on the shaft 37. If removed, install orifice fitting (1) in the “oil in”
assembly. Carefully lower the shaft sub- port of the bracket.
assembly into the pulley bore and onto the
pulley until the retainer rests on the pulley.
Use caution when lowering. Damage to the
sleeve bearings may result if the shaft is cocked
during installation.

C7-32 Fan Clutch C07001


FIGURE 7-78.

38. Turn the assembly over on the bench. Install remaining bolts (38) and lockwashers (37). Tighten each bolt to
49 - 58 N•m (36 - 43 ft lbs).

C07001 Fan Clutch C7-33


TEST PROCEDURE

1. The fan clutch should be fully locked up with 275 kPa (40 psi) oil pressure supplied at the control pressure
port.
2. Operate the fan clutch with 82° C (180° F) oil supplied to the “oil in” port for 2 hours. Manually engage and
disengage the clutch during the test to operate seals in both modes. Restrict the fan mounting hub rotation
while the clutch is disengaged, but ensure that the fan mounting hub is allowed to rotate freely while the clutch
is engaged.

The fan clutch rotation causes the pitot tubes to pump lubricating oil from inside the fan clutch,
maintaining low internal oil pressure. If lubricating oil is supplied to the fan clutch before it is rotating in
the proper direction, internal pressures will become excessive, causing the oil seals to leak.

C7-34 Fan Clutch C07001


SECTION D
ELECTRICAL SYSTEM (24VDC NON-PROPULSION)
INDEX

24VDC ELECTRIC SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1

24VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1

BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-1

VEHICLE HEALTH MONITORING SYSTEM (VHMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-1

INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-1

INTERFACE MODULE AND VHMS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-1

VHMS FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D14-1

NOTE: Electrical system wiring hookup and electrical schematics are located in Section R of this manual.

DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNING AND CONTINUE
TO EXIST AFTER SHUTDOWN IF THE REQUIRED SHUTDOWN PROCEDURES ARE NOT FOL-
LOWED. Before attempting repairs or working near propulsion system components, the following
precautions and truck shutdown procedure must be followed:
•DO NOT step on or use any power cable as a handhold.
•Never open any electrical cabinet covers or touch the retarding grid elements. Additional pro-
cedures are required before it is safe to do so. Refer to Section E for additional propulsion
system safety checks to be performed by a technician trained to service the system.
•ALL removal, repairs and installation of propulsion system electrical components, cables etc.
must be performed by an electrical maintenance technician properly trained to service the
system.
•In the event of a propulsion system malfunction, a qualified technician should inspect the
truck and verify the propulsion system does not have dangerous voltage levels present
before repairs are started.
•Prior to welding on the truck, maintenance personnel should attempt to notify the Komatsu
Factory Representative. The welding ground electrode should be attached as close as possi-
ble to the area to be welded. Never weld on the rear of the electrical control cabinet or the
retard grid exhaust air louvers.

After the truck is parked in position for the repairs, the truck must be shut down properly to ensure the
safety of anyone working in the areas of the deck, electrical cabinet, traction motors, and retarding grids.
The following procedure will ensure that the electrical system is properly discharged before repairs are
begun.

D01046 5/08 Index D1-1


TRUCK SHUTDOWN PROCEDURE
1. Reduce the engine speed to idle. Place the directional control lever in PARK. Make sure that the
parking brake applied indicator light 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. Make
sure that the rest mode indicator light is illuminated.
3. Turn the key switch to the OFF position to turn off the engine.
If the engine does not shut down, use the engine shutdown switch on the center console. Pull this
switch up until the engine stops.
4. With the key switch OFF and the engine stopped, wait at least 90 seconds. Make sure that the steer-
ing circuit is completely depressurized by turning the steering wheel back and forth several times.
The front wheels should not turn when the hydraulic pressure is relieved. If the front wheels can still
be turned, notify maintenance personnel.
5. Make sure that the link voltage light in the control cabinet is off. Notify maintenance personnel if the
light remains illuminated for longer than five minutes after the engine is shut down.
6. Locate the GF cutout switch in the access panel on the left side of the main control cabinet. Place the
switch in the CUTOUT position. This will prevent the alternator from re-energizing and creating sys-
tem voltage until the switch is returned to its former position.

D1-2 Index 5/08 D01046


SECTION D2
24VDC ELECTRIC SUPPLY SYSTEM
INDEX

ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

BATTERY SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

24VDC Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

Battery Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

24VDC Auxiliary Battery Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

Isolator Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

Engine Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

24VDC to 12VDC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

D02033 24VDC Electrical Supply System D2-1


NOTES

D2-2 24VDC Electrical Supply System D02033


24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
The truck uses a 24VDC electrical system which
supplies power for engine starting circuits and most
non-propulsion electrical components. The 24VDC
engine starting circuit is supplied by four heavy duty,
DO NOT SMOKE or allow flame around a dead
Type 8D, 12-volt storage batteries. Several
battery or during the recharging process. The
components require 12VDC and are supplied by
expelled gas from a dead cell is extremely
circuits tapped off the starting batteries.
explosive.
The batteries are of the lead-acid type, each
Excessive consumption of water indicates leakage or
containing six 2-volt cells. With the engine off, power
overcharging. Normal water usage for a unit
is supplied by the batteries. During engine cranking,
power is supplied by the four engine cranking operating eight hours per day is about 30 to 60 cm3
batteries only. When the engine is running, power is (1 to 2 oz.) per cell per month. For heavy duty
supplied by a high capacity alternator that is driven operation (24 hours per day), normal consumption
by the engine. should run about 30 to 60 cm3 (1 to 2 oz.) per cell per
week. Any appreciable increase over these figures
should be considered a danger signal.

Troubleshooting
Two most common problems that occur in the
Lead-acid storage batteries contain sulfuric acid charging system are undercharging and
which, if handled improperly, may cause serious overcharging of the truck's batteries.
burns on skin or other serious injuries to
An undercharged battery is incapable of providing
personnel. Wear protective gloves, aprons and
sufficient power to the truck's electrical system.
eye protection when handling and servicing lead-
acid storage batteries. See the precautions in Some possible causes for an undercharged battery
Section A of this manual to ensure proper are:
handling of batteries and accidents involving
• Sulfated battery plates
sulfuric acid.
• Loose or corroded battery connections
During operation, the storage batteries function as an
electrochemical device that converts chemical • Defective wire in electrical system
energy into the electrical energy that is required for • Loose alternator drive belt
operating the accessories when the engine is off.
• Defective alternator
Overcharging, which causes overheating, is first
indicated by excessive use of water. If allowed to
BATTERIES
continue, the cell covers will push up at the positive
Maintenance and Service ends and, in extreme cases, the battery container will
become distorted and cracked.
The electrolyte level of each cell should be checked
at the interval specified in Section P, Lubrication and Leakage can be detected by continual wetness of the
Service. Add water if necessary. The proper level to battery or excessive corrosion of the terminals,
maintain is 10 to 13 mm (3/8 to 1/2 in.) above the battery carrier and surrounding area. (A slight
plates. To ensure maximum battery life, use only amount of corrosion is normal in lead-acid batteries).
distilled water or other types of water recommended Inspect the case, covers and sealing compound for
by the battery manufacturer. After adding water in holes, cracks and other signs of leakage. Check the
freezing weather, operate the engine for at least 30 battery hold down connections to ensure that the
minutes to thoroughly mix the electrolyte. tension is not great enough to crack the battery or
loose enough to allow vibration to open the seams. A
leaking battery must be replaced.

D02033 24VDC Electrical Supply System D2-3


To remove corrosion, clean the battery with a The rate of self-discharge of a battery kept at 38°C
solution of ordinary baking soda and a stiff, non-wire (100°F) is about six times that of a battery kept at
brush and flush with clean water. Make sure that 10°F (50°F), and self-discharge of a battery kept at
none of the soda solution is allowed to enter the 27°C (80°F) is about four times that one at 10°F
battery cells. Make sure that the terminals are clean (50°F). Over a 30 day period, the average self-
and tight. Clean terminals are very important in a discharge runs about 0.002 specific gravity per day
voltage regulated system. Corrosion creates at 27°C (80°F).
resistance in the charging circuit, which causes
To offset the results of self-discharge, idle batteries
undercharging and gradual starvation of the battery.
should receive a booster charge (not a quick charge)
NOTE: When washing batteries, make sure that the at least once every 30 days. Batteries allowed to
cell caps are tight to prevent cleaning solution from stand for long periods in a discharged condition are
entering the cells. attacked by a crystallization of the lead sulfate on the
plates. Such batteries are called “sulfated” and are,
Addition of acid will be necessary if considerable
in the majority of cases, irreparably damaged. In less
electrolyte has been lost through spillage. Before
severe cases, the sulfated battery may be restored to
adding acid, make sure that the battery is fully
limited service by prolonged charging at a low rate
charged by putting the battery on charge and taking
(approximately 1/2 normal rate).
hourly specific gravity readings on each cell. When
all the cells are gassing freely and three successive An undercharged battery is extremely susceptible to
hourly readings show no rise in specific gravity, the freezing when allowed to stand in cold weather.
battery is considered charged. Additional acid may
The electrolyte of a battery in various stages of
now be added. Continue charging for another hour
charge will start to freeze at temperatures indicated
and check specific gravity again. Repeat the above
in the table below.
procedure until all cells indicate a specific gravity of
1.260 - 1.265 corrected to 27°C (80°F). The temperatures in the table below indicate the
points at which the first ice crystals appear. Lower
NOTE: Use 1.400 strength sulfuric acid when making
temperatures must be reached for a solid freeze.
specific gravity adjustments. Acid of higher strength
Solid freezing of the electrolyte may crack the battery
will attack the plates and separators before it has a
case and damage the positive plates. As will be
chance to diffuse into the solution.
noted, a charged battery is in no danger of freezing.
If the temperature of the electrolyte is not reasonably Therefore, a battery should be kept charged,
close to 27°C (80°F) when the specific gravity is especially during winter weather.
taken, temperature should be corrected to 27°C
(80°F) as follows:
• For every 5°C (10°F) below 27°C (80°F), 0.004
should be SUBTRACTED from the specific
SPECIFIC GRAVITY FREEZING
gravity reading.
Corrected to 27°C (80°F) TEMPERATURE
• For every 5°C (10°F) above 27°C (80°F), 0.004
1.280 -70°C (-90°F)
should be ADDED to the reading.
1.250 -54°C (-60°F)
Idle batteries should not be allowed to stand
unattended. If equipment is to stand unused for more 1.200 -27°C (-16°F)
than two weeks, the batteries should be removed 1.150 -15°C (+5°F)
and placed in a cool, dry place where they may be 1.100 -7°C (+19°F)
checked periodically and charged when necessary.
Remember, all lead-acid batteries discharge slowly
when not in use. This self-discharge takes place
even though the battery is not connected in a circuit,
and it is more pronounced in warm weather than in
cold weather.

D2-4 24VDC Electrical Supply System D02033


BATTERY SUPPLY SYSTEM
24VDC Battery Charging Alternator
A 24VDC to 12VDC converter, located toward the
Refer to Section D, Battery Charging Alternator in, for
bottom of the inside left wall of the auxiliary control
service information regarding the battery charging
cabinet, is used to convert the 24 volt battery system
alternator.
voltage to 12 volts for various truck components.
Battery Box When maintenance or repairs are performed, the
Four type 8D batteries (3, Figure 2-1) for the 24VDC batteries can be quickly disconnected from the
engine cranking circuit are located in the battery box starter or control circuits by using disconnect
in the center of the front platform. For access to the switches (7 & 8) located on battery control box (4).
batteries, open the two hinged covers by turning the An external battery charger may also be connected
cover latches (1) counterclockwise until released. to auxiliary battery receptacles (2) located on battery
Lifting eyes are attached to each end of the battery control box (4).
box so that the entire battery box assembly can be
removed, if necessary.

FIGURE 2-1. BATTERY BOX & BATTERY CONTROL BOX


1. Battery Box Cover Latch 5. Circuit Breaker (50 amp) 8. Battery Disconnect Switch
2. Auxliary Battery Receptacles 6. Engine Start Relay (System)
3. Batteries 7. Battery Disconnect Switch 9. Battery System Isolator Diode
4. Battery Control Box (Starter)

D02033 24VDC Electrical Supply System D2-5


Battery Control Box 24VDC to 12VDC Converter
Battery control box (4) is located to the left of the 24VDC to 12VDC converter (1, Figure 2-2) is used to
battery box. This box contains the battery disconnect convert the 24 volt battery system voltage to 12 volts
switches and other components listed below. for various truck components such as the radio/
cassette player, cab power windows, and the
Battery Disconnect Switches auxiliary power receptacles in the cab.
Battery disconnect switches provide a convenient The converter is powered by the starter circuit
method of disconnecting the truck batteries from the batteries. Converter output circuits are protected by
truck electrical circuits without having to remove any CB101, a 50 amp circuit breaker (5, Figure 2-1)
battery cables. Rearward disconnect switch (7) located inside the battery control box.
opens the starter battery circuit only, preventing
engine startup while still allowing battery power to the
24VDC control system circuits, if desired. Forward
disconnect switch (8) disconnects the 24VDC system
batteries.

24VDC Auxiliary Battery Receptacles


Two pairs of receptacles (2), located near the battery
disconnect switches, are provided to attach battery
charger leads for charging the batteries.
These receptacles can also be used for connecting
external batteries to aid engine starting during cold
weather. When external 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 front
receptacle and the other pair connected to the rear
receptacle on the truck.

Isolator Diode
A Schottky type isolation diode is used to provide
isolation between the electrical system battery
circuits and the dual starter motor start command
circuits. This device controls the direction of current
flow in high current applications.
Battery system isolation diode (9) allows current from
the battery charging alternator to charge the
batteries, but prevents current flow from the batteries
to the starter motors when the engine is started.
FIGURE 2-2. AUXILIARY CONTROL CABINET
Engine Start Relay (LEFT WALL)
Engine start relay (6) receives the signal to begin 1. 24VDC to 12VDC Converter
cranking from the start relay located on relay board
RB6. When the engine start relay is activated, it
provides current to the starter motors to engage the
drives and begin cranking the engine, eliminating the
need for magnetic switches.

D2-6 24VDC Electrical Supply System D02033


SECTION D3
24VDC ELECTRICAL SYSTEM COMPONENTS
INDEX

TRUCK SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

BRAKE WARNING BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

AUXILIARY CONTROL CABINET COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

Power Distribution Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

Engine Starter Failure Delay Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

5 Minute Idle Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Pulse Voltage Modulator (PVM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Auto Lube Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Control Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Diode Board - DB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6

Fuse Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7

Alarm Indicating Device (AID) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7

RELAY BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10

Relay Boards RB1, RB3, RB4, RB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10

Relay Boards RB6, RB7, RB8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11

Relay Board Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-13

BODY-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

FUSE BLOCKS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-17

CIRCUIT BREAKERS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-18

D03035 12/07 24VDC Electrical System Components D3-1


NOTES

D3-2 24VDC Electrical System Components 12/07 D03035


24 VDC ELECTRICAL SYSTEM COMPONENTS
AUXILIARY CONTROL CABINET
COMPONENTS
The following 24VDC electrical system components
are located in the auxiliary control cabinet, which is
Do not attempt repairs until the truck is properly mounted on the left side of the main control cabinet
shut down. Dangerous voltage levels are present behind the cab. The auxiliary control cabinet houses
in the propulsion system while the engine is various components for the 24VDC circuits, engine
running and for a period of time after shutdown. related devices, and terminal strips that connect truck
Refer to the Index in Section D for additional wiring harnesses with the main control cabinet and
warnings. cab.
The following information describes the components
TRUCK SHUTDOWN PROCEDURE in the auxiliary control cabinet and their operation.
1. Reduce the engine speed to idle. Move the Additional detailed information for operation and
directional control lever in PARK. Make sure troubleshooting procedures not included below can
that the parking brake applied indicator light in be found in Section E, Electrical Propulsion System,
the overhead panel is illuminated. the engine manufacturer's service publications, and
the appropriate GE publications. The electrical
2. Place the drive system in the rest mode by
schematics in Section R should be used when
turning the rest switch on the instrument panel
troubleshooting problems with the following 24VDC
ON. Make sure that the rest mode indicator light
electrical system components.
is illuminated.
3. Shut down the engine using the key switch. If,
for some reason the engine does not shut
down, use the shutdown switch on the center
console. Power Distribution Terminals
4. Verify the link voltage lights on the electrical 24VDC terminal (1, Figure 3-1) and 12VDC terminal
cabinet and next to the DID panel in the cab are (2) are mounted on the left wall of the cabinet. These
OFF. If they remain on longer than 5 minutes terminals distribute battery voltage and 12VDC for
after shutdown, the propulsion system must be devices requiring reduced voltage. The 24VDC
inspected by a technician trained to investigate terminal is a convenient test point for measuring
the cause. battery voltage during troubleshooting procedures.
5. Place the GF cutout switch in the CUTOUT
position throughout test and troubleshooting
procedures.
Engine Starter Failure Delay Timer
6. Verify that the steering accumulators have bled
down by attempting to turn the steering wheel. Engine starter failure delay timer (3) is used in the
circuitry which detects a failure of one of the two
starter motors. This circuit provides a warning to the
operator if either starter does not energize for at least
BRAKE WARNING BUZZER 2 seconds when engine starting is first attempted, or
The brake warning buzzer provides an audible alarm if either starter stops operating during the engine
for the operator if a malfunction occurs in the starting process.
hydraulic service brake system. This buzzer is
located inside the radio module in the overhead
panel. Refer to Section J for additional details.

D03035 12/07 24VDC Electrical System Components D3-3


5 Minute Idle Timer Test the 5 minute idle timer circuits as follows:
5 minute idle timer (4) is activated when the operator 1. With the key switch ON, press the engine
presses the 5 minute idle timer engine shutdown shutdown switch firmly to the momentary
switch on the instrument panel. (This is a momentary position and release (switch will return to the
switch that also latches the 5 minute idle timer in the ON position).
energized position.) When the timer is energized, 2. Turn the key switch OFF and verify the
internal contacts close and energize the relay. following:
The 5 minute idle timer circuit automatically provides Circuit 712 (to ground) remains 24 volts for
approximately five minutes of engine idle time before approximately 5 minutes. After 5 minutes,
actual engine shutdown occurs. This system allows the voltage drops to 0.
the engine cooling system to circulate coolant to
reduce and stabilize engine component The 5 minute idle indicator lamp on the
overhead display is ON when circuit 712
temperatures, when engine power requirements are
reads 24 volts.
minimal, resulting in extended engine life.
3. Repeat Step 1. While monitoring voltage at
The circuit is controlled by a 3-position rocker switch. circuit 712, turn the key switch OFF. Turn the
Pressing the bottom of the switch will turn the circuit engine shutdown switch off.
OFF. The engine will shut down by use of the key
switch, console mounted engine shutdown switch, or Verify that the voltage at circuit 712 drops to
0 when the shutdown switch is turned to
the ground level shutdown switch.
OFF.
With the rocker switch in the middle position, the
circuit is ON, but does not activate the 5 minute idle
timer circuit. The engine can be shut down
Pulse Voltage Modulator (PMV)
immediately using any one of the three switches
described above. The Pulse Voltage Modulator (6) receives a load
curve signal from the engine controls and converts it
When the top of the switch is depressed and held
to a 0 to 10 volt signal for use by a PSC card in the
momentarily, the idle timer circuit is activated. When
Integrated Control Panel (ICP).
released, the switch will return to the ON (middle)
position, and the 5 minute idle timer circuit is latched
on through the switch. The 5 minute idle timer
indicator lamp on the overhead display will also Control Power Relay
illuminate. The engine will not shut down with the key
switch. Moving the key switch to the OFF position, Control power relay (8) is energized when the control
will cause the engine to shut down after the 5 minute power switch, located in the main control cabinet, is
time delay is completed. The normal shutdown turned ON. This relay isolates the GE control power
sequence will then occur. from the truck circuits and provides power to non-
propulsion system 24VDC components.
However, if during the 5 minute idle timing sequence,
the 5 minute delay switch on the instrument panel is
pressed to the OFF position, the center console
engine shutdown switch is depressed, or the ground Auto Lube Timer
level shutdown switch is activated, the engine will
The automatic lubrication system lubrication interval
shut down immediately, followed by the normal
is controlled by auto lube timer (9). Lubrication cycle
shutdown of all systems.
frequency can be adjusted by removing the timer
cover and selecting one of five different timing
intervals available. System “on” time is automatically
determined by the timer and is not adjustable. Refer
to Section P for additional automatic lubrication
system details.

D3-4 24VDC Electrical System Components 12/07 D03035


FIGURE 3-1. AUXILIARY CONTROL CABINET - LEFT WALL
1. 24VDC Terminal 7. 12V Power Relay 13.Relay Board - RB5
2. 12VDC Terminal 8. Control Power Relay 14.Relay Board - RB6
3. Engine Starter Failure Delay Timer 9. Auto Lube Timer 15.Relay Board - RB7
4. 5 Minute Idle Timer 10.Relay Board - RB1 16.Relay Board - RB8
5. Key Switch Power Relay 11.Relay Board - RB3 17.Relay Board - RB9
6. Pulse Voltage Modulator (PVM) 12.Relay Board - RB4 18.Diode Board - DB1

NOTE: For more information about relay boards RB1 through RB9, refer to Relay Boards later in this section.

D03035 12/07 24VDC Electrical System Components D3-5


Diode Board - DB1 If a diode failure is suspected, remove and check the
diode as follows:
Diode board (18, Figure 3-1) contains 24 replaceable
diodes that are mounted on a plug-in connector for 1. Grasp the diode connector, compressing the
easy replacement. Some of the diodes are used in locking “ears” while pulling the connector off the
the coil circuit of various relays to suppress the board. Note the connector “key” used to ensure
resultant coil voltage spike when power is removed correct polarity.
from the circuit, preventing damage to other circuit NOTE: Some digital multimeters are designed to test
components (lamp filaments, etc.). Other diodes are diodes. If this type is used, follow the manufacturer's
used to control the flow of current in a circuit as instructions for proper test.
required. Resistors or diodes may also be installed in
sockets P7 through P12. 2. An analog ohmmeter can be used to test the
diode as follows:
Refer to the electrical schematic in Section R of this
a. Place the meter on the “X100” scale.
manual for specific circuits.
b. With the red meter lead (+) on the banded
end of the diode and the black lead (-) on the
other diode lead, the meter should read
between 1000 and 2000 ohms.
c. Reverse the meter leads and read infinite
resistance.
3. If no resistance is read on the meter, the diode
is open and must be replaced.
4. If the meter reads zero ohms, the diode is
shorted and must be replaced.
5. Orient the diode assembly for proper polarity
(“key” noted in step 1.) and insert connector
until locked in position on mating receptacle.
FIGURE 3-2. DIODE BOARD
1. Mounting Rail 5. Foam Block
2. Screw 6. Board
3. Nut 7. Diode
4. Mounting Plate

D3-6 24VDC Electrical System Components 12/07 D03035


Fuse Blocks Alarm Indicating Device (AID) System
Four fuse blocks (1, Figure 3-3) contain fuses that Alarm indicating device (AID) module (1, Figure 3-4
protect various circuits on the truck. Always replace a is connected to the electrical accessories circuits to
blown fuse with a new one of the same rating. For a provide the operator with a warning indication of a
listing of fuse sizes and circuits, refer to the Fuse malfunction. This system consists of up to eight
Blocks charts at the end of this section. printed circuit cards located in the auxiliary control
cabinet. The actual quantity of cards will depend on
the that are options installed on the truck.

FIGURE 3-3. AUXILIARY CONTROL CABINET -


FRONT VIEW FIGURE 3-4. AUXILIARY CONTROL CABINET -
1. Fuse Blocks RIGHT WALL
1. AID Module

D03035 12/07 24VDC Electrical System Components D3-7


The AID system enables the indicating lights to be The following briefly describe each card and its
flashing or constant. The AID also has the capability function. Refer to Section R, Schematics, for the
of operating an audible alarm along with the light. circuit components described below.
The eight printed circuit cards are:
Diode Matrix (With Sound)
• Diode Matrix (With Sound) Card (Slot 1)
• Diode Matrix (Without Sound) Card (Slot 2) The diode matrix with sound card works very much
like the other diode matrix card, except that it
• Hot Switch Inverter Card (Slot 3)
contains extra diodes to activate the alarm horn in
• Hot Switch Inverter Card (Slot 4) (Not Used) addition to the flasher. The circuits connected to
• Temperature Card (Slot 5) (Optional) terminals A1 through A8 operate in the same
• Oil Level Card (Slot 6) (Optional) manner.
• Temperature and Latch Card (Slot 7) All of the card circuits are connected to the lamp test
• Coolant Level and Flasher Card (Slot 8) switch on the overhead display area. In normal
operation, these circuits are open and not functional.
NOTE: Each card is identified with a number which When the operator pushes the lamp test switch, it
corresponds to a mating number on the housing. If activates all the indicator circuits by grounding them.
any cards are removed, make sure that the card This is used to verify that all lamps are functional.
numbers correspond with the housing numbers
during installation See Figure 3-5. Diode Matrix (Without Sound)
The diode matrix without sound card consists of a
series of diodes capable of working with eight
different indicator circuits. The indicator light can be a
flashing light by connecting it to the 12F circuit or a
steady light by connecting it to the 12M circuit. In
addition, some of the indicator light circuits are
routed through a dimmer module to allow the
operator to vary the intensity 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
detecting switch activates the circuit, it grounds the
lamp and the flasher circuit through the diodes. Any
circuits connected to terminals C1 through C8 will
operate in the same manner. The alarm horn is not
activated by this card.

Hot Switch Inverter


The hot switch inverter card is used to operate and
test the service brake indicator light. In normal
conditions Q4 transistor is off and the Indicator Light
is off. When the stoplight switch is activated, 24 volts
is sent to pin “E” of the hot switch inverter card.
FIGURE 3-5. AID SYSTEM CARD ENCLOSURE Transistor Q4 is turned on by this voltage and, in
turn, grounds the service brake indicator light. There
1. Diode Matrix With Sound is no alarm horn operation with this card.
2. Diode Matrix Without Sound
3. Hot Switch Inverter A second circuit on this card is used to operate and
4. Hot Switch Inverter (Not Used) test the retard speed control indicator light. When
5. Temperature & Latch RSC is turned OFF, transistor Q7 is off and the
6. Coolant Level & Flasher indicator light is off. When RSC is turned on, 24 volts
is sent to pin “J” of the card. This voltage turns on
Q7, grounding the indicator light circuit.

D3-8 24VDC Electrical System Components 12/07 D03035


Hot Switch Inverter (Not Used) Coolant Level & Flasher
The optional oil level card is used to turn on the low The coolant level and flasher card contains two
oil level indicator light to warn the operator that the separate circuits. The flasher circuit at the top of the
engine oil/hydraulic tank oil level is below acceptable card has Q12 transistor biased to be saturated when
levels. The oil float is connected to a variable no malfunction is present, resulting in 24 volt positive
resistor. As the oil level decreases, the resistance output on pin “H” of the card and on wire 12F. When
goes down, causing Q3 to turn on and grounding the an indicating circuit is activated, the ground side of
indicator light and alarm horn. the circuit connected to card pin “K” is grounded.
Q12 will turn off initially and then after a delay,
The optional temperature card is used to turn on the adjusted by R20, will turn on and off to give the
high oil temperature indicator light. The indicator light intermittent 24 volt output.
tells the operator hydraulic tank oil temperature has
exceeded acceptable levels. Normal temperature The other half of the circuitry on the coolant level and
setting is 121°C (250°F). As the temperature goes flasher card operates the coolant level light. The
up, the resistance in the probe decreases providing a water level probe connected to terminal B11 grounds
ground path for the indicator light and alarm horn. the 31L circuit when the coolant in the radiator is
above the probe position. The coolant saturates the
Temperature and Latch probe and electrically grounds the circuit. When the
The temperature and latch card has two circuits to circuit is grounded, Q6 transistor is off, resulting in no
operate two different indicator lights. The indication. When the coolant level drops below the
temperature circuit is controlled by a coolant probe, 31L is no longer grounded and Q6 turns on to
temperature sensor which decreases electrical ground the flasher through D5, the coolant level light
resistance as its temperature increases. It will have a through terminal D11, and the alarm horn through
resistance of approximately 1000 ohms at 85°C D6. The light and alarm horn will operate
(185°F) and 500 ohms at 121°C (250°F). The normal intermittently as their 24 volt supply is from circuit
setting is 96°C (204°F). 12F, the flasher output.

When the temperature is low and the resistance is NOTE: Some electronic engine controls monitor
high, Q1 is off and no high temperature indication coolant level. If the engine controls monitor the
occurs. When the coolant temperature is excessive, circuit, a 2KΩ resistor is installed to replace the probe
resistance decreases to a point where Q1 will turn on and disable the AID system circuit.
and ground the flasher through D8, the alarm horn
through D12, and the high temperature light through
terminal D8. R14 can adjust the temperature
(resistance) at which the circuit is activated.
NOTE: Some electronic engine controls monitor
coolant temperature. If the engine controls monitor
the circuit, a 2K ohm resistor is installed to replace
the temperature sensor and disable the AID system
circuit.
The latch circuit monitors the accumulator precharge
pressure switches. When one of the pressure
switches closes, Q5, which supplies power to the
gate of SCR Q7, will be turned off. With Q7 turned
on, Q9 will supply the ground path to turn on the low
accumulator precharge indicator light and sound the
alarm horn. The indicator light is connected to 12F
and will flash off and on. The SCR will remain on until
power is removed from the card by turning the key
switch OFF.

D03035 12/07 24VDC Electrical System Components D3-9


RELAY BOARDS Relay Boards RB1, RB3, RB4, RB5
The auxiliary control cabinet contains eight relay Each relay board of this type is equipped with four
boards to provide control for many of the 24VDC green lights (9, Figure 3-6) and one red “breaker
circuits. Two types of boards are used. One type of open” light (7). Each relay board has a fifth green (8)
board contains circuit breakers in addition to 24VDC light that has a different function on each board.
relays and a PC board for special functions. The Four green lights (9) are labeled K1, K2, K3, or K4.
second type of board contains relays only. These lights will be on only when that particular
All relays are interchangeable. The circuit breakers control circuit has been switched ON and the relay
are interchangeable, providing that the circuit coil is being energized. The light will not turn on if the
breaker capacity is the same. relay board does not receive the 24 volt signal to turn
on a component.
If illuminated, red “breaker open” light (7) indicates
that a circuit breaker on that relay board is in the OFF
position. A light on the overhead display panel will
Do not interchange or replace any circuit breaker
also illuminate, informing the operator that a circuit
with one of a different capacity than specified for
breaker is in the OFF position. The red “breaker
the circuit. Serious damage or a fire may result if
open” light will turn ON whenever there is a voltage
the wrong capacity breaker is used.
difference across the two terminals of a circuit
breaker.
The relay boards are identified as follows: If a control switch has been turned ON and a green
(K) light is on, but that component is not operating,
Relay Board Functions check the following on the relay board for that circuit:
RB1 Clearance/Turn Signal Lights If a circuit breaker light is on, press all the
circuit breakers to make sure that they are
RB3 Stop, Retard, Backup Lights all on. There is no visual indication as to
RB4 Parking Brake, Horn, Body-Up, which circuit breaker has been tripped.
Engine Cranking Check the operation of the component. If it
trips again, check the wiring or component
RB5 Headlights (standard) for the cause of the overload.
RB6 Backup Horn, Start Relay, Engine The contacts inside the relay may not be
Interlock, 5 Minute Idle Timer, Ether closing, or the contacts may be open,
Start preventing an electrical connection. Swap
RB7 Starter Relays, Bleeddown Power, relays and check again. Replace defective
Auto Lube Solenoid & Timer, relays. Relays may take one minute to trip
and 30 seconds before they can be reset.
Starter Failure Relays #1 and #2,
Headlights (HID) Check the wiring and all of the connections
between the relay board and the
RB8 PLMIII Lights, Shutter Control, TCI component for an open circuit.
RB9 Engine Start, Start Lockout, Starter The component may be defective. Replace
Failure Relays #3 and #4, Parking the component.
Brake OFF There is a poor ground at the component.
Repair the ground connection.
Refer to Figure 3-1 for the location of each relay
board. Refer to the Circuit Breakers chart at the end
of this section for electrical circuit identification
numbers.

D3-10 24VDC Electrical System Components 12/07 D03035


1. Relay Board
2. Screw
3. Screw
4. Circuit Breaker
5. Circuit Panel Card
6. Screw
7. Breaker Open Light (RED)
8. Bleed Down Light (GREEN)
(Relay Board 4 Only)
9. K1, K2, K3, K4 Lights
(GREEN)
10. Screw
11. Relay
12. Circuit Harness Connector

FIGURE 3-6. TYPICAL RELAY BOARDS - RB1, RB3, RB4, RB5

To replace a relay:
NOTE: The relays are labelled to identify the
applicable circuits and components Also, refer to the
Fuse Blocks charts at the end of this section.
1. Remove one screw (10, Figure 3-6) holding the
crossbar in place and loosen the other screw.
2. Swing the crossbar away.
3. Gently wiggle and pull outward to remove relay
(11).
4. Line up the tabs and install a new relay.
5. Place the crossbar in its original position and
install screw (10). Tighten both screws.

D03035 12/07 24VDC Electrical System Components D3-11


To replace a circuit breaker: Relay Board RB6, RB7, RB8, RB9
NOTE: Always replace a circuit breaker with one of Relay boards 6, 7 and 8 (Figure 3-7) do not contain
the same amperage capacity as the one being circuit breakers or modular cards. Additional circuits
removed. may be added by utilizing a spare relay socket as
described below:
1. Activate the battery disconnect switches.
2. Unplug all wiring harnesses from the relay The control circuit for the relays are the “+” and “-”
board. Remove the four relay board mounting terminals:
screws. Remove the relay board from the truck. • “+” terminal is for positive voltage.
3. Remove four hold down screws (2, Figure 3-6) • “-” terminal is for grounding of the control circuit.
(one in each corner) in the circuit breaker cover • Either circuit can be switched “open” or “closed” to
plate. Remove two screws (6) and card (5). control the position of the relay.
4. Remove the nuts on the wire terminal leads on The terminals of the switched circuit from the relay
the circuit breaker to be replaced. Remove contacts are labeled as follows:
mounting screws on circuit breaker to be
• NC - Normally Closed
replaced.
• COM - Common
5. Lift out circuit breaker. Retain flat washers from
• NO - Normally Open
wire terminals.
6. Install new circuit breaker of the same capacity COM terminal is for the voltage source
rating as the one removed. Install one nut and (protected by a circuit breaker) coming into
two flat washers for each wire connection to the the relay which will supply the electrical
power for the component being controlled.
new circuit breaker.
7. Install cover plate and all screws removed NC terminal is connected (through the
during disassembly. relay) to the “COM” terminal when the relay
is not energized (when the control circuit
8. Carefully install card (5) with screws (6). terminals “+” & “-”) are not activated).
9. Install relay board in truck and connect all wiring
NO terminal is connected (through the
harnesses. relay) to the “COM” terminal when the relay
is energized (by the control circuits “+” & “-”
being energized).
To replace a circuit panel card:
NOTE: DO NOT remove the small screws that hold
the cover plate to the circuit panel. Replace circuit
panel as a complete assembly.
1. Place battery disconnect switches in the OFF
position.
2. Remove the two mounting screws (6, Figure 3-
6) and carefully remove the circuit panel card
from the relay board.
3. Line up the new circuit panel in slots and with
the socket on the relay board and install
carefully.
4. Install two mounting screws (6).

FIGURE 3-7. AUXILIARY RELAY BOARD -


RB6, RB7, RB8, RB9
1. Circuit Board 5. Mounting Plate
2. Mounting Rail 6. Foam Block
3. Screw 7. Relay
4. Nut

D3-12 24VDC Electrical System Components 12/07 D03035


Relay Board Functions Relay Board 4 (RB4)
The following describes the components and 1 - Steering Pressure Bleed Down Timer Module
functions of each relay board. card
1 - Bleed Down Light (Green): This light is
illuminated when the bleeddown solenoid is
Relay Board 1 (RB1) being energized. The bleeddown timer will
1 - Flasher Power Light (Green): This light will be energize the solenoid for 90 seconds after the
illuminated when the turn signals or hazard key switch is turned OFF.
lights are activated. 3 - 12.5 amp circuit breakers (CB20, CB21, CB22)
1 light will be illuminated during right turn 4 - Relays
signal operation
Parking Brake Status Relay (K1)
2 light will be illuminated during left turn
signal operation Engine Cranking Oil Pressure Interlock
Relay (K2)
3 light will be illuminated when clearance
lights are activated. Horn Relay (K3)
4 light will be flashing when the turn signals Body-Up Relay (K4)
or hazard lights are in operation.
NOTE: If circuit breakers (CB13 & CB15) are in the
off position, no warning will be noticed until the Relay Board 5 (RB5)
clearance light switch is turned ON. 1 - Light Display Module card
1 - Flasher Module card 1 - Lights Control Light (Green): This light is
2 - 12.5 amp circuit breakers (CB13, CB15) illuminated when 24 volts is being supplied to
the battery terminal of the light switch.
4 - Relays
5 - 12.5 amp circuit breakers
Left Turn Light Relay (K1) (CB23, CB24, CB25, CB26, CB27)
Right Turn Light Relay (K2) 4 - Relays
Clearance Lights Relay (K3) Left Low Beam Relay (K1)
Flasher Relay (K4)
Right Low Beam Relay (K2)
Left High Beam Relay (K3)
Relay Board 3 (RB3) Right High Beam Relay (K4)
1 - Light Module Display card
1 - Rev Light (Green): This light is illuminated
whenever the directional control lever is in the
REVERSE position and the key switch is in the
ON position.
4 - 12.5 amp circuit breakers
(CB16, CB17, CB18, CB19)
4 - Relays
Manual Backup Lights Relay (K1)
Stop Lights Relay (K2)
Retard Lights Relay (K3)

D03035 12/07 24VDC Electrical System Components D3-13


Relay Board 6 (RB6) Relay Board 8 (RB8)
The following relays are installed on RB6: The following relays are installed on RB8:
Backup Horn Relay (K1) 70% Load Signal to PSC Relay (K1)
Engine Interlock Relay (K2) Full Load Signal to PSC Relay (K2)
Engine Start Relay (K3) Shutter Control Relay (K3)
Spare Relay (K4) PLMIII Lights Relay (K4)
Ether Start Relay (K5) A/C Shutter Control Relay (K5)
5 Minute Idle System Relay (K6) PLMIII Red Lights Relay (K6)
5 Minute Idle System Relay (K7) PLMIII Amber Lights Relay (K7)
5 Minute Idle System Relay (K8) PLMIII Green Lights Relay (K8)

Relay Board 7 (RB7) Relay Board 9 (RB9)


The following relays are installed on RB7: The following relays are installed on RB7:
Starter Motor #2 Relay (K1) Spare Relay (K1)
Starter Motor Failure #1 Relay (K2) Spare Relay (K2)
Starter Motor Failure #2 Relay (K3) Spare Relay (K3)
Starter Motor #1 Relay (K4) Park Brake Off Relay (K4)
Auto Lube Solenoid Relay (K5) Starter Motor Failure #3 Relay (K5)
HID Headlights Relay (K6) Engine Start Relay (K6)
Bleeddown Power Supply Relay (K7) Engine Start Lockout Relay (K7)
Auto Lube Timer Relay (K8) Starter Motor Failure #3 Relay (K8)

D3-14 24VDC Electrical System Components 12/07 D03035


BODY-UP SWITCH Adjustment
Body-up switch (3, Figure 3-8) is located inside the Before adjusting the body-up switch, inspect the
right frame rail near the front of the body. It must be body pads for wear and damage. Replace the body
adjusted to specifications to ensure that the proper pads if required. The body must be resting on the
electrical signal is obtained when the body is raised frame in the normal body down position when
or lowered. The body-up switch is designed to adjustments are made.
prevent propulsion in REVERSE when the dump 1. Loosen capscrews (2, Figure 3-8) and adjust
body is not resting on the frame rails. The switch also proximity switch bracket (3) to achieve an air
prevents forward propulsion with the body up unless gap (dimension “A”) of 12.7 to 15.9 mm (0.50 to
the override button is depressed and held. 0.62 in.) between the sensing area
(crosshatched area as marked on the switch)
Operation
and actuator arm (4). Tighten the capscrews
When the body is resting on the frame, actuator arm after the adjustment.
(4) causes the electrical contacts in the magnetically 2. If necessary, loosen actuator arm mounting
operated switch to close. When the body is raised, capscrews (5), and position arm until centered
the arm moves away from the switch, opening the over sensing area of switch. Vertical set up
contacts. The electrical signal is sent to the control dimension (“B”) should be 1.63 in. (41.5 mm).
system and the body-up relay. Tighten the capscrews.
The switch must be properly adjusted at all times.
Service
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch Keep the sensing area clean and free of metallic dust
assembly. and other debris that may damage or inhibit
operation of the switch. If the switch is damaged or
not functioning, the switch must be replaced.

1. Switch Mounting Bracket


2. Adjustment Capscrews
3. Proximity Switch
4. Actuator Arm
5. Adjustment Capscrews

FIGURE 3-8. BODY-UP SWITCH

D03035 12/07 24VDC Electrical System Components D3-15


HOIST LIMIT SWITCH
Hoist limit switch (5, Figure 3-9) is located inside the
right frame rail above the rear suspension, near the
body pivot pin. The hoist limit switch is designed to
stop the hoist cylinders before they reach full
extension, preventing possible damage to the dump
body or hoist cylinders.

Operation
When the hoist cylinders approach maximum stroke
and the body pivots on the pins, actuator arm (3)
moves close enough to the magnetically-operated
switch to close the electrical contacts. When the
contacts close, an electrical signal is sent to the
hoist-up limit solenoid valve, located in the hydraulic
brake cabinet, to prevent further oil flow to the hoist
cylinders.
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch
assembly.

Adjustment
1. Raise the body so that the hoist cylinders are
within 152 mm (6 in.) of maximum travel.
2. Adjust the hoist limit switch to achieve an air
gap (dimension “A”) of 12.70 to 14.30 mm (0.50
to 0.56 in.) between the sensing area and
actuator arm (3). Tighten the capscrews.

Service
Keep the sensing area clean and free of metallic dust
and other debris that may damage or inhibit
operation of the switch. If the switch is damaged or
not functioning, the switch must be replaced.
FIGURE 3-9. HOIST LIMIT SWITCH ADJUSTMENT

1. Body 4. Switch Mounting


2. Frame Plate
3. Actuator Arm 5. Hoist Limit Switch

D3-16 24VDC Electrical System Components 12/07 D03035


FUSE BLOCK #1
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 15 A/C, Heater Blower Motor 12H
2 10 Windshield Washer / Wiper 63
3 5 Instrument Panel Gauges 712G
4 10 Key Switch Power 712P
5 10 Hoist Solenoid 712H
6 15 Turn Signal / Clearance Lights 712T
7 10 Engine Options 712E
8 10 AID and Indicator Lights 12M
9 5 Engine Start Failure 712SF
10 10 Engine Shutters 712R
11 10 Dome Light Switch 712A
17 15 Key Switch Supplemental Power 11KS
18 15 PLMIII 39J
19 5 PLMIII 39G

FUSE BLOCK #2
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 15 Service Lights 11SL
2 15 Cab Dome, Fog, Ladder Lights 11L
3 15 Hazard Lights 4G
4 10 Interface Module 11INT
5 10 VHMS & Orbcomm Controllers 85
6 20 Modular Mining System 11M
7 15 Display Module 11DISP
8 15 Headlights 11HDL
9 15 Oil Reserve System Pump 11ORS
10 15 Oil Reserve System Control 11RCNT
11 20 Hydraulic Bleed Down 11BD
17 10 Radio Memory 65

FUSE BLOCK #3
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 15 Cab Drive System 71P
2 10 Automatic Lube Pump 68A
13 10 Right Front Wheel Speed Sensor 15RFWS
14 10 Left Front Wheel Speed Sensor 15LFWS
17 10 Cigarette Lighter 67C
18 20 R.H. Cab Window 67R
19 20 L.H. Cab Window 67P

D03035 12/07 24VDC Electrical System Components D3-17


FUSE BLOCK #4
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
1 10 Brake Circuits 71BC
2 5 PLMIII 712K, 712PL
3 5 Interface Module 87
4 5 VHMS 71VHM
5 5 Modular Mining System 712MM
6 5 Display Module 86
17 5 Temperature Gauge 15V
18 5 Pedal Voltage 15PV
19 5 Engine Interface 15VL

CIRCUIT BREAKERS
LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT
RB1 - CB13 12.5 Turn Signals / Clearance Lights 11CL
RB1 - CB15 12.5 Tail Lights 41T
RB3 - CB16 12.5 Retard Lights 44D
RB3 - CB17 12.5 Manual Backup Lights 47B
RB3 - CB18 12.5 Stop Lights 44A
RB3 - CB19 12.5 Backup Lights and Horn 79A
RB4 - CB20 12.5 Engine Control Power 23D
RB4 - CB21 12.5 Service Lights, Horn, Solenoid 11A
RB4 - CB22 12.5 Engine Run Relay 439E
RB5 - CB23 12.5 Headlights, Left Low Beam 11DL
RB5 - CB24 12.5 Headlights, Right Low Beam 11DR
RB5 - CB25 12.5 Headlights, Left High Beam 11HL
RB5 - CB26 12.5 Headlights, Right High Beam 11HR
RB5 - CB27 12.5 Headlights and Dash Lights 11D

D3-18 24VDC Electrical System Components 12/07 D03035


SECTION D10
BATTERY CHARGING ALTERNATOR
INDEX

BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

CHARGE VOLT AND AMP VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Undercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Overcharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Acid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Non-Use or Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-7

BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8

Terminal Identification and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Battery Positive (B+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Battery Negative (B-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

DC Output (D+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

AC Output (R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Regulator Harness Plug Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Battery/Alternator Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-10

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-12

D10003 07/06 Battery Charging Alternator D10-1


DIMENSIONS AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-13

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Troubleshooting Alternator (On-Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-16

Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17

REGULATOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-18

Regulator Bypass Test (No Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-18

Regulator Bypass Test (Amp Rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-19

BENCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Identification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Advanced Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Bench Test 1: No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Bench Test 2: Full Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-21

Bench Test 3: Regulator Bypass Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-21

STATIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Identification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Regulator Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Check For Shorted Power Transistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-23

FIELD COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24

Field Coil Test 1: Check for Open or Shorted Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24

Field Coil Test 2: Check For Grounded Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24

STATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-25

Stator Test 1: Check For Stator-To-Stator Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-25

D10-2 Battery Charging Alternator D10003 07/06


Stator Test 2: Check For Grounded Stators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-26

THERMAL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-26

Initial Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-26

Verifying a Faulty Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-27

TROUBLESHOOTING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-28

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32

ALTERNATOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-34

Special Tools and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-34

Epoxy Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-35

Liquid Threadlockers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-35

Elastoplastic Silicone Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-35

ALTERNATOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-38

ALTERNATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-40

Regulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-40

Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-41

Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-42

Anti-Drive End Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-42

Anti-Drive End Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-44

Drive End Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-46

Drive End Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-52

Field Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-53

Drive End and/or Anti-Drive End Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-55

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-57

ALTERNATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-57

Anti-Drive End Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-57

Drive End Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-59

Field Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-62

Drive End Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-64

D10003 07/06 Battery Charging Alternator D10-3


Drive End Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-66

Rotor and Rotor Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-66

Drive End Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-67

Anti-Drive End Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-71

Anti-Drive End Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-72

Regulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-75

THERMAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-76

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-76

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-78

SUPPORT STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-78

D10-4 Battery Charging Alternator D10003 07/06


BATTERY CHARGING SYSTEM

BATTERY CHARGING SYSTEM


ELECTRICAL SYSTEM DESCRIPTION
The Komatsu truck utilizes a 24VDC electrical sys-
tem which supplies power for all non-propulsion elec- Lead-acid storage batteries contain sulfuric acid,
trical components. The 24VDC power is supplied by which if handled improperly, may cause serious
two pairs of 12-Volt storage batteries wired in series. burns on the skin or other serious injuries. Wear
The batteries are a lead-acid type, each containing protective gloves, aprons, and eye protection
six 2-Volt cells. With the key switch on and the when handling and servicing lead-acid storage
engine off, power is supplied by the batteries. When batteries. See the precautions in General Informa-
the engine is operating, the electrical power (non- tion, Section A, of this manual to ensure proper
propulsion) is supplied by a 28-Volt alternator. Refer handling of the batteries and/or accidents involv-
to Schematics, Section R, for specific electrical hook- ing sulfuric acid.
up information.
Maintenance and Service
CHARGE VOLT AND AMP VALUES
Check the electrolyte level of each cell at the interval
The volt and amp levels are a function of the battery specified in Lubrication and Service, Section P. Add
state-of-charge. If the batteries are in a state of dis- water, if necessary. The proper electrolyte level is 10
charge, as after extended cranking time to start the to 13 mm (0.375 - 0.50 in.) to above the plates. To
engine, system voltage, when measured after the ensure maximum battery life, use only distilled water
engine is started, will be lower than the regulator set or water recommended by the battery manufacturer.
point. The system amperage will also be high. This is After adding water in freezing temperature, operate
a normal condition for the charging system. The the engine for at least 30 minutes to thoroughly mix
measured values of system Volts and amps will the electrolyte.
depend on the level of battery discharge. In other
words, the greater the battery discharge level, the
lower the system Volts and the higher the system
amperage will be. The Volt and amp readings will
change; system Volts reading will increase up to the DO NOT smoke or allow a flame around a dead
regulator set point and the system amperage will battery or during recharging. The expelled gas
decrease to a low level (depending on other loads) from a dead battery cell or a charging battery is
as the batteries recover and become fully charged. extremely explosive and can cause serious
bodily injury.
BATTERY Excessive consumption of water indicates leakage or
During operation, the storage batteries function as an overcharging. Normal water usage for a truck operat-
electrochemical device for converting chemical ing eight hours per day is about 30-60 ml (1-2 oz) per
energy into the electrical energy required for operat- cell, per month. For heavy-duty operation (24 hours
ing the accessories when the engine is off. per day), normal consumption is about 30-60 ml (1-2
oz) per cell, per week. Any appreciable increase in
water consumption is considered a danger signal. No
water consumption may indicate undercharging or
sulfated battery plates.

D10003 07/06 Battery Charging Alternator D10-5


Troubleshooting NOTE: When washing the batteries, ensure the cell
caps are tight, preventing any cleaning solution from
The two most common problems that occur in the
entering the battery cells.
charging system are undercharging and overcharg-
ing of the truck's batteries. Acid Levels
Undercharging The addition of acid will be necessary if considerable
electrolyte has been lost through spillage. Before
An undercharged battery is incapable of providing
adding acid, ensure the battery is fully charged. This
sufficient power to the truck's electrical system.
is accomplished by putting the battery on a battery
Some possible causes for an undercharged battery charger and taking hourly specific gravity readings on
are: each cell. When all the cells are charged (gassing
freely) and three successive hourly readings show no
Sulfated battery plates
rise in specific gravity, the battery is considered fully
Loose or corroded battery connections charged. Additional acid may now be added. Con-
Defective wire in the electrical system tinue charging for another hour and again check the
specific gravity. Repeat the above process until all
Loose alternator drive belt cells indicate a specific gravity of 1.260 to 1.265 cor-
Defective alternator or regulator rected to 27°C (80°F).
Defective battery equalizer NOTE: Use 1.400 strength sulfuric acid when making
specific gravity adjustments. Acid of higher strength
Overcharging will attack the plates and separators before it has a
Overcharging, which causes battery overheating, is chance to diffuse into the solution.
first indicated by excessive use of water. If allowed to If the temperature of the electrolyte is not reasonably
continue, the cell covers will push up at the positive close to 27°C (80°F) when the specific gravity is
ends of the battery case. In extreme situations, the taken, the temperature factor must be corrected to
battery container will become distorted and cracked. 27°C (80°F):
Leakage can be detected by continual wetness of the • For every 5°C (10°F) below 27°C (80°F), subtract
battery or excessive corrosion of the terminals, bat- 0.004 from the specific gravity reading.
tery carrier, and surrounding area. A slight amount of
• For every 5°C (10°F) above 27°C (80°F), add
corrosion is normal in lead-acid batteries. Inspect the
0.004 to the reading.
case, covers, and sealing compound for holes,
cracks, or other signs of damage. Check the battery Non-Use or Storage
hold-down connections to ensure they are not over-
tightened, which could cause a crack in the battery. If Remove idle batteries (unused for more than two
the battery connections are too loose, it could allow weeks) from the truck and place in a cool, dry place.
vibration, causing the battery case seams to break Periodically check and charge, when necessary.
open. A leaking battery must be replaced. Remember, all lead-acid batteries discharge slowly
when not in use. This self-discharge takes place even
Corrosion though the battery is not connected in a circuit and is
more pronounced in warmer weather than in cold.
Corrosion creates resistance in the charging circuit,
which causes undercharging and gradual starvation of The rate of self-discharge of a battery kept at 38°C
the battery. (100°F) is about six times faster than that of a battery
kept at 19°C (50°F). Self-discharge of a battery kept
To remove corrosion, clean the battery with a solution at 27°C (80°F) is about four times faster than that of
of ordinary baking soda and a stiff, non-wire brush. one at 10°C (50°F). Over a thirty day period, the
Then rinse the battery with clean water. DO NOT allow average self-discharge is about 0.002 specific gravity
the baking soda solution into the battery cells. Dry the per day at 27°C (80°F).
battery and ensure the battery terminal connections
are clean and tight. Clean terminals are very important
in a voltage regulated system.

D10-6 Battery Charging Alternator D10003 07/06


To offset the results of self-discharge, booster-charge
idle batteries (not a quick charge) at least once every
thirty days. Batteries not used for long periods in a
discharged condition are attacked by a crystallization
of the lead sulfate on the plates. Such batteries are
called sulfated and are, in the majority of cases,
irreparably damaged. In less severe cases, the sul-
fated battery may be restored to limited service by
prolonged charging at a low rate (approximately 1/2
normal rate).

Freezing
An undercharged battery is extremely susceptible to
freezing when stored in cold weather.
The electrolyte of a battery in various stages of
charge will start to freeze at temperatures indicated
in Table 10-1.
The temperatures in Table 10-1 indicate the points at
which the first ice crystals appear. Lower tempera-
tures must be reached for a solid freeze. Solid freez-
ing of the electrolyte may crack the battery case and
damage the positive plates. A battery with at least a
75% charge is in no danger of freezing, especially
during winter weather.

Table 10-1: OPERATING TEMPERATURES


Specific Gravity Freezing
Corrected to 27°C Temperature
(80°F) Degrees
1.280 -70°C (-90°F)
1.250 -54°C (-60°F)
1.200 -27°C (-16°F)
1.150 -15°C (+5°F)
1.100 -7°C (+19°F)

NOTE: If the temperature of the electrolyte is not rea-


sonably close to 27°C (80°F) when the specific grav-
ity is taken, adjust the temperature factor to 27°C
(80°F).

D10003 07/06 Battery Charging Alternator D10-7


BATTERY CHARGING ALTERNATOR This is a basic dual stator alternator constructed from
shell assembly (8) containing one stator at each end
GENERAL INFORMATION and a field coil between the stators.

General Description Drive end housing (9) and anti-drive end housing (6)
each contain a bearing to support drive and rotor
The Niehoff model C653A 28-Volt (260 Amp) alterna- shaft (1). They are attached to each end of the shell
tor is self-rectifying. All windings and current-trans- assembly by long threaded studs.
mitting components are non-moving, so there are no
brushes or slip rings to wear out. Drive end housing assembly (9) has an area called
control housing (2), containing all the required inter-
When controlled by voltage regulator (5), these alter- nal electrical connections for the alternator. It also
nators become self-energizing through an internal contains a thermal switch used to protect the B+ ter-
dual diode trio. A residual magnetic field induces a minal.
small voltage in the stator and energizes the field
coil. The field coil continues receiving incremental Battery positive terminal (4) is located on the face of
voltage until full voltage is achieved. Alternating cur- control housing (2) for connection to the truck’s bat-
rent (AC) is rectified into a direct current (DC) output tery positive circuit. The ground circuit cable can be
through the diodes. The regulator controls voltage attached to either of two ground terminals (10)
output and has a D+ terminal to provide a DC output located on the front housing. Fan guard (7) protects
signal to the truck’s electrical system, confirming maintenance personnel from the rotating fan when
alternator operation. An R terminal provides optional the engine is operating.
AC output. Identification plate (3) contains general alternator infor-
mation, including model number and serial number.
.

FIGURE 10-1. ALTERNATOR EXTERIOR

1. Drive Shaft with Woodruff Key 6. Anti-Drive End Housing


2. Control Housing 7. Fan Guard and Cooling Fan Assembly
3. Identification Plate 8. Shell Assembly
4. Battery Positive Terminal (B+) 9. Drive End Housing
5. Voltage Regulator 10. Ground Terminals (B-)

D10-8 Battery Charging Alternator D10003 07/06


Terminal Identification and Location Regulator Harness Plug Identification

FIGURE 10-3. PIN CONNECTION IDENTIFICATION

Alternator Specifications
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28VDC
Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Negative
Regulator Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 10-2. TERMINAL LOCATIONS
Regulator Settings . . . . . . . . . . . . . . . . . . . . . . . 27.5
B+. Battery Positive D+. DC Output ...................................... 28.5
B-. Battery Negative R. AC Output ...................................... 28.0
...................................... 29.0
Battery Positive (B+)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 29 kg (65 lbs)
Main positive power terminal on the alternator.
Located on the control housing. Performance Curve

Battery Negative (B-) Measurements listed on the curves are for a stabi-
lized machine at maximum output at temperatures
Main negative power terminal (ground) on the alter- indicated for each curve.
nator. Located on the drive end housing.

DC Output (D+)
Positive DC voltage output from the alternator. May
be used for specific control circuit. Located on the
regulator. Limited to one or two amp output.

AC Output (R)
Relay terminal. AC current output terminal for the
tachometer or for relay use. Located on the regulator.

FIGURE 10-4. ALTERNATOR PERFORMANCE


CURVE

D10003 07/06 Battery Charging Alternator D10-9


Battery/Alternator Terminology Diode Trio: Assembly of three diodes, one diode
connected to each stator phase tap. Used typically to
NOTE: Charge voltage and amp rates vary from
operate as a signaling source, once the alternator is
battery type to battery type, based on battery
rotating, to tell the regulator to turn on (self-energiz-
construction technology and physical size of the
ing signal), or to provide current for the field coil oper-
battery.
ation.
AC: Alternating current (AC) output of the alternator.
Diode Trios: Dual use of two diode trios, one trio per
Alternator: General term for a vehicle generator stator, on dual stator alternators.
using solid-state devices to rectify output power and
DMM: Digital Multimeter. A handheld test instrument
provide DC output.
to digitally display test values. The preferred test
Amps, Low: A minimum or lowest charging system meter has high impedance value (10 Meg-ohms).
amp value required to maintain the battery state of
Drive End: End of the alternator is equipped to
charge, obtained when testing the charging system
receive mechanical power from the primary power
with a fully charged battery and no other loads
source via the pulley or drive coupling.
applied. This value will vary with battery type.
Fan: Fan located at the anti-drive end of the alterna-
Amps, Medium: A system amp value which can
tor.
cause the battery temperature to rise above the ade-
quate charging temperature within 4-8 hours of Ground: Return path of electrical circuit. May be
charge time. To prevent battery damage, the charge separate wire, component housing, or vehicle chas-
amps must be reduced when the battery temperature sis. (B-) is considered the ground on modern vehicle
rises. Check the battery manufacturer’s recommen- systems.
dations for proper rates of charge amps.
Harness: Enclosed bundle of wires used to connect
Amps, High: A system amp value which can cause electrical devices.
the battery temperature to rise above adequate
Phase: Single output winding of an alternator. Most
charging temperature within 2-3 hours of charge
dual stator alternators have six phases, three phases
time. To prevent battery damage, the charge amps
per stator.
must be reduced when the battery temperature rises.
Check the battery manufacturer’s recommendations Polarity: Distinguishes between positive (+) and
for proper rates of charge amps. negative (-) in an electrical circuit.
Anti-Drive End: End of alternator farthest from drive Rectifier Assemblies: Assembly of power diodes
end (drive pulley). that convert AC current output of the alternator stator
phases to DC current output. Rectifier assemblies
Charge Voltage: Nominal value to which the regula-
are modular designed. Rectifier modules are
tor is set. The actual charge voltage level is deter-
grouped in single blocks mounted in an end housing.
mined by the battery type and the system duty cycle
Modular rectifier blocks can be replaced individually.
and may vary slightly.
Self-energized: The alternator turns itself on and
Control Housing: Part of the housing assembly con-
begins to produce electricity at predetermined rotor
taining internal electrical connections of the alterna-
speed through special circuits designed into the reg-
tor and mounting area for the control unit.
ulator or the alternator.
DC: Direct current (DC) output of the alternator.

D10-10 Battery Charging Alternator D10003 07/06


Set Point: The voltage value to which the regulator is
set. The voltage value is established by the battery
type and the vehicle duty cycle. There are four val-
ues available on the regulator. The set point valve
may be fixed (flat compensation) or variable, based
on operating temperature (negative temperature
compensation).
Significant Magnetism: A change in the strength or
intensity of a magnetic field present in the alternator
rotor shaft when the field coil is energized. The mag-
netic field strength when the field coil is energized
must feel stronger than when the field is not ener-
gized.
Surface Charge: A higher than normal battery volt-
age occurring when the battery is removed from a
battery charger. The surface charge must be
removed to determine true battery voltage and state
of charge.
Voltage B+: A voltage value obtained when measur-
ing voltage at the battery positive terminal or alterna-
tor (B+) terminal.
Voltage, Battery: The steady-state voltage value as
measured with the battery in an open circuit with no
battery load. This value relates to the battery state of
charge.
Voltage, Charge: A voltage value obtained when the
charging system is operating. This value will be
higher than the battery voltage and must never
exceed the regulator voltage set point.
Voltage Droop or Sag: A normal condition which
occurs when the load demand on the alternator is
greater than rated alternator output at a given rotor
shaft rpm.
Voltage Regulator (also Regulator): Device to con-
trol the alternator output voltage. Modern regulators
are solid-state devices. The regulator is mounted on
the alternator. Some regulators have several voltage
set points available for different operating conditions
or battery types.

D10003 07/06 Battery Charging Alternator D10-11


WIRING DIAGRAM

FIGURE 10-5. WIRING DIAGRAM

D10-12 Battery Charging Alternator D10003 07/06


DIMENSIONS AND TORQUE VALUES

FIGURE 10-6. TORQUE SPECIFICATIONS AND OVERALL DIMENSIONS

TORQUE SPECIFICATIONS
Item Description Metric SAE
1 Ground Bolt (B-), M10 X 1.5 15 N·m 11 ft lbs
2 Pulley Nut, M20 X 1.5 163 N·m 120 ft lbs
3 Output Bolt (B+), M12 X 1.75 32 N·m 24 ft lbs
4 Fan Nut, M16 X 1.5 67 N·m 50 ft lbs
5 Regulator Hold Down Screw, M5 X 0.8 8.5 N·m 75 in. lbs
6 Regulator Terminal (R), M6 X 1 4.5 N·m 40 in. lbs
7 Regulator Terminal (D+), M5 X 0.8 4.5 N·m 40 in. lbs
DIMENSIONS
A Housing Diameter 203.2 mm 8.0 in.
B Overall Length Minus Drive Shaft 292.0 mm 11.5 in.
C Shaft Diameter 22.22 mm 0.875 in.
D Height (Centerline to Top) 142.0 mm 5.59 in.
E Height (Centerline to Bottom) 135.6 mm 5.34 in.
F Width (Centerline to Regulator) 139.2 mm 5.48 in.

D10003 07/06 Battery Charging Alternator D10-13


PERIODIC MAINTENANCE TESTING
Alternator performance depends on the condition of
the components in the charging system. The most GENERAL INFORMATION
important components in the charging system are the
Troubleshooting Alternator (On-Truck)
alternator drive belt, battery, and related cables and
connections. A loose drive belt, weak battery, or cor- Most 24-Volt charging system problems can be diag-
roded cables and connections can cause the alterna- nosed with the alternator installed on the truck, oper-
tor to work extra hard, leading to overheating and a ating under normal conditions. Many problems can
reduction in performance. When performing any be attributed to loose or corroded cable connectors.
scheduled maintenance on your vehicle, ensure It is essential that all battery charging cables are in
these components are working properly. The alterna- satisfactory condition and all connections are clean
tor itself requires little maintenance. and securely tightened.
1. The most important maintenance requirement Equipment Required
for an alternator is to keep the air cooling pas-
sages free of dirt and obstruction. • Voltmeter, 0-40 Volt range (Digital type preferred)
2. To ensure that air cooling passages are clean, • Ammeter, 0-400 amp range (Digital, inductive
the alternator can be washed using a garden type preferred)
hose. • Jumper wires
3. During washing, avoid spraying high pressure
water directly on the regulator and regulator Preliminary Checks
connector. This can cause moisture to get past Ensure that an undercharged battery condition has
the seals in the connector and cause perfor- not been caused by accessories having been left on
mance problems. for extended periods.
4. After washing, dry the alternator by operating
1. Check the alternator drive belt.
the engine and alternator a few minutes. Main-
tenance requirements for internal components, 2. Ensure the automatic belt tensioner is working
such as alternator bearings, depend on the correctly.
application, usage, and environment. 3. If a battery defect is suspected, check the bat-
tery.
4. Inspect the wiring for defects. Check all connec-
tions for tightness and cleanliness. Remove and
clean the battery cables.
5. The truck is equipped with a battery equalizer
system. Verify the proper operation of the
equalizer and the individual battery voltages.
Refer to Battery Equalizer, Section D, 24VDC
Electrical Supply System.
6. Check the (B-) cable, (B+) cable, and alterna-
tor-to-regulator wiring harness connections.
Repair or replace any damaged component
before troubleshooting.
7. Ensure the thermal switch is functioning properly.
Refer to the Thermal Switch section in this chap-
ter for additional information.

D10-14 Battery Charging Alternator D10003 07/06


8. Check the battery. The batteries must be in NOTE: Until electrical system component
good condition and fully charged. If any battery temperatures stabilize, the conditions listed here may
condition is marginal, replace it with one known be observed during cold start voltage tests.
to be in good condition. a. Maintenance-type batteries display the fol-
For split battery pack, dual voltage systems, lowing characteristics.
battery rest voltages with 0.3 V. When the 12V 1). Immediately after engine start, the sys-
battery voltage is more than 0.3 V lower than tem Volts are lower than regulator set
24V battery voltage, check the 12V battery cir- point with medium amps.
cuit to verify adequate charge. 2).Three to five minutes into the charge
Polarity of the battery and the alternator must cycle, higher system Volts and reduced
agree; reverse polarity will damage the alterna- amps.
tor. The alternator is negative ground. 3). Five to ten minutes into the charge cycle,
9. Check the voltage output and use the informa- system Volts are at, or nearly at, the regu-
tion below to determine possible cause. lator set point, and the amps are reduced
a. Causes of low voltage to a minimum.
1). Loose or broken drive belt b. Low maintenance-type batteries display the
2). Batteries low state of charge same characteristics as maintenance-type
3). Current load on system greater than batteries, except cycle times may be longer.
the alternator can produce
c. Maintenance free-type batteries display the
4). Defective wiring or poor ground path
following characteristics.
5). Low regulator set point
1). Immediately after engine start, the sys-
6). Defective voltage regulator
tem Volts are lower than the regulator set
7). Defective alternator
point with low charging amps.
8). Lost residual magnetism
2). Fifteen to thirty minutes into the charge
b. Causes of high voltage cycle, still low Volts and low amps.
1). Wrong regulator 3). Fifteen to thirty minutes into the charge
2). High regulator set point cycle, Volts increase several tenths, amps
3). Defective regulator increase gradually, then increase quickly
4). Defective alternator to medium to high amps.
c. Causes of no voltage output. See 4). Twenty to thirty-five minutes into the
Regulator Bypass Test (No Output) for charge cycle, Volts increase to the set
additional testing information. point and amps decrease.
1). No drive belt d. High-cycle, maintenance-free type batteries
2). No battery (B+) voltage at alterna- display the following characteristics.
tor's (B+) terminal 1). These batteries respond much better than
3). Defective regulator the standard maintenance-free batteries.
4). Defective alternator 2). The charge acceptance of these batteries
5). Lost residual magnetism may display characteristics similar to stan-
10. Check the condition of the battery and the dard, maintenance-type batteries.
charge voltage reactions.

D10003 07/06 Battery Charging Alternator D10-15


Test Set-up
1. Discharge the battery as follows:
a. Disable the fuel system.
b. Turn all lights and accessories on. Crank the
engine for 10-15 seconds to discharge the
battery.
c. Turn all lights and accessories off.
d. Enable the fuel system.
2. Determine which set point is used on the regu-
lator (27.5, 28.0, 28.5, 29.0). The set point of
the alternator is 28V. Normal range is within ±
0.3V of set point, as shown in Table 10-2.

Table 10-2: VOLTAGE REGULATOR


System Factory Normal
Voltage Setting Range
27.5 27.2 - 27.8
28.0 27.7 - 28.3
24
28.5 28.2 - 28.8
29.0 28.7 - 29.3
FIGURE 10-7. TROUBLESHOOTING
Refer to Figure 10-7 for the following steps. Install 1. Alternator Under 4. Alternator (B+)
meters directly at the alternator, as shown, to elimi- Test Terminal
nate variations in readings due to cable lengths, etc. 2. 0 to 400 AMP 5. Alternator (B-)
Ammeter Ground Terminal
3. Open the battery disconnect switch. Remove 3. 0 to 40VDC 6. Truck Batteries
the battery cable from the alternator (B+) termi- Voltmeter
nal. 4. Attach the meters as indicated by Figure 10-7.
Measure the voltage and amperage at the alter-
nator, not at the batteries or an intermediate
point.
a. Connect the ammeter negative lead to the
end of the cable removed in Step 3. Connect
the ammeter positive lead to the alternator
(B+) terminal.
b. Connect the red lead of a voltmeter to the
alternator (B+) terminal, and the black lead
of the voltmeter to the (B-) terminal on the
alternator.
5. Secure all the test equipment leads to prevent
damage or short circuits when the engine is
started.
6. Reconnect the battery disconnect switch.

D10-16 Battery Charging Alternator D10003 07/06


Test Procedure 2. Watch the meter reading(s). If the battery is suf-
ficiently discharged, the amps must be high
within ± 10% of the output specified by the per-
formance curve. Volts must be within or below
the normal range as the battery approaches full
The following tests require working near the charge. Amps must fall as the voltage rises.
engine when it is on. Use caution when working When the amps and Volts stabilize, note the
near the engine fan, alternator fan, and fan belts. readings and refer to Table 10-3.

Table 10-3: AMP/VOLTAGE READINGS


1. Start the engine and accelerate to high idle.
Amps Volts Diagnosis
HIGH LOW Charging system is good. Battery
is not yet fully charged. Wait for
charging system to bring to full
charge: Amps must decrease and
Volts must stabilize within normal
If the charge voltage is above 33-Volts, immedi- range.
ately shut the engine off. Electrical system dam-
HIGH NORMAL Watch until amps fall, or Volts
age may occur if the charging system is allowed
exceed normal range. If amps
to operate at high voltage. decrease and Volts remain normal,
charging system is good. If Volts
exceed normal, regulator and/or
field coil must be replaced. Go to
Static Tests.
HIGH HIGH Stop the test. Regulator and/or
field coil replaced. Go to Static
Tests.
LOW LOW Ensure voltmeter leads are
attached at the alternator. If the
connections are good, the alterna-
tor and/or regulator must be
repaired or replaced. Go to Bench
Test 3.
LOW NORMAL Regulator is good. Go to Bench
Test 2.
LOW HIGH Stop the test. If battery and voltme-
ter check good, the regulator and/
or field coil must be replaced.

3. The batteries are considered fully charged if the


charge voltage is at the regulator set point, and
the charge amps remain at the lowest value for
10 minutes.
4. If the charging system is not performing prop-
erly, go to the Regulator Bypass test in the next
section.

D10003 07/06 Battery Charging Alternator D10-17


REGULATOR TESTING 3. If the shaft is still not magnetized, remove the
jumper from the alternator (D+) terminal on the
Regulator Bypass Test (No Output) regulator and go to Step 4.
If the Troubleshooting Alternator test procedure indi- 4. If the shaft is not magnetized:
cates low or no output, perform the following test to a. If connected, unplug the alternator-to-regula-
determine if the voltage regulator is defective or if the tor wiring harness connection.
alternator is defective.
b. Install a jumper wire from the alternator (B+)
1. A self-energized alternator may have lost its terminal to pin F in the wiring harness plug.
magnetism.
c. Momentarily (1 second), connect a jumper
a. Touch a steel tool to the shaft on the anti- wire from pin A to the alternator (B-) terminal.
drive end to detect any magnetism.
d. Touch the shaft with the steel tool to detect
b. If the shaft is magnetized, proceed to Step 5. significant magnetism.
c. If the shaft is not magnetized, proceed to e. If the shaft is not magnetized, the alternator
Step 2. is defective.
2. If the shaft is not magnetized:
f. If the shaft is magnetized, the regulator is
a. Momentarily (1 second), connect a jumper defective.
wire from the regulator (D+) terminal to the
alternator (B+) terminal.
b. Touch the shaft with the steel tool to detect
significant magnetism.
c. If the shaft is magnetized, proceed to Step 5;
otherwise go to Step 3.

FIGURE 10-9. WIRING HARNESS PLUG JUMPER


WIRE CONNECTION
1. Wiring Harness Plug 2. Regulator

5. Connect a voltmeter across pin D and pin C in


the wiring harness plug. Does battery voltage
FIGURE 10-8. JUMPER WIRE CONNECTION exist?
a. If no voltage, the alternator is defective.
1. Plug 2. Regulator
b. If voltage is present, proceed to Step 6.

D10-18 Battery Charging Alternator D10003 07/06


6. Set the voltmeter to the diode test scale.
a. Connect the black lead of the voltmeter to
pin E in the wiring harness plug.
b. Connect the red lead to the (B-) terminal on
the alternator. Limit the time the terminal is connected to a few
seconds. Doing so can protect the charging sys-
c. The voltmeter must read a voltage drop.
tem from excessive voltage increase.
d. Reverse the leads. The voltmeter must read
OL.
e. If there is no voltage drop, the alternator is Table 10-4: REGULATOR BYPASS TEST
defective.
Connect Disconnect Diagnosis
f. If there is a voltage drop, proceed to Step 7.
Amps increase Amps Alternator is good.
7. Install a jumper from the alternator (B+) terminal decrease Replace the regula-
to pin F in the wiring harness plug. tor only if low amps/
low Volts are indi-
a. Momentarily (1 second), connect a jumper cated by Bench Test
wire from pin A to the alternator (B-) terminal. 1 or 2.
b. Again, touch the shaft with a steel tool to No change No change The alternator must
detect significant magnetism. Is the shaft be repaired. Go to
magnetized? Static Tests.
c. If the shaft is not magnetized, the alternator
is defective.
d. If the shaft is magnetized, the regulator is
defective.

Regulator Bypass Test (Amp Rating)


1. Disconnect alternator-to-regulator wiring har-
ness plug (1, Figure 10-9).
2. Connect a jumper wire from pin F (F+ terminal)
in the alternator-to-regulator harness plug to the
alternator (B+) terminal.
3. Start the engine and accelerate to high idle.
4. Momentarily touch pin A (F- terminal) wiring
harness plug to the alternator ground terminal
(B-). Observe whether the amps increase or
decrease.
a. If the amps increase to within ± 10% of the
rated output when connecting (F-) to ground
(B-), the alternator is good. Refer to Table
10-4.
b. If the amps decrease when disconnecting
pin A (F-) from alternator ground (B-), the
alternator is good. Refer to Table 10-4.

D10003 07/06 Battery Charging Alternator D10-19


BENCH TESTING Bench Test 1: No-Load Test
1. With the battery connected and no electrical
load, operate the alternator at 5000 rpm.
2. Compare the test results to the No Load Test,
Perform the following on-bench tests when: Table 10-5, and take the appropriate action, as
stated in the table.
• On-vehicle test results are not available.
• Confirming on-vehicle test results. Table 10-5: NO LOAD TEST
Amps Volts Diagnosis
Equipment
HIGH LOW Test bench battery is discharged
• Voltmeter, 0-40 Volt range (Digital type preferred) or defective. Allow to charge or
replace.
• Ammeter, 0-400 ampere range (Digital, Inductive
type preferred.) HIGH NORMAL Allow time to stabilize while moni-
toring the Volts. If the Volts
• Test bench with 30-40 hp motor able to drive the increase above the normal range,
alternator to 8000 rpm. Mount the alternator on the regulator and/or field coil must
the test bench per the bench manufacturer’s be replaced. If the amps
instructions. Ensure the test bench batteries are decrease, the charging system is
at 95% or higher state of charge. good.

Identification Record HIGH HIGH The regulator and/or field coil


must be replaced. Go to Static
List the following items for troubleshooting: Testing.
Alternator model number ______________ LOW LOW The alternator and/or regulator
must be repaired or replaced. Go
Regulator model number ______________ to Bench Test 3.
Set point(s) listed on regulator __________ LOW NORMAL The regulator is good. Go to
Bench Test 2.
Advanced Troubleshooting
LOW HIGH Stop the test. The alternator is
a. A voltage reading at the regulator set point of defective, bench is not working
± 0.2 Volts is considered normal. properly, or the alternator is wired
improperly to the bench.
b. The alternator rated output (listed on the
nameplate) within ± 10% is determined at
5000 rpm.

D10-20 Battery Charging Alternator D10003 07/06


Bench Test 2: Full Load Test 2. Set up the load on the alternator the same as
Bench Test 2.
1. With the load set to the rated output (listed on
the nameplate) ± 10%, operate the alternator at 3. Note whether the amps increased to within ±
5000 rpm. 10% of the rated output when connecting pin A
(F-) to alternator ground (B-.)
2. Compare the test results to Table 10-6, and take
the appropriate action, as stated in the table. 4. Note whether the amps decrease when discon-
necting pin A (F-) from the alternator ground.
Table 10-6: FULL LOAD TEST Compare the test results to Table 10-7, and take
the appropriate action, as stated in the table.
Amps Volts Diagnosis
HIGH LOW The test bench battery is dis-
charged or defective. Allow the
battery to charge or replace the
battery. Limit the time the terminal is connected to a few
HIGH NORMAL The charging system is good. seconds. Doing so can protect the charging sys-
HIGH HIGH Stop the test. The regulator and/ tem from excessive voltage increase.
or field coil replaced. Go to Static
Testing. Table 10-7: REGULATOR BYPASS TEST
LOW LOW The alternator and/or regulator Connect Disconnect Diagnosis
must be repaired or replaced. Go
to Bench Test 3. Amps increase Amps decrease The alternator is
good. Replace the
LOW HIGH Stop the test. The alternator is regulator only if low
defective, the bench is not work- amps/low Volts are
ing properly, or the alternator is indicated by Bench
wired improperly to the bench. Test 1 or 2.
No change No change The alternator must
Bench Test 3: Regulator Bypass Test be repaired. Go to
Static Testing.
Perform this test only when directed by other tests.
1. Bypass the regulator by installing a jumper
between pin A (F-) and pin F (F+).

FIGURE 10-10. PIN CONNECTION


IDENTIFICATION

D10003 07/06 Battery Charging Alternator D10-21


STATIC TESTING Check For Shorted Power Transistor
1. Set the DMM to the diode test scale and zero
the meter.

Static tests must confirm on-vehicle and bench


tests. For best results, disassemble the alterna-
tor, as needed, to access the parts.

Equipment
• Digital Multimeter (DMM)
• Ammeter (digital, inductive)
• Regulator tester
FIGURE 10-11. PIN CONNECTION
Identification Record IDENTIFICATION
Alternator model number ______________ 2. Connect one meter lead to pin A (F-, Figure 10-
Regulator model number ______________ 11) connector socket in the regulator, and con-
nect the other lead to pin C (B-) connector
Set point(s) listed on regulator __________
socket in the regulator. Observe the meter read-
Regulator Tester ing.
3. Reverse the leads and observe the meter reading.
A regulator tester can test all regulator functions. If a
regulator tester is used, follow the regulator tester 4. In one direction, the DMM must register a tone.
manufacturer’s instructions. In the other direction, the DMM must show OL
(out of limits).
If a regulator tester is not available, the regulator can
5. If the DMM shows zero in both directions, the
only be tested for a shorted power transistor.
power transistor is shorted and the regulator
must be replaced.

NOTE: If regulator failure is indicated, field coil failure


must also be suspected.

D10-22 Battery Charging Alternator D10003 07/06


Circuit Tests 3. The expected reading listed for each test must
be obtained.
1. Before testing, check for visible signs of dam-
aged components. 4. Replace any component that fails.
2. Conduct the tests described in Alternator Pin- 5. Remove wiring harness (1, Figure 10-12)
to-Pin Tests, Table 10-8. before any test.

Table 10-8: ALTERNATOR PIN-TO-PIN TESTS


Test Meter Meter (+) Lead Meter (-) Lead Expected
No. Scale Connection Connection Tested Circuit Reading
1 Ohms Pin C Alt. B- Terminal Regulator ground circuit 0 ohms
2 Ohms* Pin A Pin F Field coil resistance 1.5 ± 0.2 ohms
3 Ohms Pin F Alt. B- Terminal Insulated OL (out of limits)
4 Ohms Pin A Alt. B- Terminal Insulated OL (out of limits)
5 Diode Test Pin B Alt. B+ Terminal Phase winding and diode <0.7 Volts (flow)**
6 Diode Test Alt. B+ Terminal Pin B Phase winding and diode OL (blocking)**
7 Diode Test Pin B Alt. B- Terminal Phase winding and diode OL (blocking)*
8 Diode Test Alt. B- Terminal Pin B Phase winding and diode <0.7 Volts (flow)**
9 Ohms Pin D Alt. B+ Terminal Regulator power circuit 0 ohms
10 Diode Test Alt. B+ Terminal Alt. B- Terminal All diodes in parallel OL (blocking)
11 Diode Test Alt. B- Terminal Alt. B+ Terminal All diodes in parallel <0.8 Volts (flow)
12 Diode Test Alt. B- Terminal Pin E Dual diode trio <0.7 Volts (flow)
13 Diode Test Pin E Alt. B- Terminal Dual diode trio OL (blocking)

* Applies only when the field coil is attached to the


rectifier/housing assembly.
** If the expected reading is not achieved, check the
thermal switch inside the rectifier/housing assem-
bly and test the switch for continuity.

D10003 07/06 Battery Charging Alternator D10-23


FIELD COIL TESTS
This test is used to check for an open or shorted field
coil.

Field Coil Test 1: Check for Open or Shorted Field


Coil
1. Set the digital multimeter DMM to x1 scale.
Ensure the DMM is zeroed.
2. Connect the meter leads from pin A (F-, Figure
10-13) and pin F (F+) in the regulator harness
plug. The DMM must show 1.2 ± 0.2 ohms.
a. If the meter shows more than 1.5 ohms, the
field coil is open.
b. If the meter shows less than 0.5 ohm, the
field coil is shortened. Replace the field coil.

FIGURE 10-12. WIRING HARNESS PLUG JUMPER


WIRE CONNECTION
1. Wiring Harness Plug 2. Regulator

FIGURE 10-13. PIN CONNECTION


IDENTIFICATION

Field Coil Test 2: Check For Grounded Field Coil


1. Set the digital multimeter (DMM) to x10K scale.
Ensure the DMM is zeroed.
2. Connect one meter lead to pin A (F-, Figure 10-
14) in the regulator harness plug. Connect the
other lead to the alternator ground (B-) terminal.
The DMM must show a very high resistance. If
the DMM reads less than 100K ohms, the field
coil is grounded. Replace the field coil.

D10-24 Battery Charging Alternator D10003 07/06


3. Move the drive lead from pin A (F-) to pin F (F+) STATOR TESTS
in the harness plug. The DMM must show a
These alternators have delta-wound stators. Test 1
very high resistance. If the ohmmeter shows
will show the condition of the phase lead from the
less than 100K ohms, the field coil is grounded.
ring terminal at the diode end of the lead to the sol-
Replace the field coil.
dered connection at the phase winding. Test the
phase coil windings on a bench stator tester, follow-
ing the tester’s instructions.
Before performing tests:
1. Check the stator for signs of damage, such as
burnt insulation or a loose coil.
2. Disconnect the phase lead wire from the mount-
ing terminals.

FIGURE 10-14. WIRING HARNESS PLUG JUMPER


WIRE CONNECTION
1. Wiring Harness Plug 2. Regulator

FIGURE 10-15. PHASE LEAD LOCATIONS

Stator Test 1: Check For Stator-To-Stator Conti-


nuity
1. Set the DMM to the ohms scale and zero the
meter.
2. Connect one meter lead to phase lead P1 (Fig-
ure 10-15), connect other meter lead (one at a
time) to each phase lead P4, P5, and P6.
Repeat for P2 and P3.
3. The DMM must show OL (out of limits) each
time. If the DMM shows a value, replace the
stator.

D10003 07/06 Battery Charging Alternator D10-25


Stator Test 2: Check For Grounded Stators Initial Test
1. Set the DMM to the ohms scale and zero the 1. Disconnect the wiring harness plug from the
meter. regulator.
2. Connect one DMM lead to the (B-) terminal on 2. If necessary, remove the cover from the drive
the alternator, and connect the other meter lead end housing.
to each phase lead P1, P2, and P3 (Figure 10- 3. Check for continuity between pin B (phase 1) of
15). the wiring harness plug and the phase lead
3. If the resistance reading is other than OL (out of (diode) connection (2), shown in Figure 10-16.
limits) at any connection, the stator is grounded This connection is just left of the 11 O'clock
to the shell. Replace the stator. position when looking at the alternator from the
4. Connect one DMM lead to the (B-) terminal on drive end.
the alternator, and connect the other DMM lead a. If continuity exists, there is a problem with
to each phase lead P4, P5, and P6. the alternator and not with the thermal
5. If the resistance reading is other than OL (out of switch.
limits) at any connection, the stator is grounded b. If there is no continuity, the thermal switch is
to the shell. Replace the stator. probably faulty.

THERMAL SWITCH TEST


If the alternator is not operating properly, check the
thermal switch. This switch is a normally closed (NC)
switch which must have continuity between the wires
from the switch.

FIGURE 10-16.

1. Pin B (Phase) 2. Phase Lead


Connection

D10-26 Battery Charging Alternator D10003 07/06


Verifying a Faulty Thermal Switch
1. Remove the cover from the control box on the
drive end housing.
2. Locate the thermal switch inside the control
box.
3. Test the two wires from the thermal switch for
continuity.
a. If there is no continuity, the switch is faulty.
b. If there is continuity, there may be a problem
with either the alternator or the wiring har-
ness.

D10003 07/06 Battery Charging Alternator D10-27


TROUBLESHOOTING TIPS
PROBLEM CAUSE/SOLUTION
1. Installed the alternator and connected the A self-energizing type alternator can lose its residual magne-
tism and not work properly. Residual magnetism is the small
cables (B+/B-(GND)) but the alternator has no
output. What could be wrong? amount of magnetic field that remains in the alternator when
there is no field current present. This residual magnetism is
Refer to the Regulator Bypass test (No Output)
necessary to start the alternator. Once established, the resid-
section for additional testing information.
ual magnetism slowly declines over time when the alternator
is not used. In practical terms, this time period is months. To
test for the presence of residual magnetism, touch a steel
wrench or screwdriver to the rotor shaft on the anti-drive end
of the alternator. If a light magnetic attraction is present, the
residual magnetism is present. If there is no attraction, the
residual magnetism is lost and must be restored or the alter-
nator may not self-energize. See 2. Self-energizing alternator
loses residual magnetism.
2. Self-energizing alternator loses residual Once an alternator is magnetized at the factory, it must hold
magnetism. its residual magnetic field for the duration of its life. In rare
instances, residual magnetism can be lost either during an
Refer to the Regulator Bypass test (No Output)
extended period of inactivity (shelf time) or if the alternator
section for additional testing information.
was exposed to a strong external magnetic field.
Momentarily (1 second), connect a jumper wire from the
jumper (D+) terminal on the regulator to the (B+) alternator
output terminal. The alternator must operate normally. If not,
further troubleshooting is required.

3. How can voltage regulators be tested? Voltage regulators can be tested using several methods.
Refer to the Regulator Bypass test (No Output) 1. The first method is to remove the suspect regulator and
section for additional testing information. substitute a known good regulator and then conduct the
alternator output test. If the alternator performs properly,
the suspect regulator is confirmed defective and must
be replaced.
2. The second method, incorporating the process of elimi-
nation, is to follow a diagnostic sequence and test the
individual alternator component functions to determine if
the components are good or bad. After systematically
eliminating the alternator components as the cause of
the problem, most likely, the regulator is defective.
Replace the regulator.
3. The third method involves utilizing a direct regulator
tester which is commercially available. When using a
tester to test a regulator, follow the instructions supplied
by the tester manufacturer and service manual for
proper terminal connections. If the regulator is not prop-
erly connected, the tester or the regulator may be dam-
aged. Refer to the regulator tester manufacturer's
instructions to determine if the regulator is defective.

D10-28 Battery Charging Alternator D10003 07/06


PROBLEM CAUSE/SOLUTION
4. The regulator has four different voltage settings The voltage regulator is equipped with a selectable voltage
from 27.0V to 29.5V on the 28.0V systems. set point. This feature allows the choice of the regulated volt-
Which is used? age output of the alternator according to the type of batteries
in use on the truck.
Refer to the Regulator Removal procedure in the
Alternator Disassembly section for additional infor- The lower voltage settings are used for maintenance-type
mation. batteries. The maintenance-type batteries require slightly
lower charge voltage to maintain performance. Excessive
voltage settings on the maintenance-type batteries will lead to
overcharging and premature failure of the batteries.
The higher voltage settings are used for maintenance-free
batteries. In general, a vehicle equipped with maintenance-
free batteries must have the regulator charge voltage set
point adjusted to one of the two higher settings on the regula-
tor. If the voltage setting is set too low for the maintenance-
free batteries, the insufficient charge voltage will keep the
battery from reaching full charge. Over time, this can lead to a
no start condition and reduce the battery life. An incorrectly
adjusted regulator voltage set point will result in either a con-
tinuous overcharging or undercharging condition, which can
affect battery performance and shorten the battery life.
The highest regulator voltage setting can be used only on
vehicles equipped with battery isolators. The battery isolators
are generally used on vehicles with two or more batteries.
The isolator set-up allows for independent discharge of one
battery, while the other battery remains fully charged for
engine restart. Due to the design nature of the isolator, the
alternator voltage setting must be increased to overcome a
voltage drop that occurs as the current flows through the iso-
lator. This voltage drop can be as high as one Volt. If the volt-
age is set lower than the battery type requires, it will lead to
an undercharge condition, a no start situation, and will reduce
the battery life.
If regulator replacement is necessary, set the new regulator
charge voltage set point to the same voltage setting as on the
regulator being replaced. Confirm that this is the correct set-
ting for the type of battery being used. The ambient tempera-
ture may also play a role in determining the correct regulator
charge voltage set point. When the vehicle is operated contin-
uously in cold climates, and the battery is not maintaining a
state of full charge, the regulator voltage set point may be
adjusted to the next higher set point appropriate for the given
battery type.

D10003 07/06 Battery Charging Alternator D10-29


PROBLEM CAUSE/SOLUTION
5. What is an alternator field coil, and how can the coil be The alternator field coil acts as an electromagnet
tested? when field current is applied. The stronger the mag-
netic field, the higher the alternator output when the
Refer to the Field Coil tests section for additional testing
shaft is turned. The strength of the magnetic field is
information.
dependent on the resistance of the field coil winding
(which determines the amperes of current the field
coil draws) and the number of wire turns in the field
coil. The most common symptoms associated with
alternator field coil failure are a no output condition,
reduced output, and sometimes an over-charge con-
dition.
The field coil can be tested for resistance value or
short to ground using an ordinary multi-meter. To test
the alternator's field coil resistance, refer to the Field
Coil Tests for additional testing information.
6. What is the function of the R terminal on the regulator The R terminal represents a tap or direct connection
and what can be measured there? to the alternator stator that has electric power only
when the alternator is turning and producing power.
The terminal output is utilized on some applications
for rpm or tachometer function. This requires a cali-
bration circuit that relates the alternator shaft speed
to the engine speed. The output at the R terminal is
AC voltage. The average voltage output can be mea-
sured with an ordinary multi-meter. The R terminal
output, depending on the electrical load, will be equiv-
alent to approximately one-half of the alternator regu-
lated voltage output. In other words, on the 28-Volt
system, the average voltage reading will be about 14-
Volts.

7. An alternator is being tested on a test bench and it does The maximum alternator output is dependent on the
not reach its full-rated output. What could be wrong? alternator shaft speed. If the test bench motor is not
properly rated, the alternator shaft will turn too slowly.
The alternator will not reach its rated output. When
testing an alternator on a test bench, ensure the test
bench motor is powerful enough to drive the alterna-
tor shaft at full load. To properly test the alternator
rated at 28-Volts and more than 200 amps, a bench
motor rated at 30 hp is required. Testing an alternator
using an underrated bench motor can lead to misdi-
agnosis and unnecessary component replacement.

D10-30 Battery Charging Alternator D10003 07/06


PROBLEM CAUSE/SOLUTION
8. When the alternator voltage is measured at the alterna- When there is a difference in voltage measured
tor (B+) terminal, it is considerably higher than alterna- between two places in the same circuit, the most
tor voltage measured at the battery (B+) terminal. What likely cause is excessive resistance in that circuit.
could be wrong? This difference, as measured between two points, is
called a voltage drop. The excessive resistance in the
circuit can be a result of poor connections at the ter-
minals or undersize gauge of the connecting cable.
All connecting cables in any electrical system must
be of sufficient gauge for the length of the cable to be
able to carry the necessary current within the circuit.
If the gauge is too small, the resulting voltage drop
will impair electrical system performance. This is a
critical issue for the charging system because exces-
sive voltage drops in the system, on the positive or
the negative side, can prevent the batteries from
recharging properly. The maximum difference
between the measurements must not exceed 0.8-
Volts for the 28-Volts system. To maintain accuracy
when testing the charging system, measure the volt-
age drop with the alternator at no load and at maxi-
mum load to check how the load current can affect
the voltage. Undersized cables also heat up when
conducting electrical current. This causes the insula-
tion to either soften or get brittle, and represents a
safety hazard in the system.

D10003 07/06 Battery Charging Alternator D10-31


ALTERNATOR
ALTERNATOR REPAIR

The alternator weighs approximately 32 kg (70


lbs). To prevent personal injury, it is recom-
The charging system is capable of causing phys- mended that a sling and overhead lifting device
ical harm. Use caution during the removal/instal- be used when removing the alternator.
lation procedures to protect personnel from 1. Disconnect the battery power:
injury.
a. If the truck is equipped with a battery equal-
izer, open the battery disconnect switch to
remove power from the system.
b. Remove the battery cables using the follow-
ing sequence:
1). Remove the battery positive (+) cables
first.
2). Remove the negative (-) cables last.
2. Securely attach a sling around the alternator,
and hook the sling to an overhead lifting device.
3. Remove battery cable (1, Figure 10-18) from
the (B+) terminal on alternator (2).

FIGURE 10-17. BATTERY CHARGING


ALTERNATOR
1. Alternator 2. Radiator

Removal
The following instructions cover the removal of alter-
nator (1, Figure 10-17) from a Komatsu engine. Radi-
ator (2) has been removed from the truck in some
pictures to clearly show the removal process. How-
ever, the radiator does not need to be removed to
remove the alternator.

FIGURE 10-18. REMOVE BATTERY CABLE


1. Battery Cable (B+) 2. Alternator
Terminal
To prevent shorting of the electrical system, dis-
connect the positive battery cable from the bat-
tery before starting this procedure.

D10-32 Battery Charging Alternator D10003 07/06


4. Remove ground strap (1, Figure 10-19) from 5. Remove eight lock nuts (1, Figure 10-21) from
the alternator by removing cap screw (1, Figure the front cover of the belt guard assembly.
10-20). It is not necessary to completely remove 6. Remove cover (2).
the ground cable unless it is damaged and must
be replaced.

FIGURE 10-21. BELT GUARD ASSEMBLY

1. Lock Nuts 2. Cover


FIGURE 10-19. GROUND STRAP
1. Ground Strap 2. Sub Frame 7. Use a ¾ inch square drive breaker bar to
release the tension on automatic belt tensioner
(1, Figure. 10-22.)
8. Remove belt (2). Replace the belt if signs of
wear or damage are found.

FIGURE 10-20. GROUND STRAP CONNECTION


1. Ground Strap 2. Cap Screw

FIGURE 10-22. AUTOMATIC BELT TENSIONER


ASSEMBLY

1. Automatic Belt 2. Belt


Tensioner

D10003 07/06 Battery Charging Alternator D10-33


9. Remove outer alternator bracket half (1, Figure 4. Use a ¾ inch square drive breaker bar to
10-23) by removing four lock nuts (2). release the tension on automatic belt tensioner
(1, Figure 10-22) and install belt (2).
10. Remove the alternator from the inner bracket
half. 5. Install cover (2, Figure 10-21) using eight lock
nuts (1).
6. Install ground strap (1, Figure 10-19) to the
alternator. Tighten ground cable cap screw (2,
Figure 10-20) to 15 N·m (11 ft lbs). If the ground
strap cable was removed from the frame, reat-
tach it.
7. Install battery cable (B+) to the terminal on
alternator (2, Figure 10-18). Tighten the nut to
32 N·m (24 ft lbs).
8. Connect the battery cable to the battery.
a. If the truck is equipped with a battery equal-
izer, close the battery disconnect switch.
b. If the truck is not equipped with a battery
equalizer, install the negative cable to the
negative battery post. Then, install the posi-
FIGURE 10-23. MOUNTING BRACKET tive cable to the positive battery post.
1. Alternator Bracket 2. Lock Nut Special Tools and Lubricants
(Top Half) Table 10-9: REQUIRED LUBRICANTS AND
SEALANTS
For additional information on disassembling the alter-
nator, see the Alternator Disassembly procedure in Komatsu Description Use
this chapter. Part #
XA3401 Grease Lubricate spiral rings
Installation
— Liquid Thread lock screws
Threadlockers
— Elastoplastic Insulate electrical
Silicone Resin connections
The alternator weighs approximately 32 kg (70
lbs). To prevent personal injury, it is recom- — Epoxy Install new stator
mended that a sling and overhead lifting device Adhesive wedges
be used when removing the alternator.
1. Securely attach a sling around the alternator
and hook the sling to an overhead lifting device.
2. Place the alternator on the inner bracket half.
3. Install outer alternate bracket half (1, Figure 10-
23). Install four lock nuts (2) and tighten to stan-
dard torque.

D10-34 Battery Charging Alternator D10003 07/06


Epoxy Adhesive Elastoplastic Silicone Resin
Master Bond, Inc. Dow Corning 1-2577 Low VOC RTV is a one-part
154 Hobart Street clear, RTV cure with mild heat acceleration possible.
Hackensack, NJ 07601 USA It has a hard slick finish with abrasion resistance, sol-
Phone: 201-343-8983 vent-borne with low VOC which is ozone-safe. This
Fax: 201-343-2132 silicon meets UL and MIL Specs and contains a UV
www.masterbond.com indicator.
Typical Properties:
Viscosity/Flowability
Epoxy adhesive, EP11HT, is a one component, heat
(cps or mPa sec) = 1,250;
curing, structural epoxy adhesive with high shear
Durometer = 25 D;
strength, easy handling, and high temperature resis-
Specific Gravity = 0.88;
tance. Cures at elevated temperatures, e.g. 90-120
RT Tack Free Time = 6 minutes;
minutes at 121°C (250°F) or 60-90 minutes at 149°C
Room Temp Cure Time = 60 minutes;
(300°F). The minimum cure temperature is 121°C
Heat Cure Time = 2 minutes @ 60°C (140°F;
(250°F). EP11HT attains tensile shear strengths in
Agency Listing = UL 94 V-0 or HB & 746C / Mil Spec;
excess of 22753 kPa (3,300 psi) and forms rigid and
Dielectric Strength, Volts/mil = 340;
dimensionally stable bonds. The service temperature
Dielectric Strength kV/mm = 13.4;
range is -51°C to 204°C (-60°F to 400°F). As a one
Volume Resistivity ohm-cm = 1.9E+14
part system, it does not require mixing prior to use
and has an unlimited working life at room tempera- Dow Corning Corporation
ture. EP11HT bonds well to a wide variety of sub- Corporate Center
strates, including metals and most plastics. It has PO Box 994
excellent resistance to a wide range of chemicals Midland MI 48686-0994 USA
including acids, bases, oils, salts, and many solvents. Phone: 989-496-7881
This adhesive is 100% reactive and does not contain Fax: 989-496-6731
any solvents or volatiles. The standard color is tan. www.dowcorning.com
The cured adhesive fully meets the requirements of
MIL-MMM-A-132.

Liquid Threadlockers
Loctite 222 Low Strength Threadlocker is an anaero-
bic sealant. This low-strength threadlock is used for
small screws less than 6 mm (.25 in.) in diameter.
The parts can be separated using hand tools.

Henkel Corporation
1001 Trout Brook Crossing
Rocky Hill, Connecticut 06067 USA
Phone: 860-571-5100
Internet: www.loctite.com

D10003 07/06 Battery Charging Alternator D10-35


Table 10-10: REQUIRED TOOLING
XA3320 Field Coil Removal/Installation Tool
XA3322 Stator Installation Tool
Customer-supplied dealer manufactured support stand
Three jaw gear puller (rotor removal, anti-drive end
housing, and anti-drive end shaft bearing)
Air impact wrench (pulley nut and fan nut)
Air chisel with a rounded point hammer bit (to loosen
rust from rotor, item 47)
Torque wrench (inch pounds)
Torque wrench (foot pounds)
FIGURE 10-25. XA3322 STATOR INSTALLATION
Torx bit T15 (field coil screws, item 53)
TOOL
Torx bit T20 (drive end cover plates and control unit
cover plates, item 6)
Torx bit T25 (rotor screws, item 46)
Allen socket wrench 3 mm (fan guard, item 69)
Deep well socket 6 mm (nut, item 54)
Socket 8 mm (voltage regulator screws, item 38)
Socket 9 mm (drive end and anti-drive end housings
lock flange nuts, item 14)
Socket 11 mm (stator wire hex jam nut, item 11)
Socket 24 mm (fan nut, item 67)
Socket 30 mm (pulley nut, item 1)
Small screwdriver (to release sockets in electrical plug,
item 30)
Expandable pliers (studs, item 61, and pulley bushing,
item 4) FIGURE 10-26. CUSTOMER-SUPPLIED DEALER
Internal heavy-duty snap ring pliers (items 8, 10) MANUFACTURED SUPPORT STAND
Hydraulic Press

FIGURE 10-27. THREE JAW GEAR PULLER


FIGURE 10-24. XA3320 FIELD COIL
REMOVAL/INSTALLATION TOOL

D10-36 Battery Charging Alternator D10003 07/06


NOTES

D10003 07/06 Battery Charging Alternator D10-37


ALTERNATOR EXPLODED VIEW

FIGURE 10-28. ALTERNATOR

D10-38 Battery Charging Alternator D10003 07/06


1. Lock Nut 36. Harness, Wiring
2. Flat Washer 37. Regulator
3. Pulley (supplied with engine) 38. Screw, Hex
4. Bushing, Pulley
39. Washer, Stainless Steel Bellville
5. Ring, Spiral
40. Washer, Bellville
6. Screw, Pan
41. Lock Nut
7. Plate, Cover
8. Ring, Beveled Retainer 42. Nut
9. Bearing, Front 43. Washer, Bellville
10. Ring, Flat Retainer 44. Bushing, Pulley
11. Nut, Hex Jam 45. Shaft and Core, Rotor Assembly
12. Flat Washer 46. Screw, Torx
13. Insulator 47. Rotor Assembly
14. Nut, Lock Flange 48. Rotor Shaft and Core Assembly
15. Flat Washer 49. Key, Woodruff
16. Cap Screw, Stainless Steel 50. Ring, Spiral
17. Lock Washer 51. Ring, Carrier
18. Lock Washer, Stainless Steel 52. Coil and Stator Assembly, Field
19. Cap Screw 53. Screw, Torx
20. Housing, Drive End 54. Nut
21. Cover, Control Unit 55. Wedge, Stator (attached to stator with epoxy
glue)
22. Switch, Thermal
56. Stator, Drive End
23. Cap Screw, Hex Head
57. Bushing, Tension (not used in mounting)
24. Lock Washer, Stainless Steel
58. Shell
25. Flat Washer
59. Stator, Anti-Drive End
26. Cover Plate, Stud Assembly
60. Coil, Field
27. Cap Screw, Stainless Steel
61. Stud
28. Lock Washer
62. Bearing, Anti-Drive End
29. Flat Washer
63. O-Ring
30. Shell Connector (Plug)
64. Housing, Anti-Drive End
31. Pin Connector, Female
65. Fan
32. Plug, Wedge Lock
66. Washer, Bellville
33. Shell Connector (Receptacle)
67. Nut
34. Receptacle, Wedge Lock
68. Guard, Fan
35. Pin Connector, Male
69. Screw, Pan
70. Grommet

D10003 07/06 Battery Charging Alternator D10-39


Regulator Removal
1. Remove voltage regulator (37).
a. Disconnect wiring harness (36) from voltage
regulator (37).
Wedges must be reinstalled and sealed in place
b. Remove and save four screws (38) and four
correctly to prevent damage to the internal parts
Bellville washers (39) using an 8 mm socket.
during operation.

ALTERNATOR DISASSEMBLY
NOTE: Disassemble the alternator only as far as
necessary to replace any defective part(s).

The alternator weighs approximately 32 kg (70


lbs). Be careful when moving or positioning the
alternator to prevent personal injury.

FIGURE 10-29.
36. Wiring Harness 37. Voltage Regulator
The following replacement parts are mandatory:
spiral rings (5, 50), O-rings (63), lock nuts (14),
bearings (9, 62), and all lock washers. All small
hardware is included in a kit. Refer to the Parts
book.

FIGURE 10-30.
38. Screw 39. Bellville Washer

D10-40 Battery Charging Alternator D10003 07/06


2. If replacement of the voltage regulator is neces- NOTE: DO NOT lose the metal portion of grommet
sary, record the setting of the selectable voltage washers (70).
set point switch on the back side of the voltage 2. Remove fan (65) by removing nut (67) using an
regulator. When installing a new voltage regula- air impact wrench and a 24 mm socket. Also,
tor, set the selectable voltage set point switch to remove Bellville washer (66).
the same switch position as the faulty regulator.

FIGURE 10-33.
FIGURE 10-31.
65. Fan 67. Nut
NOTE: The setting of this switch can depend on the 66. Bellville Washer
type of battery being used. Refer to the Battery
section for additional information.

Fan Removal
1. Remove fan guard (68) by removing six Allen
head screws (69) using a 3 mm Allen wrench. When removing nut (67), the use of an air impact
wrench is recommended.

FIGURE 10-32.
FIGURE 10-34.
68. Fan Guard 70. Grommet Washer
69. Allen Head Screw

D10003 07/06 Battery Charging Alternator D10-41


3. Remove and discard spiral ring (50) from fan Anti-Drive End Housing Removal
(65).
1. Scribe a single mark on side of shell (58) and
drive end housing (20). Scribe a double mark on
the side of shell (58) and anti-drive end housing
(64). This will ensure the proper reassembly of
the end housings.

FIGURE 10-35.

50. Spiral Ring 65. Fan

Pulley Removal
1. Remove pulley (3, Figure 10-24) from the drive
end by removing nut (1) using an air impact
wrench and a 30 mm socket. Also, remove
washer (2) and woodruff key (49).

FIGURE 10-37.
20. Drive End Housing 64. Anti-Drive End
58. Shell Housing

FIGURE 10-36.
1. Nut 49. Woodruff Key
2. Washer

NOTE: Removal of the pulley may require a three


jaw gear puller.

D10-42 Battery Charging Alternator D10003 07/06


NOTE: Disassembly of the alternator can be made 3. Remove and discard nine lock flange nuts (14)
easier by using a support stand, as shown. The from anti-drive end housing (64) using a 9 mm
Support Stand section in this chapter provides socket.
dimensions to manufacture the stand.

FIGURE 10-40.
FIGURE 10-38.
14. Lock Flange Nuts 64. Anti-Drive End
Housing

4. Remove anti-drive end housing (64) from shell


(58).

The alternator weighs approximately 32 kg (70 NOTE: Removal may require the use of a three jaw
lbs). Be careful when moving or positioning the gear puller.
alternator to prevent personal injury.

2. Position the alternator in the support stand with


the anti-drive end facing up.

FIGURE 10-41.
58. Shell 74. Three Jaw
64. Anti-Drive End Gear Puller
Housing
FIGURE 10-39.

D10003 07/06 Battery Charging Alternator D10-43


5. Remove and discard two O-rings (63) from 7. Remove and discard spiral ring (50) from carrier
inside diameter of anti-drive end housing (64). ring (51).
.

FIGURE 10-42. FIGURE 10-44.


63. O-Rings 64. Anti-Drive End
Housing 50. Spiral Ring 51. Carrier Ring

6. Remove bearing (62) from rotor shaft (48) along


Anti-Drive End Rotor Removal
with ring carrier (51) using a three jaw gear puller.
1. Remove one Torx screw (46) using a number
T25 Torx bit. Scribe a mark on the face of the
rotor at the center of the screw hole. This will be
used to correctly position the rotor during
assembly.

FIGURE 10-43.
48. Rotor Shaft 62. Bearing
51. Ring Carrier

FIGURE 10-45.

46. Screw 47. Rotor

D10-44 Battery Charging Alternator D10003 07/06


NOTE: If necessary to loosen rust, use an air chisel
with a rounded-point hammer bit to vibrate the area
between screw holes on the rotor face.
4. Thread three screws (46) into the puller holes.
Tighten the screws evenly to start removing
The rotor retaining screws have been installed
rotor (47) from rotor shaft (48).
with a thread lock compound (Loctite). DO NOT
use air impact tools to remove screws (46). Use .
only hand tools to carefully remove these
screws. Using air tools can cause the screws to
break, resulting in damage.

FIGURE 10-48.
46. Screw 48. Rotor Shaft
47. Rotor
FIGURE 10-46.

46. Screw 47. Rotor


2. Remove remaining five Torx screws (46) using
a number T25 Torx bit.
3. Clean out three threaded puller holes in top of Threaded screws (46) may not be long enough to
rotor (47). completely remove rotor (47) from the rotor shaft. If
necessary, use a three jaw gear puller to completely
remove the rotor. Using the three jaw gear puller
may damage the rotor if it is rusted to the rotor shaft.

FIGURE 10-47.

46. Screw 47. Rotor


FIGURE 10-49.
47. Rotor. 74. Three Jaw
Gear Puller

D10003 07/06 Battery Charging Alternator D10-45


5. Remove the rotor from the rotor shaft. 2. Place the alternator in the support stand with
the drive end facing up.

FIGURE 10-50.
FIGURE 10-52.

Drive End Housing Removal


3. Remove cover plate (7) by removing six Torx
screws (6) using a number T20 Torx bit.

Ensure the single mark has been scribed


between drive end housing (20) and shell (58).
This mark will be used during the assembly pro-
cess to correctly align the two parts.

1. Position the support stand so the large diameter


hole is facing up.

FIGURE 10-53.

6. Screw 7. Cover Plate

FIGURE 10-51.

D10-46 Battery Charging Alternator D10003 07/06


4. Remove six hex jam nuts (11, Figure 10-54) 5. Mark the location of the six phase leads for
using an 11 mm socket. Remove the phase proper reassembly. Place a different identifica-
leads from the terminals. If necessary, remove tion mark on both the housing and each phase
flat washers (12, Figure 10-55) and insulators lead terminal.
(13).

FIGURE 10-56.
FIGURE 10-54.
11. Hex Jam Nuts 20. Drive End Housing
6. Remove and discard nine lock flange nuts (14)
using a 9 mm socket.

FIGURE 10-55. FIGURE 10-57.


12. Flat Washers 13. Insulators
14. Lock Flange Nuts 20. Drive End Housing

D10003 07/06 Battery Charging Alternator D10-47


7. Remove the sealing compound from the face of 9. Carefully pull out and disconnect plug (30) from
the drive end housing where the field coil leads receptacle (33) by releasing the lock and dis-
enter the control unit connecting the gray plug assembly.
.

FIGURE 10-58. FIGURE 10-60.


8. Remove five Torx screws (6) from control unit 30. Plug 33. Receptacle
cover (21) using a T20 Torx bit. Remove control
unit cover (21).
10. Remove orange wedge lock (32).

FIGURE 10-61.

30. Plug 32. Wedge Lock

FIGURE 10-59.
6. Screw 21. Control Unit Cover

D10-48 Battery Charging Alternator D10003 07/06


11. Using a small flat-blade screwdriver, release the 13. Pull the field coil leads through the opening in
female pin connectors from the plug assembly. the drive end housing.

FIGURE 10-62. FIGURE 10-64.

12. Remove the two field coil leads from plug (30), 14. Lift drive end housing (20), along with rotor (47)
and remove the orange seal from the field coil and rotor shaft (48), off of shell assembly (58).
leads. This may require two people; one to lift the
housing, and the other to guide the phase leads
out of the housing.

FIGURE 10-63.
20. Drive End Housing 30. Plug
FIGURE 10-65.
20. Drive End Housing 48. Rotor Shaft
47. Rotor 58. Shell Assembly

D10003 07/06 Battery Charging Alternator D10-49


15. Remove pulley bushing (4). 16. Remove spiral ring (5) from pulley bushing (4)
and discard.

FIGURE 10-66.
4. Pulley Bushing 20. Drive End Housing FIGURE 10-68.
4. Bushing 5. Spiral Ring

NOTE: Use a pair of expandable pliers and gently


wiggle (move side-to-side) the pulley bushing out of 17. Place drive end housing (20) into a hydraulic
the housing. press with the outer surface of the housing sup-
ported by the press table.

FIGURE 10-67.
4. Pulley Bushing 75. Expandable Pliers FIGURE 10-69.
20. Drive End Housing 77. Hydraulic Press

D10-50 Battery Charging Alternator D10003 07/06


18. Press rotor shaft (48) out of front bearing (9). 20. Remove flat retainer ring (10) using heavy-duty
internal snap ring pliers. Save the ring.

FIGURE 10-70.
FIGURE 10-72.
9. Front Bearing 48. Rotor Shaft
10. Flat Retainer Ring 9. Front Bearing

19. Remove beveled retainer ring (8) using heavy-


duty internal snap ring pliers. Save the retainer 21. Place the drive end housing face down on a
ring. hydraulic press with the outer surface of the
housing supported by the press table.

FIGURE 10-71.
FIGURE 10-73.
8. Beveled Retainer 9. Front Bearing
Ring

D10003 07/06 Battery Charging Alternator D10-51


2. Remove one Torx screw (46) using a number
T25 Torx bit. Scribe a mark on the face of the
rotor at the center of the screw hole. This will be
used to correctly position the rotor during
assembly.
Use a bearing driver with a slightly smaller diam-
eter than the outer race of the bearing. Pressing
against the inner race of the bearing will cause
bearing damage.
22. Use a bearing driver to remove the bearing from
the housing. Discard the bearing.

FIGURE 10-76.
46. Screw 47. Rotor

FIGURE 10-74.
The rotor retaining screws have been installed
Drive End Rotor Removal with a thread lock compound (Loctite). DO NOT
1. If necessary, remove drive end rotor (47) from use air impact tools to remove screws (46). Use
rotor shaft (48), using the following steps. only hand tools to carefully remove these
screws. Using air tools can cause the screws to
break, resulting in damage.

3. Remove remaining five Torx screws (46) using


a number T25 Torx bit.
4. Place rotor (47) and rotor shaft (48) into a
hydraulic press and remove the shaft. Ensure
the rotor is fully supported by the press table.

FIGURE 10-75.

47. Drive End Rotor 48. Rotor Shaft

D10-52 Battery Charging Alternator D10003 07/06


Field Coil Removal 4. Reposition the alternator in the support stand
with the drive end facing up.

DO NOT damage or bend studs (61).


1. Position the alternator in the support stand with
the anti-drive end facing up.
2. Permanently mark the letters ADE on the sur-
face of field coil (60) in the location of the miss-
ing screw.
3. Remove eight Torx screws (53) using a number
T15 Torx bit.

FIGURE 10-78.

5. Permanently mark the letters DE on the surface


of field coil (60) in the location of the missing
screw.
6. Remove eight Torx screws (53) using a number
T15 Torx bit.

FIGURE 10-77.
53. Screws 60. Field Coil

Field coil retaining screws (53) have been


installed with a thread lock compound (Loctite).
DO NOT use air impact tools to remove screws. FIGURE 10-79.
Use only hand tools to carefully remove these
screws. Using air tools can cause the screws to 53. Screws 60. Field Coil
break, resulting in damage.

D10003 07/06 Battery Charging Alternator D10-53


7. Place XA3320 field coil removal/installation tool
on top of the field coil.

DO NOT damage the field coil leads during the


removal process.
NOTE: If a new field coil will be installed, mark the
letters (in the same location and orientation) from
Steps 2 and 5 on the new replacement field coil.

9. Carefully remove the field coil from the stator.


The clearance between the field coil and stator
is minimal. Use caution during the removal pro-
cess. As the field coil is removed, ensure the
two field coil leads are removed without dam-
FIGURE 10-80. age.

8. Engage the recessed areas of the tool with the NOTE: In some instances, removal of the field coil
field coil bobbin ears. Rotate the tool clockwise may be easier by placing the anti-drive end of the
approximately five degrees to release the field alternator in an upward position and pulling the field
coil from the stator tabs. coil out of the stator.

FIGURE 10-82.

FIGURE 10-81.

D10-54 Battery Charging Alternator D10003 07/06


Drive End and/or Anti-Drive End Stator Removal 4. Permanently scribe or etch a single mark
aligned with the center of two stud holes, across
the top surface of anti-drive end stator (59) and
end of shell (58). Repeat at an adjacent hole.

Remove and replace one faulty stator at a time.


This process will ensure the alignment of stators
(56, 59) to shell (58). Refer to the appropriate
Installation section for specific installation
instructions.
1. Position the alternator in the support stand with
the drive end facing up.
2. Permanently scribe or etch a single mark,
aligned with the center of a stud hole, across
the top surface of drive end stator (56) and end
of shell (58).

FIGURE 10-84.

58. Shell 59. Anti-Drive End


Stator

A single scribe mark identifies the stator as the


drive end stator. The double mark identifies the
stator as the anti-drive end stator. It is critical
FIGURE 10-83. that these marks be precisely aligned during
assembly. If the marks are not precisely aligned,
56. Drive End Stator 58. Shell the phase leads, field coil leads, and the mount-
ing holes will not properly align. If a new stator is
3. Reposition the alternator in the support stand being installed, it is critical to precisely transfer
with the anti-drive end facing up. the location of the mark(s) to the new part.

D10003 07/06 Battery Charging Alternator D10-55


5. Remove the shell assembly from the support 8. Position the shell in the support stand with the
stand. Remove hex head nuts (54) from studs faulty stator in a downward position. Place sta-
(61) using a deep well 6 mm socket. Discard tor installation/removal tool XA3320 on top of
nuts (54). Use expandable pliers to hold the the tabs of the stator being removed. Ensure
enlarged portion of the stud. the recessed portion of the tool is fully engaged
with the stator tabs

Ensure the stator installation/removal tool is


engaged with the stator tabs of the part being
removed and not the stator in the upper position.
The shell assembly is manufactured with a raised
area in the center of the shell. The stators can
only be removed by pushing them out through
the end of the shell.

9. Place the shell assembly into a hydraulic press


and remove the faulty stator. Figure 10-86
FIGURE 10-85. shows the drive end stator being removed.
54. Hex Head Nuts 61. Studs

NOTE: Hex head nuts (54) have been installed using


a thread locking compound. Use care when
removing.

6. Remove and save nine studs (61) from the sta-


tors.
7. If a stator needs to be replaced, remove only
the faulty stator.
a. If removing the anti-drive end stator, place a
mark on the drive end stator where each
anti-drive end phase lead is located. Cut the
three terminals off the anti-drive end phase
FIGURE 10-86.
leads and discard.
b. If removing the drive end stator, break out NOTE: The tabs of the stator may bend slightly
the six glued in wedges on the drive end sta- downward during the removal process. Continued
tor with the anti-drive end phase leads downward pressure will push the stator out of the
behind them. shell.

D10-56 Battery Charging Alternator D10003 07/06


10. Carefully pull the three anti-drive end stator CLEANING AND INSPECTION
phase leads through the spaces between the 1. Ensure all parts being reused are thoroughly
stator windings. clean.
2. Ensure all parts being reused are in good condi-
tion. Replace any damaged parts.

ALTERNATOR ASSEMBLY
Before starting the installation procedure, ensure all
the parts are available and in good condition.
Replace any damaged parts before assembly.

All electrical wiring connections are coated with


a Dow Corning® 1-2577 low VOC RTV coating or
FIGURE 10-87. equivalent. DO NOT use a coating containing
acetic acid (vinegar smell) on any electrical com-
11. If it is necessary to remove the other stator, first ponents. Using any other coating will cause part
reinstall a new stator in place of the removed damage.
stator. Then, reposition the shell in the hydraulic
press with the remaining stator in a downward
position.

The following replacement parts are mandatory:


spiral rings (5, 50), O-rings (63), lock nuts (14),
bearings (9, 62), and all lock washers. All small
hardware is included in a kit. Refer to the Parts
book.

Anti-Drive End Stator Installation


This procedure assumes the drive end stator is
already installed in the shell, and a new anti-drive
end stator is being installed.
NOTE: New stators do not have terminals on the
phase leads. The leads must be cut to length,
FIGURE 10-88. insulation sleeves installed, and terminals soldered
onto the wires during final assembly.
12. Place the shell assembly into a hydraulic press
and remove the other faulty stator (56 or 59).
1. Precisely transfer the two scribed assembly
marks from faulty anti-drive end stator (59) to
the replacement stator.
2. Place the stator in the opening of shell (58).

D10003 07/06 Battery Charging Alternator D10-57


NOTE: If the drive end stator will not be replaced, 4. Insert six alignment studs through the holes in
route the phase leads from the replacement anti- anti-drive end stator (59) aligning them with the
drive end stator through the corresponding spaces holes in drive end stator (56).
(marked in Step 7a of the Disassembly procedure,
.
page 55) between the drive end stator windings. New
insulation sleeves and terminals will be installed on
the phase leads during final assembly.

FIGURE 10-91.

56. Drive End Stator 59. Anti-Drive End


Stator
FIGURE 10-89. 5. Place the shell with the stator into a hydraulic
press. Place stator installation tool XA3322 on
top of the stator.
3. Align the two scribed marks on the stator with
the scribed marks on shell (58). It is critical that
these scribed marks be carefully aligned. If the
marks are not precisely aligned, the wiring and
the mounting holes will not properly align.

FIGURE 10-92.

FIGURE 10-90.

D10-58 Battery Charging Alternator D10003 07/06


8. If the drive end stator needs to be replaced, fol-
low the steps in the next section. If the drive end
stator does not need replacement, go to the
Field Coil Installation section in this manual.

Ensure the shell is supported in a hydraulic Drive End Stator Installation


press so the alignment studs are not damaged by
This procedure assumes the anti-drive end stator is
the supports.
already installed in the shell, and a new drive end
6. Press the stator into the shell. The top surface stator is being installed.
of stator (59) will be flush with the end of shell
(58) when fully installed. 1. Precisely transfer the scribed assembly mark
from faulty drive end stator (56) to the replace-
. ment stator.
2. Place the stator in the opening of the shell.
3. Route three anti-drive end stator phase leads
through the corresponding spaces between the
drive end stator windings.
NOTE: There are two methods for routing the anti-
drive end phase leads. Follow either Step 3a or 3b.

a. Primary method (recommended): Break out


the six wedges on the replacement drive end
stator. Route the phase leads through the
corresponding spaces between the drive end
stator windings. Glue the six replacement
FIGURE 10-93. wedges in place using the recommended
58. Shell 59. Stator epoxy adhesive after the drive end stator is
pressed in place.
7. Remove the shell and stator assembly from the
press. Remove the installation tool. Remove the
six alignment studs.

FIGURE 10-95.

FIGURE 10-94.

D10003 07/06 Battery Charging Alternator D10-59


b. Alternative method: Remove the insulation 4. Place the stator in the opening of the shell. Pre-
sleeves from the three anti-drive end phase cisely align the scribed mark. It is critical that
leads. DO NOT damage the insulation this scribed mark be carefully aligned. If the
sleeves during removal. Carefully feed the mark is not precisely aligned, the wiring and the
terminal ends up through the corresponding mounting holes will not properly align.
spaces between the drive end windings. Use
a pick tool to pull the terminals though the
windings. Reinstall insulation sleeves after
the drive end stator is pressed in place.

FIGURE 10-97.

5. Insert six alignment studs through the holes in


the drive end stator aligning them with the holes
FIGURE 10-96. in the anti-drive end stator.

If the insulation sleeves are damaged or not


installed properly, excessive damage can be
caused to the alternator when current is pro-
duced during operation.

FIGURE 10-98.

D10-60 Battery Charging Alternator D10003 07/06


6. Place the shell with the stator in a hydraulic 8. Remove the shell and stator assembly from the
press. Place stator installation tool XA3322 on press. Remove the installation tool. Remove the
top of the stator. Position the studs in the open- six alignment studs.
ings of the tool.

FIGURE 10-101.
FIGURE 10-99.
NOTE: Precisely align the alignment marks on both
stators and the shell. If they are not aligned, remove
the stator(s) and reinstall.

9. Install nine studs (61) through stators (56 and


Position the shell in a hydraulic press so the 59). Install the studs from the anti-drive end of
alignment studs are not damaged by the sup- the alternator with the enlarged portion of the
ports. stud on the anti-drive end.

7. Press the stator into the shell. The top surface


of drive end stator (56) will be flush with end of
shell (58) when fully installed.

FIGURE 10-102.

56. Drive End Stators 61. Studs


59. Anti-Drive End
Stators
FIGURE 10-100.
56. Drive End Stator 58. Shell

D10003 07/06 Battery Charging Alternator D10-61


10. Install hex head nuts (54) onto the studs. Use a 2. Align the letters ADE on the field coil with the
suitable thread lock compound such as Loctite non-tabbed portion of the stator, and route the
222. Tighten the nuts to 3 N·m (30 in. lb) in an two field coil leads through the corresponding
alternating pattern. space between the stator windings.

Field Coil Installation


NOTE: If a new field coil is being installed, transfer
the letters ADE (anti-drive end) and DE (drive end)
from the faulty field coil to the corresponding
locations on the replacement field coil.

1. Position shell (58) on the support stand with the


drive end facing down.

FIGURE 10-104.

NOTE: New field coils do not have terminal pins


installed on the leads. The leads must be cut to
length and the new terminal pins crimped on during
final assembly.

FIGURE 10-103.

58. Shell 73. Support Stand

D10-62 Battery Charging Alternator D10003 07/06


3. Carefully push the field coil downward through 5. Engage the recessed areas of the tool with the
stator tabs (59). The clearance between the field coil bobbin ears. Rotate the tool clockwise
field coil and stator is minimal and will require approximately five degrees to engage the field
care during the installation process. As the field coil with the stator tabs. Ensure the letters ADE
coil is installed, ensure the two wires are not are now aligned with the non-tabbed area of the
damaged. Push the field coil downward until the stator.
mating surfaces between the field coil bobbin
ears and the stator tabs are vertically aligned.

FIGURE 10-107.

FIGURE 10-105.
6. Install eight field coil screws coated with a
59. Stator Tabs 60. Field Coil thread locking compound (such as Loctite 222
or equivalent). Tighten the screws to 2 N·m (20
in. lb).
4. Place field coil removal/installation tool XA3320
on top of the field coil.

FIGURE 10-108.

FIGURE 10-106.

D10003 07/06 Battery Charging Alternator D10-63


DO NOT install a screw in the marked hole DO NOT install a screw in the marked hole
because there is no corresponding stator tab. If because there is no corresponding stator tab. If
installed, the screw will fall into the stator cavity, installed, the screw will fall into the stator cavity,
damaging internal parts during operation. damaging internal parts during operation.

Drive End Bearing Installation


7. Reposition the shell assembly in the support
1. Install flat retainer ring (10) into the drive end
stand with the drive end facing up.
housing, as shown, using heavy-duty, internal
snap ring pliers.

FIGURE 10-109.
FIGURE 10-111.

8. Install eight field coil screws coated with a 10. Flat Retainer Ring 76. Snap Ring Pliers
thread locking compound (such as Loctite 222
or equivalent). Tighten the screws to 2 N·m (20
in. lb).

Fully support the housing before pressing the


bearing into the housing. Position the diameter of
the bearing driver against the outer bearing race.
Pressing on the inner race of the bearing will result
in bearing damage.

FIGURE 10-110.

D10-64 Battery Charging Alternator D10003 07/06


2. Place drive end housing (20) and front bearing 4. Lubricate the spiral ring with Komatsu grease
(9) in a hydraulic press. Press the bearing into XA3401. Wind new spiral ring (5) into the
the bore until completely seated against the flat groove around pulley bushing (44).
retainer ring.

FIGURE 10-114.
FIGURE 10-112.
5. Spiral Ring 44. Pulley Bushing
9. Front Bearing 20. Drive End Housing

5. Compress spiral ring (5) and install pulley bush-


3. Install beveled retainer ring (8) using heavy- ing assembly into the inside bore of the drive
duty, internal snap ring pliers. Position the bev- end housing. Position the thickest flange of the
eled portion of the retaining ring facing up. pulley bushing facing up (towards the inside of
the alternator).

FIGURE 10-113.
FIGURE 10-115.
8. Beveled Retainer 76. Snap Ring Pliers
Ring 5. Spiral Ring 20. Drive End Housing

D10003 07/06 Battery Charging Alternator D10-65


Drive End Rotor Installation Rotor and Rotor Shaft Installation
1. If removed, install drive end rotor (47) onto shaft 1. Press rotor and rotor shaft assembly (47, 48)
assembly (48). into drive end housing (20).
a. Place the rotor and rotor shaft assembly into
a hydraulic press with the rotor shaft fully
supported.
b. Place drive end housing (20) onto rotor shaft
(48).
c. Press the drive end housing onto the rotor
shaft. Press the housing onto the shaft using
a bearing driver, which will press against the
inner bearing race.

FIGURE 10-116.

47. Drive End Rotor 48. Shaft Assembly

2. Center the screw hole in rotor shaft (48) with


the slot in rotor (47).

FIGURE 10-118.

20. Drive End Housing 48. Rotor Shaft


47. Rotor Assembly Assembly

When installing the drive end housing, press


only on the inner race of the bearing. Pressing on
any other surface will result in bearing damage.
FIGURE 10-117.

47. Drive End Rotor 48. Shaft Assembly


2. Rotate the shaft to verify the bearing moves
3. Install five Torx screws (46) using a T25 Torx bit. freely.
Apply thread lock compound (Loctite 222) and
tighten to 7 N·m (65 in. lb). DO NOT install a
screw in the marked hole at this time.
4. Ensure the screw hole has remained centered
in the slot on the face of the rotor. Apply thread
lock compound (Loctite 222) and install the
screw. Tighten to 7 N·m (65 in. lb).

D10-66 Battery Charging Alternator D10003 07/06


Drive End Housing Installation 3. As the drive end housing is installed, guide the
two field coil leads and the six stator phase
1. Place shell assembly (58) into the support
leads through the proper openings in the drive
stand with the drive end facing up.
end housing.
NOTE: If necessary, install new terminal ends on the
wires. On the stator phase leads cut the wires to
length, strip the correct amount of wire insulation,
install insulating sleeves over the wires, and solder
on the new terminal ends. On the new field coil leads,
cut the wires to length, strip the correct amount of
wire insulation, and crimp on the new terminal pins.

FIGURE 10-119.
58. Shell Assembly 73. Support Stand

DO NOT damage the stator windings or studs FIGURE 10-121.


while repositioning the alternator.

2. Align the scribed marks on the drive end hous-


ing and the shell. Install the rotor shaft and
housing assembly onto the shell. A rod can be
used to verify the mounting tabs on the shell
and the drive end housing are properly aligned.

FIGURE 10-120.

D10003 07/06 Battery Charging Alternator D10-67


4. Install nine new lock flange nuts (14) onto studs 6. Place the stator phase leads onto the stator
(61). Tighten the nuts to 5 N·m (45 in. lb) using phase lead studs and install new hex jam nuts
an alternating pattern. (11). Tighten the nuts to 3 N·m (30 in. lb).

FIGURE 10-122. FIGURE 10-124.

14. Lock Flange Nuts 61. Studs 11. Jam Nuts 20. Drive End Housing

5. Install insulator (13) and then flat washer (12)


on the stator phase lead studs.

Position the insulation sleeves on the stator


phase leads over the arm of each terminal ring to
avoid a possible short circuit.

FIGURE 10-123.

12. Flat Washer 13. Insulator

D10-68 Battery Charging Alternator D10003 07/06


7. Lubricate the spiral ring with Komatsu grease 9. Guide the two field coil leads through the open-
XA3401. Wind new spiral ring (5) into the ing in the drive end housing and into the control
groove around pulley bushing (4). housing.

FIGURE 10-125. FIGURE 10-127.

4. Pulley Bushing 5. Spiral Ring

8. Compress spiral ring (5) and install pulley bush-


ing assembly (4) into the outside of drive end
housing (20). Position the thickest flange of the
pulley bushing facing up (towards the outside of
the alternator).

FIGURE 10-126.

4. Pulley Bushing 20. Drive End Housing


Assembly
5. Spiral Ring

D10003 07/06 Battery Charging Alternator D10-69


10. Install the orange wire seal over the field coil 11. Connect plug assembly (30) with receptacle
leads. Install the two terminal sockets into plug assembly (33).
assembly (30). Install orange wedge (32) to lock
the sockets into the plug.

FIGURE 10-129.

30. Plug Assembly 33. Receptacle


Assembly

12. Apply Dow Corning® 1-2577 low VOC RTV, or


equivalent, onto all electrical connections. Also,
seal the opening where the field coil leads enter
the control unit.

FIGURE 10-128.

30. Plug Assembly 32. Wedge

NOTE: Ensure the brown wire in the plug assembly


corresponds to the white wire in the receptacle
assembly. Ensure the red wire corresponds with the
black wire.

FIGURE 10-130.

D10-70 Battery Charging Alternator D10003 07/06


13. Install cover plate (7). Apply thread lock com- Anti-Drive End Rotor Installation
pound (Loctite) and install six Torx screws (6) 1. Reposition the alternator in the support stand
using a T20 Torx bit. Tighten the screws to 3 N·m with the anti-drive end facing up.
(30 in. lb).

FIGURE 10-133.
FIGURE 10-131.
6. Screws 7. Cover Plate
2. Install anti-drive end rotor (47) onto shaft
assembly (48). Align the previously-scribed
14. Apply Dow Corning® 1-2577 low VOC RTV, or mark on the face of the rotor with the center of
equivalent, onto the cover before installing. the screw hole.
Install control unit cover (21). Apply thread lock
compound (Loctite) with five Torx screws (6)
using a T20 Torx bit. Tighten to 3 N·m (30 in.
lb).

FIGURE 10-134.
47. Anti-Drive End Rotor 48. Shaft Assembly

FIGURE 10-132.
6. Screws 21. Control Unit Cover

D10003 07/06 Battery Charging Alternator D10-71


3. Apply thread lock compound (Loctite) and Anti-Drive End Housing Installation
install five Torx screws (46) using a T25 Torx bit. 1. Lubricate the spiral ring with Komatsu grease
DO NOT install a screw in the scribed hole at XA3401. Wind new spiral ring (50) into the
this time. Tighten the five screws to 7 N·m (65 groove of carrier ring (51).
in. lb).

FIGURE 10-137.
FIGURE 10-135.
46. Screw 47. Rotor 50. Spiral Ring 51. Carrier Ring

2. Install two new O-rings (63) in anti-drive end


4. Ensure the alignment mark has remained cen- housing (64).
tered with the screw hole. Apply thread lock
compound (Loctite), install the screw. Tighten to
7 N·m (65 in. lb).

FIGURE 10-138.
63. O-Rings 64. Anti-Drive End
FIGURE 10-136. Housing
46. Screw 47. Rotor

D10-72 Battery Charging Alternator D10003 07/06


3. Compress spiral ring (50) and install carrier ring 5. Apply thread lock compound (Loctite 222) and
assembly (51) into the anti-drive end housing, install nine new lock flange nuts (14). Tighten to
(towards the inside of the alternator). This part 5 N·m (45 in. lb) in an alternating pattern.
can be installed in either direction.

FIGURE 10-141.
FIGURE 10-139.
14. Lock Flange Nuts 64. Anti-Drive End
50. Spiral Ring 51. Carrier Ring Housing
Assembly

6. Install anti-drive end bearing (62) over the rotor


4. Align the installation scribe marks on shell (58) shaft. Place the shell assembly into a hydraulic
and anti-drive end housing (64). Install the anti- press. Press the bearing into the bore of anti-
drive end housing over rotor shaft (48) and nine drive end housing (64) until it is completely
studs (61). seated against the pulley bushing.

FIGURE 10-140. FIGURE 10-142.


48. Rotor Shaft 61. Studs
62. Bearing 64. Anti-Drive End
58. Shell 64. Anti Drive-End
Housing
Housing

D10003 07/06 Battery Charging Alternator D10-73


10. Install fan guard (68). Apply thread lock com-
pound (Loctite). Install Allen head screws (69)
using a 3 mm Allen socket wrench. Tighten the
screws to 7 N·m (65 in. lb).

When installing the anti-drive end bearing, press


only on the inner race of the bearing. Pressing on
any other surface will result in bearing damage.

7. Rotate the shaft to verify the bearing moves freely.


8. Lubricate the spiral ring with Komatsu grease
XA3401. Wind new spiral ring (50) into the
groove around fan (65).

FIGURE 10-143.
50. Spiral Ring 65. Fan

FIGURE 10-145.
9. Install the fan onto the rotor shaft with Bellville
washer (66) and nut (67). Use an air impact 68. Fan Guard 70. Grommets
wrench and a 24 mm impact socket to tighten 69. Allen Head Screws
the nut to 6 N·m (50 ft lb).
.
NOTE: Verify the metal grommet washers are still in
grommets (70).

FIGURE 10-144.

D10-74 Battery Charging Alternator D10003 07/06


11. Remove the alternator from the support stand. NOTE: The setting of this switch can depend on the
Install woodruff key (49) in the rotor shaft. type of battery being used. Refer to Battery in this
Install pulley (3) with flat washer (2) and nut (1). chapter for additional information.
Use an air impact wrench and a 30 mm impact
socket to tighten the nut to 163 N·m (120 ft lb).
2. Place the regulator on the alternator. Install four
screws (38) with Bellville washers (39) using an
8 mm socket. Tighten the screws to 8 N·m (70
in. lb).

FIGURE 10-146.
1. Lock Nut 49. Woodruff Key
2. Flat Washer
FIGURE 10-148.
Regulator Installation
38. Screws 39. Bellville Washers
1. Set the selectable voltage set point switch on
the back side of the regulator to the correct
position.
3. Connect wiring harness (36) to voltage regula-
tor (37).

FIGURE 10-147.

FIGURE 10-149.
36. Wiring Harness 37. Voltage Regulator

D10003 07/06 Battery Charging Alternator D10-75


THERMAL SWITCH 3. Remove the plastic tie strap securing the wires
together.
Removal
1. Disconnect wiring harness plug (36) from volt-
age regulator (37).

FIGURE 10-152.

FIGURE 10-150. 4. Remove all the sealant from around thermal


switch (22).
36. Wiring Harness Plug 37. Voltage Regulator

2. Remove nine Torx screws (6) using a T20 Torx


bit. Remove covers (21, 26).

FIGURE 10-153.
22. Thermal Switch

FIGURE 10-151.
6. Screws 26. Stud Assembly
21. Control Unit Cover

NOTE: If desired, disconnect field coil plug (30) from


receptacle (35). This will provide additional clearance
when removing the thermal switch.

D10-76 Battery Charging Alternator D10003 07/06


5. Remove hex head bolt (23) using a 13 mm 7. Remove thermal switch (22).
socket. Also, remove Bellville washer (24) and a. Reposition the two insulation sleeves to
flat washer (25). expose the wiring connections.
b. Remove the heat shrink insulation from both
wiring connections.
c. Unsolder each wire from the wiring terminal
sleeves.

FIGURE 10-154.
23. Hex Head Bolt 25. Flat Washer
24. Bellville Washer

6. Identify and mark the wiring terminals for proper FIGURE 10-156.
reassembly. These terminals must be reinstalled
in the same location as they were removed.
The order of the connections from top to bottom is:
rectifier terminal (1)
rectifier terminal (1),
B+/sense terminal (2),
thermal switch terminal (3),
flat washer,
Bellville washer, and
bolt

FIGURE 10-157.

FIGURE 10-155.

D10003 07/06 Battery Charging Alternator D10-77


Installation SUPPORT STAND
1. Place the appropriate diameter heat shrink Disassembly of the alternator can be made easier by
insulation onto the thermal switch wires. using a support stand, as shown. This drawing pro-
2. Solder the new thermal switch wires into the vides the dimensions to manufacture the stand.
wiring terminal sleeves.
3. Position the heat shrink insulation over each
wiring connection and apply heat to seal the
connection.
4. Reposition the insulation sleeve over each wir-
ing connection.
5. Place the wiring terminal connections in the cor-
rect order. Refer to Step 6, Removal, for the
proper installation order. Install hex head bolt
(23) with lock washer (24) and flat washer (25).
Tighten the bolt to 28 N·m (20 ft lb).

The thermal switch connection is coated with a


Dow Corning® 1-2577 low VOC RTV coating, or FIGURE 10-158.
equivalent. DO NOT use a coating containing
acetic acid (vinegar smell) on any electrical com-
ponents. Using any other coating will cause part
damage.

6. Coat the thermal switch connection with Dow


Corning® 1-2577 low VOC RTV coating, or
equivalent.
7. Secure the wires together using a plastic tie
strap.
8. Apply Dow Corning® 1-2577 low VOC RTV
coating, or equivalent, onto the cover plates
before installing. Install control unit cover plates
(21, 26). Apply a thread lock compound (Loc-
tite) to the screws with nine Torx screws (6)
using a T20 Torx bit. Tighten to 3 N·m (30 in.
lb).
9. Connect wiring harness (36) to voltage regula-
tor (37).

D10-78 Battery Charging Alternator D10003 07/06


SECTION D11
VEHICLE HEALTH MONITORING SYSTEM (VHMS)
INDEX

VHMS BASIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3


Gather Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3
Convert and Record Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3
Communicate Data to Off-Board Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-4

USING VHMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5


Turning VHMS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5
Normal VHMS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5
Turning VHMS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-6
Downloading from the VHMS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-6

VHMS DATA ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7


Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7
Machine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7
VHMS History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7
Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-8
Manual Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-8
Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-10
Histogram (Load Map) Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-10
Haul Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D11-11
Alarm and Snapshot Triggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-12
Satellite Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-12

VHMS DIAGNOSTIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14


Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14
VHMS LED Digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14

VHMS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-15

VHMS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-16


VHMS Tool Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-16
VHMS Setting Tool Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-16

VHMS INITIALIZATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17


VHMS Controller Setup Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17
VHMS Snapshot Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-20
VHMS Download Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-21
VHMS FTP Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-22
VHMS Initialization Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-23

WHEN REPLACING A VHMS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-24

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-1


VHMS CONTROLLER CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-29
Necessary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-29
Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-29
VHMS Controller Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-30

ORBCOMM CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32

D11-2 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


VEHICLE HEALTH MONITORING SYSTEM (VHMS)
VHMS BASIC FEATURES Convert and Record Data
The center of the Vehicle Health Monitoring System VHMS controller (2, Figure 11-1) processes data
(VHMS) is the VHMS controller, which gathers data received from external controllers and stores the
about the operation of the truck from sensors and following data in internal memory:
other controllers installed on the truck. Refer to
• Fault codes from the engine, Interface Module,
Figure 11-1 for an overview of the VHMS and PLM III
components.
• Snapshots of data when specific fault codes
For instructions on how to use VHMS software occur
programs, refer to VHMS Software elsewhere in this
• Trends of specific engine and chassis
section. For error codes, check-out and parameters
troubleshooting procedures, refer to VHMS
Troubleshooting and Check-out Procedures • Load map and other measures of engine and
elsewhere in this section. chassis usage
• Haul cycle summary information, including
payload, distance traveled, and travel times
Gather Data In addition to data gathered from external controllers,
the VHMS records information about the vehicle and
The VHMS controller gathers data from three
VHMS usage, including:
sources. Real-time and alarm data from each
controller is gathered continually. In addition, haul • Key ON and engine ON record
cycle summary data from the PLM III is requested by • VHMS configuration changes.
the VHMS controller one time per day.
The system performs three primary functions:
1. Gathers data from on-board sources:
• PLM III controller
• Interface Module (IM)
• Engine controllers
2. Converts data into usable formats and records it
into permanent memory.
3. Communicates data to off-board systems:
• Satellite (OrbComm)
• PC download
NOTE: The electric drive system does provide a
limited number of faults to the interface module.
Refer to VHMS Troubleshooting later in this section
for a complete listing of fault codes that are
generated by the drive system.

FIGURE 11-1. VHMS COMPONENTS


1. Orbcomm Controller 4. Red LED Digits
2. VHMS Controller 5. Green LED Light
3. Interface Module

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-3


FIGURE 11-2. VHMS COMPONENT FLOW CHART

Communicate Data to Off-Board Systems


VHMS has two methods to communicate data to off- In order to collect all the necessary machine data, a
board systems: preventive maintenance (PM) snapshot needs to be
recorded every 500 hours of operation. The snapshot
• Via satellite to the WebCARE database
and other data is then downloaded into a laptop PC.
• Download to a laptop PC running the VHMS This data is to be sent to Komatsu via the FTP
Technical Analysis Toolbox software program which is a part of the VHMS Technical
Communication to the satellite (using OrbComm) Analysis Tool Box program. Refer to the check-out
occurs automatically, but only sends critical data procedure for more detailed information regarding a
items. OrbComm controller (1, Figure 11-1) is located PM snapshot.
inside the auxiliary control cabinet. OrbComm
antenna (1, Figure 11-3) is mounted on the front left
corner of the cab by magnetic mount (2).
Communication to a laptop PC occurs whenever a
user connects a laptop PC to the VHMS controller
and requests a data download. All VHMS data is
available for download to a laptop PC. Once
downloaded to a laptop PC, the information is then
sent to Komatsu via FTP. This data is then compiled
at the Komatsu computer server. Based on this
information, the local Komatsu distributor will suggest
improvements and provide information aimed at
reducing machine repair costs and downtime.

D11-4 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


Turning VHMS ON
The VHMS controller is turned on by the truck key
switch (circuit 712). Immediately after receiving input
from the key switch signal, the VHMS controller
begins its power-up initialization sequence. This
sequence takes about three seconds, during which
time red LED digits (4, Figure 11-1) on the top of the
VHMS controller unit will display a circular sequence
of flashing LED segments. The VHMS controller will
not support a connection from a laptop PC or a
manual snapshot during this initialization time.
The VHMS controller is connected directly to the
battery circuit, which provides a constant 24 volt
signal from the truck batteries. However, the VHMS
controller has the ability to turn itself off and will do so
automatically within three minutes after the key
switch is turned off.

The battery disconnect switch, located at the


truck battery box, will remove 24 volt power from
FIGURE 11-3. ORBCOMM ANTENNA the VHMS controller and cause the VHMS
controller to lose all data gathered since the key
1. Orbcomm Antenna 2. Magnetic Mount switch was last turned on. DO NOT disconnect
the batteries until the VHMS controller has
completed its shutdown operations and has
turned off its LED digits.

USING VHMS
The primary tool for configuring, downloading, and Normal VHMS Operation
viewing VHMS data is the VHMS Technical Analysis The red LED digits on the top of the VHMS controller
Toolbox software. Use of this software requires: indicate the current condition of the system. The
• A laptop PC running Windows 95/98/2000/ME/ possible conditions are shown in Table 1.
XP operating system.
• A serial cable to connect the laptop PC to the Table 1: VHMS Status
VHMS controller.
LED DISPLAY DESCRIPTION
Refer to the VHMS Technical Analysis Tool Box
Flashing LED segments
instruction manual for additional information about Power-on initialization
in circular sequence
using this software.
Numeric display, counting
NOTE: It is recommended that the engine be OFF 00 - 99 at rate of 10 Normal Operation
when downloading or configuring the VHMS numbers per second
controller.
Normal operation, but
Flashing Fault Codes
a fault code is active

NOTE: Only a limited number of fault codes are


displayed on the LED display. Most fault conditions
are recorded internally in the VHMS controller, but
are not indicated on the LED digits.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-5


Turning VHMS OFF Downloading from the VHMS Controller
The VHMS controller is connected directly to the Downloading data requires a laptop PC running
truck batteries, but will remain in normal operation Windows 95/98/2000/ME/XP operating system, the
only if the truck key switch input (circuit 712) is on. VHMS Technical Analysis Toolbox software, and a
When the VHMS controller senses that the truck key serial cable to connect the laptop PC to the VHMS
switch has been turned off, it finishes its internal controller. Refer to the VHMS Technical Analysis Tool
processing and then saves recent data into Box instruction manual for additional information
permanent memory. This process can take up to about using this software.
three minutes.
When a download to a laptop PC is performed,
If 24 volt power is removed from the VHMS controller certain files are generated to store data. A listing of
before it has time to save data to permanent memory, the file types and data is shown in Table 2.
data loss or corruption may occur.
VHMS diagnostic port (2, Figure 11-4), located on the
The VHMS controller will turn off the red LED digits D.I.D. panel at the rear of the operator cab, is used to
when it is off. download from the VHMS controller.

Do not remove 24 volt power from the VHMS


controller unless the red LED digits on the VHMS
controller are off!

FIGURE 11-4. DIAGNOSTIC PORTS


1. IM Diagnostic Port
2. VHMS Diagnostic Port

D11-6 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


Table 2: File Types of Download Data
File Name Data Type Description
cyc_int0 Cycle Interval Changes in engine speed
csvdata_3f.csv Temporary Brake Load Map
Fault0.csv Fault History Records all faults
index00.csv Index Lists all common data files
loadm1.csv Temporary Load Map
mcn_his0.csv Machine History Key On, Key Off
m_area0.csv Running Area Map Records engine operation distribution
m_drct0.csv Running Direction Map Records engine performance movement
snap00.csv Snapshot Records snapshot data over time period
vhmshis0.csv VHMS History Records changes to VHMS
*.k Zipped File Contains all data files

VHMS DATA ITEMS Machine History

Fault Codes The VHMS controller maintains a history of the most


recent 400 Key ON and Engine ON conditions.
The VHMS controller maintains a history of the most
recent 600 fault codes. For each fault code, the
VHMS controller records the following information:
VHMS History
• Fault Code Number
The VHMS controller maintains a history of the most
• SMR (service meter reading) when the fault recent 400 VHMS configuration changes. The VHMS
occurred controller will record a history entry each time one of
• Time/Date when the fault occurred the following configuration changes occurs:
• SMR (service meter reading) when the fault • Changing the date or time of the VHMS
cleared controller
• Time/Date when the fault cleared • Changing the OrbComm satellite settings
• Performing a VHMS memory clear operation
If a fault occurs more than once within 30 minutes,
the VHMS controller will only maintain a single fault
entry, but it will count the number of times the fault
occurred and was cleared. This feature prevents an
intermittent fault that occurs repeatedly from filling up
the fault memory.
Serious fault conditions will be sent to WebCARE via
the OrbComm satellite network as well as being
recorded in permanent memory. Some fault codes
are configured to generate a snapshot when they
occur. Refer to Table 6 for detailed information
showing which fault codes will send data to
WebCARE and which ones trigger a snapshot.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-7


Snapshots Manual Snapshots
A snapshot is a time history of real-time data that is A manual snapshot is taken by pressing the data
recorded before and after the instant that a fault code store button (1, Figure 11-5), located at the rear of
occurs. The VHMS controller is continually recording the center console. When the 7.5 minute snapshot is
real-time data for various engine data items. This being recorded by the VHMS controller, VHMS
allows the VHMS controller to record data for the snapshot in progress light (2) will be illuminated.
time period before and after a fault code occurred. During the first five minutes, the LED will be on
continuously. During the next two minutes, the LED
Only certain fault codes generate snapshots. When a
will flash slowly. During the last 30 seconds, the LED
snapshot enabled fault code occurs, the VHMS
will flash rapidly.
controller will record data for 330 seconds (5.5
minutes) before the fault to 120 seconds (2 minutes) Manual snapshots are used to record current
after the fault. machine data that can then be downloaded and
stored on a laptop PC. These snapshots can be used
In order to conserve storage memory, the VHMS
to observe current conditions on a machine. Over
controller records snapshot data at two different
time, these snapshots can be compared and trends
sample rates. Each data item is recorded at a rate of
can be monitored. During the snapshot recording
one sample every 10 seconds up until 30 seconds
period, the machine should be driven over a variety
prior to the fault occurrence. Each data item is then
of conditions so useful data can be collected.
recorded at a rate of one sample per second from 30
seconds prior to 120 seconds after the fault
occurrence.
If a snapshot enabled fault condition occurs more
than one time, the VHMS controller will record the
snapshot for the first (earliest) fault occurrence. The
only exception is the manual snapshot button, in
which case the VHMS controller will record the latest
(most recent) snapshot.
Refer to Table 3 for all the items that are recorded in
each snapshot.

FIGURE 11-5. REAR OF CENTER CONSOLE


1. Data Store Button
2. VHMS Snapshot In Progress Light

D11-8 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


Table 3: Snapshot Data
Data Item Data Source
Engine Coolant Temperature Cummins QUANTUM Controller

Engine Oil Pressure Cummins QUANTUM Controller

Accelerator Position% Cummins QUANTUM Controller

Engine Speed Cummins QUANTUM Controller

Exhaust Gas Temperature (Left Front) Cummins CENSE Controller

Exhaust Gas Temperature (Left Rear) Cummins CENSE Controller

Exhaust Gas Temperature (Right Front) Cummins CENSE Controller

Exhaust Gas Temperature (Right Rear) Cummins CENSE Controller

Engine Oil Temperature Cummins CENSE Controller

Fuel Rate Cummins QUANTUM Controller

Boost Pressure Cummins QUANTUM Controller

Blow-by Pressure Cummins QUANTUM Controller

Vehicle Speed PLM III

Sprung Weight PLM III

haul cycle State PLM III

Brake Pressure Interface Module

Hoist Pressure 1 Interface Module

Hoist Pressure 2 Interface Module

Steering Pressure Interface Module

Front Left Brake Oil Temperature Interface Module

Front Right Brake Oil Temperature Interface Module

Rear Left Brake Oil Temperature Interface Module

Rear Right Brake Oil Temperature Interface Module

Ambient Temperature Interface Module

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-9


Trends The VHMS controller maintains an engine speed vs.
fuel rate histogram called the Engine Load Map, and
The VHMS controller develops trends by monitoring
a brake pressure vs. speed histogram.
real-time data and reducing the data into 20 hour
statistical values. For each trended data item, the The Engine Load Map histogram shows time-at-level
VHMS controller can determine the maximum value, for specific engine speed and fuel rate combinations.
minimum value, and average value during the
The Brake Pressure vs. Speed histogram shows
preceding 20 hour period. Table 4 shows the type of
time-at-level for specific brake pressure and vehicle
statistical data recorded for each item.
speed combinations.
NOTE: Trend data is only collected when the engine
Two engine load maps are maintained in the VHMS
is running.
controller. The Permanent Load Map contains load
Histogram (Load Map) Data map data for the life of the engine. The Temporary
Load Map contains load map data since the most
The VHMS controller develops histograms by recent memory clear action.
sampling data every 100ms while the engine is
running. The data is presented as a two dimensional Although the engine data is sampled every 100ms
histogram showing time-at-level for various internally, the histograms are only updated every two
combinations of the two input data items. hours.

Table 4: Trend Data


Data Item Data Source MAX AVG MIN
Engine Coolant Temperature QUANTUM Controller X X

Engine Oil Pressure QUANTUM Controller X X

Engine Speed QUANTUM Controller X

Atmospheric Pressure QUANTUM Controller X

Exhaust Gas Temperature CENSE Controller X

Engine Oil Temperature CENSE Controller X

Fuel Rate QUANTUM Controller X

Boost Pressure QUANTUM Controller X

Blow-by Pressure QUANTUM Controller X

Brake Pressure Interface Module X X

Hoist Pressure 1 Interface Module X

Hoist Pressure 2 Interface Module X

Steering Pressure Interface Module X

Front Left Brake Oil Temperature Interface Module X X

Front Right Brake Oil Temperature Interface Module X X

Rear Left Brake Oil Temperature Interface Module X X

Rear Right Brake Oil Temperature Interface Module X X

Ambient Temperature Interface Module X X X

D11-10 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


Haul Cycle Data VHMS controller maintains a record of the payload
summary data from the past 100 daily transmissions
The VHMS controller downloads haul cycle data from
to OrbComm.
Payload Meter III one time every 24 hours, at a time
specified by the VHMS Setting Tool software. The NOTE: The haul cycle summary statistics exclude
data consists of a summary report of all haul cycles haul cycles that the Payload Meter III controller has
completed in the past 24 hours. The summary data marked as 'not trusted'. The total number of haul
items are listed in Table 5. cycles that occurred during the summary period, but
were excluded from the summary, are indicated in
After receiving the haul cycle summary data from
the 'Total Excluded Cycles' field. See the Payload
Payload Meter III, the VHMS controller immediately
Meter III coverage in Section M, Options, for more
attempts to send the data to WebCARE via the
information on excluded cycles.
OrbComm satellite. The haul cycle summary data is
also stored in VHMS controller internal memory. The

Table 5: Haul Cycle Data


Summary Data Item Description
Summary Start Time Start time of first haul cycle in summary
Summary End Time Start time of last haul cycle in summary
Total Cycles Total haul cycles included in this summary
Total Excluded Cycles Total haul cycles occurring during summary period, but excluded from the statistics
Average Carried Load Average Gross Payload
Standard Deviation of Carried Load Standard Deviation of Gross Payload
Number of Loads Over Rated Number of haul cycles with carried load > rated payload for this truck.
Number of Loads Over 110% Number of haul cycles with carried load > 110% of rated payload for this truck.
Number of Loads over 120% Number of haul cycles with carried load > 120% of rated payload for this truck.
Maximum Carried Load Maximum carried load during this summary
Maximum Speed EMPTY Maximum truck speed while truck was empty
Average Speed EMPTY Average truck speed while truck was empty
Maximum Speed LOADED Maximum truck speed while truck was loaded
Average Speed LOADED Average truck speed while truck was loaded
Maximum Sprung Load Maximum instantaneous sprung weight recorded during this summary
Average Maximum Sprung Load Average of all 'Maximum Sprung Load' values recorded in each haul cycle
Maximum Frame Torque Maximum instantaneous frame torque recorded during this summary
Average Maximum Frame Torque Average of all 'Maximum Frame Torque' values recorded in each haul cycle.
Right Front Tire TKPH Total tire ton kilometer per hour recorded for the right front tire.
Left Front Tire TKPH Total tire ton kilometer per hour recorded for the left front tire
Rear Tires TKPH Total tire ton kilometer per hour recorded for the rear tires
Relative Application Severity Total frame damage recorded during this summary
Reserved_1 Future Use
Reserved_2 Future Use
Reserved_3 Future Use

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-11


Alarm and Snapshot Triggers Satellite Features
Serious fault conditions will be sent to WebCARE via The VHMS controller sends data to WebCARE via
the OrbComm satellite network, as well as being the OrbComm satellite network in the following
recorded in permanent memory. Some fault codes conditions:
are configured to generate a snapshot when they • A fault code occurs that has been configured
occur. for transmission via OrbComm.
Table 6 shows which fault codes trigger a snapshot • A periodic event occurs, such as reception of
and which fault codes will be sent to WebCARE via daily PLM III summary data or a 20 hour trend.
satellite. • A remote request for data is received via the
satellite network.

Table 6: Alarm and Snapshot Triggers


VHMS Sent via Snapshot
VHMS Fault Description Source
Fault Code OrbComm Trigger
#A018 RR Flat Cylinder Warning PLM III X
#A019 LR Flat Cylinder Warning PLM III X
#A101 Pump Filter Switches IM X
#A107 Propel System Caution IM X
#A108 Propel System Temp Caution IM X
#A109 Propel System Reduced Level IM X
#A115 Low Steering Precharge IM X
#A124 No Propel / Retard IM X
#A125 No Propel IM X
#A126 Hydraulic Tank Level IM X
#A127 IM Sensor +5V Low IM X
#A128 IM Sensor +5V High IM X
#A190 Auto Lube Switch IM X
#A194 High FL Brake Oil Temp IM X X
#A195 High FR Brake Oil Temp IM X X
#A196 High RL Brake Oil Temp IM X X
#A197 High RR Brake Oil Temp IM X X
MFA0 Manual Trigger Manual X X
C00115 Speed Signal Lost Engine X X
C00135 Oil Pressure Circuit Failed High Engine X X

D11-12 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


Table 6: Alarm and Snapshot Triggers (continued)
VHMS Sent via Snapshot
VHMS Fault Description Source
Fault Code OrbComm Trigger
C00143 Low Oil Pressure Engine X X
C00151 High Coolant Temperature Engine X X
C00155 High IMT LBF Engine X X
C00158 High IMT LBR Engine X X
C00162 High IMT RBF Engine X X
C00165 High IMT RBR Engine X X
C00214 High Oil Temperature Engine X X
C00219 Remote Oil Level Low Engine X X
C00233 Low Coolant Pressure Engine X X
C00234 Engine Overspeed Engine X X
C00235 Low Coolant Level Engine X X
C00261 High Fuel Temperature Engine X X
C00292 OEM Temp out of Range Engine X X
C00293 OEM Temp Failed High Engine X
C00294 OEM Temp Failed Low Engine X
C00296 OEM Pressure Out of Range Engine X X
C00297 OEM Pressure Failed High Engine X
C00298 OEM Pressure Failed Low Engine X
C00473 Remote Oil Level Signal Invalid Engine X X
C00555 High Blow-by Pressure Engine X X
C00639 Intake Air Leak LBR Engine X X
C00641 High Exh Temp #1 LB Engine X
C00642 High Exh Temp #2 LB Engine X
C00643 High Exh Temp #3 LB Engine X
C00644 High Exh Temp #4 LB Engine X
C00645 High Exh Temp #5 LB Engine X
C00646 High Exh Temp #6 LB Engine X
C00647 High Exh Temp #7 LB Engine X
C00648 High Exh Temp #8 LB Engine X
C00651 High Exh Temp #1 RB Engine X
C00652 High Exh Temp #2 RB Engine X
C00653 High Exh Temp #3 RB Engine X
C00654 High Exh Temp #4 RB Engine X
C00655 High Exh Temp #5 RB Engine X
C00656 High Exh Temp #6 RB Engine X
C00657 High Exh Temp #7 RB Engine X
C00658 High Exh Temp #8 RB Engine X

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-13


VHMS DIAGNOSTIC FEATURES VHMS CONTROLLER
VHMS provides several basic data items that are The VHMS controller collects and stores signals from
useful for troubleshooting failures in the VHMS itself. sensors and data from other controllers. It also gives
commands for transmitting the accumulated data
through the communications system. The controller
Fault History operates on 20VDC - 30VDC.

The fault history recorded in the VHMS controller can


help identify failures within the system and in the
communications network to the engine controllers,
interface module, or PLM III. For a complete listing of
all the error codes, refer to the VHMS
Troubleshooting and Checkout Procedures in this
section.

VHMS LED Digits


The VHMS controller indicates some system errors
or communication errors on two red LED digits (2,
Figure 11-6) on the controller. Error codes are
flashed as a two-part sequence. If no errors are
occurring, the VHMS LED's count from 00 - 99
continuously at a rate of 10 numbers per second. For
a complete listing of all the error codes, refer to the
VHMS Troubleshooting and Checkout Procedures in
this section.
The VHMS controller also has two red LED lights (10
and 11, Figure 11-6).
Light (10) PLM III communication
• OFF - no communication with the PLM III
controller
• ON - is communication with the PLM III
controller
FIGURE 11-6. VHMS CONTROLLER
Light (11) OrbComm
• OFF - no communication with OrbComm 1. VHMS Controller 7. Connector CN1
controller 2. LED Digit Display 8. Connector CN2A
• ON - communication with OrbComm controller 3. Connector CN3B 9. Connector CN2B
4. Connector CN3A 10. PLM III Light
• FLASHING - satellite in view 5. Connector CN4B 11. OrbComm Light
6. Connector CN4A

D11-14 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


Removal Installation
If the VHMS controller has to be replaced, the 1. Install the new VHMS controller and connect
following steps must be performed in order to the wiring harnesses to it. Connect the laptop
maintain accurate information after the controller has PC to the VHMS controller with the serial cable.
been replaced. If the new VHMS controller is not set 2. Connect battery power. Turn the key switch ON,
up correctly (like the one being removed), the data in but do not start the engine.
the controller and at WebCARE may not be usable. 3. With the VHMS Setting Tool software, enter the
Some steps will require using a laptop PC and the Service ID and choose the “Save/Load”
VHMS Setting Tool software or the VHMS Technical function.
Analysis Tool Box software. For more detailed 4. From the file menu, select “Load”.
instructions on performing these steps with a laptop 5. Capture a screen shot (“Alt” and “Print Screen”
PC and software, refer to “VHMS Software” later in keys at the same time) of the Save
this section. Confirmation window, paste it into a Microsoft
During the controller replacement process, two data Word document and save it.
downloads will have to be taken (one before, one 6. Click the [OK] button to load the settings.
after) and sent to WebCARE. Also, a VHMS 7. Click the [Apply] button to reset the controller,
Initialization form will have to be filled out and sent to then click the [OK] and [Yes] buttons to confirm.
Komatsu North America as shown on the form. Then select the [Close] button.
8. Fill out a “VHMS Initialization” form and send it
1. With the key switch OFF, connect a laptop PC to Komatsu as instructed on the form.
to the VHMS controller using the serial cable. 9. Exit the VHMS Setting Tool program.
2. Using a laptop PC and the VHMS Technical 10. Turn the key switch OFF and wait three
Analysis Tool Box software, perform a complete minutes.
data download from the VHMS controller. Refer
11. Turn the key switch ON. Wait three minutes and
to “When Replacing a VHMS Controller” later in
watch for any error messages on the VHMS
this section.
controller LED lights that might indicate a
3. Save this data so it can be sent to WebCARE at problem in the system.
a later time when a connection to the internet is
available. 12. If there are no error messages, continue to Step
13. If there are error messages, refer to the
4. Using the VHMS Setting Tool software, enter
VHMS Troubleshooting and Checkout
the Service ID and choose the “Save/Load”
procedures elsewhere in this section.
function.
5. From the File menu, select “Save”. 13. Using a laptop PC and the VHMS Technical
Analysis Tool Box software, perform a complete
6. Capture a screen shot (“Alt” and “Print Screen” data download from the VHMS controller.
keys at the same time) of the Save
Confirmation window, paste it into a Microsoft 14. Confirm the download data is good by using the
Word document and save it. VHMS Technical Analysis Tool Box software.
Make sure the settings are correctly applied by
7. Click the “OK” button to save the settings.
looking at the date, time, SMR, etc.
8. Exit the VHMS Setting Tool program.
15. Turn the key switch OFF. Disconnect the laptop
9. Turn the key switch OFF.
PC from the VHMS controller.
10. Wait three minutes, then disconnect battery
16. Use internet access available to the laptop PC
power.
to send the download data set that was taken
11. After the two LED lights are off, disconnect the before the VHMS controller was removed from
wiring harnesses and remove the VHMS the truck to WebCARE. Use the FTP feature
controller. built into the VHMS Technical Analysis Tool Box
program to send the files.
17. Use the FTP program to send the download
data set that was taken after the new VHMS
controller was installed to WebCARE.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-15


VHMS SOFTWARE The data files, application code and flashburn
software are only required if the interface module is
To work with the Vehicle Health Monitoring System
being replaced. Replacement interface modules from
(VHMS), several special tools and software
Komatsu do not have any software installed in them.
programs are required. Refer to Tables 1 and 2 for
detailed information on VHMS software and tools. NOTE: Be aware that the software and data files are
updated periodically. Check with the local Komatsu
Refer to the following pages for detailed information
distributor for the latest software versions.
on how to perform certain procedures using VHMS
specific software.

Table 7: VHMS Software


Part Number Name Description Source
VHMS Technical
Version 3.04.03.01 To maintain VHMS system Komatsu Distributor
Analysis Tool Box
Version 3.06.00.00 VHMS Setting Tool To initialize VHMS system Komatsu Distributor
1.4.7.39 PDM Payload Meter III Data Manager Komatsu Distributor
EJ0575-5 PLM III PLM III Controller Software to work with VHMS Komatsu Distributor

Table 8: VHMS Tools


Name Description Source
200 MHz or higher
64 MB RAM or more
Serial or USB Port
Laptop PC Purchase Locally
CD/DVD -Rom drive
Floppy Disk Drive
Windows 95/98/2000/ME/XP
Male DB9 connector at one end
Serial cable (RS232 port) Purchase Locally
Female DB9 connector at other end
USB port to RS232 serial port
Adaptor (If the laptop PC does not have an RS232 port, Purchase Locally
this adaptor is required.)

VHMS Tool Box Installation VHMS Setting Tool Installation


1. Insert the CD. The VHMS Technical Analysis 1. Insert the CD. If the VHMS Technical Analysis
Tool Box software will begin installing Tool Box software begins installing
automatically. automatically, select the [Cancel] button to stop
2. Accept the recommended defaults and finish the installation process.
installing VHMS Technical Analysis Tool Box. 2. Open My Computer.
3. Double-click on the new icon on the desktop, 3. Right-click on the CD drive and select Open.
VHMS Technical Analysis Tool Box. 4. Open the Setting Tool folder.
4. Initialize the software by inserting the Set Up 5. Double-click on the Setup.exe file.
Disk.
6. Accept the recommended defaults and finish
5. Enter the User Name. The User Name is user. installing VHMS Setting Tool.
6. Enter the Password. The Password you entered
the first time will be your Password from then
forward, unless you change it.
7. VHMS Technical Analysis Tool Box is installed.

D11-16 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


VHMS INITIALIZATION PROCEDURE VHMS CONTROLLER SETUP PROCEDURE
When a new VHMS-equipped truck is being VHMS Setting Tool software program
assembled, there are several procedures to perform
in order to initialize the system. Following the 1. Start the VHMS Setting Tool software program.
procedures will ensure a smooth initialization There will be three choices to choose from.
process which should not take longer than an hour to • Use the [VHMS Setting] function to initialize a
complete. To ensure the initialization process has truck or change a truck's settings.
been completed properly, check off each item on the
list below as it is done. It is important to complete the • Use the [When VHMS needs to be replaced]
function when replacing a truck's VHMS
entire procedure at one time. Submitting a data
controller.
download with a date and SMR that does not match
the VHMS Initialization form will not allow the system • Use the [Review setting information] function
to be initialized. when only needing to view a truck's settings.

NOTE: The interface module must be fully


operational before initializing the VHMS controller.
The initialization procedure consists of the following:
Select Operation
VHMS Controller Setup Procedure 2. Select VHMS Setting, then click [Next].
VHMS Snapshot Procedure
VHMS Download Procedure
VHMS FTP Upload Procedure
VHMS Initialization Forms

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-17


VHMS Setting Function Machine Information Setting(2)
3. Select Set up & All clear if initializing a truck, 5. Verify that the Machine Information Settings are
then click [Next]. correct. If not, enter the correct settings. Then
click [Next].

Machine Information Setting(1) Date & Time Setting


4. Verify that the Machine Information Settings are 6. Enter the correct Time Zone, Date and Time.
correct. If not, enter the correct settings. Then Check [DST (Summer Time)] if the truck's
click [Next]. location uses Daylight Savings Time. Then click
[Next].

D11-18 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


GCC Setting Setting Summary
7. Choose the correct GCC code. The GCC code 8. Verify that all the setting information is correct
tells trucks that are equipped with Orbcomm and click [Apply].
which satellite ground station to use. Then click
[Next].

9. Click [YES].

10. Click [OK].

11. Click [OK]. The VHMS Setting Tool program will


close.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-19


VHMS SNAPSHOT PROCEDURE 3. While the manual snapshot is being taken,
operate the truck.
A snapshot through VHMS records important data
about different systems on the truck. Take snapshots a. Operate the engine at high and low idle.
on a periodic schedule and store them as part of the b. Raise the dump body to the full dump
truck history. These snapshots can then be position.
compared and trends can be analyzed to predict
future repairs. c. Lower the dump body to the frame, then hold
it in the power down position momentarily.
A single snapshot records truck data for 7.5 minutes.
d. Turn the steering wheel to full left, then full
NOTE: On AC drive trucks, a laptop PC should also right against the stops momentarily.
be connected to the GE drive system to allow for
e. Travel forward to maximum speed and apply
maximum horsepower check of the engine during the
the brakes hard.
snapshot recording process.
f. Travel in reverse.
g. Perform a horsepower check using a laptop
1. Allow the truck to run until it is at normal
PC connected to the GE drive system.
operating temperatures.
4. The white LED will begin flashing slowly after
2. Press and hold the GE data store switch for
five minutes has elapsed, then flash rapidly
three seconds, then release it. The white data
during the last 30 seconds.
store in progress LED should illuminate.
5. Wait until the LED has finished flashing. After
one more minute, turn the key switch OFF to
stop the engine. Verify that the VHMS controller
red LED display is off.
6. Use VHMS Technical Analysis Tool Box
program to download the snapshot data into a
laptop PC. Use the FTP feature to send the
download data to WebCARE.

D11-20 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


VHMS DOWNLOAD PROCEDURE 16. Select the [Machine History] option from the list
on the left side of the screen.
NOTE: Always verify a full download has been taken
before disconnecting the laptop PC from the truck. 17. Verify that the key ON/OFF and engine ON/OFF
records are recorded correctly.
1. Turn the key switch to the OFF position to stop
the engine. 18. Exit any open windows on the laptop PC.
2. Turn the key switch to the ON position, but DO 19. Verify that a full download has been taken.
NOT start the engine. Refer to Location of Downloaded Files on
3. Allow the VHMS controller to start up. This Computer for more detailed instructions.
should take about one minute. Verify the red 20. Disconnect the VHMS cable from the laptop PC
LED display starts counting up. and from the truck.
4. Attach the VHMS serial cable to the truck's
21. Turn the key switch to OFF.
VHMS port and the other end to the laptop PC’s
serial port. Location of Downloaded Files
5. Double-click on the VHMS Technical Analysis
When a download using VHMS Technical Analysis
Tool Box icon on the laptop PC's desktop.
Tool Box is performed, several files are downloaded
6. Enter the appropriate User Name and onto the computer. They are organized in a specific
Password and click the [OK] button. way so that they can be used by VHMS Technical
7. Double-click on the [Download] icon. Analysis Tool Box at a later time. This structure is
8. Select the COM port in the Port No. drop-down created automatically when the computer is used to
box and click the [Connection] button. perform the download from the VHMS controller. The
situation may arise where the files need to be sent to
9. Verify that the date and time is correct for
someone, or someone gives these files to you.
current local date and time. Also verify that the
displayed service meter hours are equal to the 1. Open Windows Explorer by right-clicking on the
value entered previously. Start button and choosing Explore.
10. If this is the first time this laptop PC has been 2. In the left frame, the computer's file structure
connected to the truck, you will need to will be displayed. The right frame will show the
download its definition file by clicking the [OK] details for the folder that is highlighted in the left
button. frame.
3. In the left frame, navigate to the download files.
11. Verify that a manual snapshot (MFAO) has been
recorded. The display should show an item
named “Snapshot” with the code MFAO and
The basic path is as follows:
text “Manual Trigger”.
12. On the Download screen, click the [Select All] - Desktop
button. All items will become checked. - My Computer
- Local Disk (C:)
13. Click the [Download] button. The download may - VHMS_Data
take one to ten minutes. Generally, if there are - Model
several snapshots in the download items, the - Serial Number
download will take longer. - Date
14. Click the [OK] button to complete the download. - Check Number
15. Verify that the “Download Completed” message NOTE: The Date folder is named in the format
is displayed. Click on [Exit]. YYYYMMDD.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-21


VHMS FTP UPLOAD PROCEDURE
After downloading, the VHMS data resides on the
laptop PC that performed the download. At this point,
it can be reviewed and analyzed using VHMS
Technical Analysis Tool Box on this laptop PC only. In
order to make this data available to others, it must be
sent to an online database named WebCARE. Once
the data has been uploaded via FTP to WebCARE, it
is accessible to anyone with an internet connection
and an ID and password.
VHMS Technical Analysis Tool Box is used to
perform the FTP upload. Perform an FTP upload as
soon as the person who performed the download can
obtain an internet connection. All downloads should
be uploaded to WebCARE.

1. Double-click on the VHMS Technical Analysis


Tool Box icon on the laptop PC's desktop.
The screenshot shows the location the VHMS 2. Enter the appropriate user name and password
download files on a computer. The Check Number and click the [OK] button.
folder is named in the format CHK000#. Each time a 3. Double-click the [FTP] icon.
download is taken, it is placed in one of these folders.
The first download will be in the CHK0001 folder. If a
second download is taken on the same day, will be in
the CHK0002 folder, etc.
Once the appropriate folder is selected, the contents
will be shown in the right frame. These files can then
be e-mailed or copied to a disk.
If someone provides VHMS download files through 4. At the FTP Client Login window, enter the FTP
e-mail or on a disk, the same folder organization User ID and Password.
must be created in order to view them in VHMS User ID = komatsu
Technical Analysis Tool Box. Password = vhms

D11-22 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


5. The target directory should be set to the laptop 7. After selecting the correct file to send, click the
PC's hard drive (usually drive C:\). [Send (FTP)] button.
a. Double-click the VHMS_Data folder to drop 8. Click the [Yes] button to verify that you want to
down the model folders. upload the data to WebCARE.
b. Double-click the appropriate model folder to
drop down the serial number folders.
c. Double-click the appropriate serial number
folder to drop down the date folders.
d. Double-click the appropriate date folder to
drop down the check number folders.
e. Double-click the appropriate check number
folder to display its contents in the files
window. 9. If the sending file was uploaded successfully,
the file will appear in the OK window. If the
sending file was not uploaded successfully, the
file will appear in the NG (No Good) window.
Make sure that the laptop PC has an internet
connection.

6. Some models will automatically create a


sending file during the download process.
Others need to have the sending file created at
this time. A sending file is just a compressed
version of all the other downloaded files. If there
is already a sending file in the Send File
window, you do not need to perform this step. If 10. Click the [OK] button, then the [Exit] button.
there is not a sending file in the Send File Close all other open windows.
window, click the [Make Sending File] button.

NOTE: The compressed sending file will look similar


VHMS INITIALIZATION FORMS
to this file name, and will always end with a “.K”.
P_930E_-_A30462_1105208857.K Complete the initialization check list and initialization
forms found later in this section. Send the
initialization form to Komatsu.

Initialization is now complete.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-23


WHEN REPLACING A VHMS 3. Click the [Save] button.
CONTROLLER
Refer to the VHMS controller removal and installation
instructions earlier in this section to replace a VHMS
controller. Follow the steps below when using the
VHMS Setting Tool software to save the data and
settings so they can be transferred from the old
controller to the new controller.

1. Select the [When VHMS Needs To Be


Replaced] function.

4. Click the [OK] button.

5. Replace the VHMS controller.


2. Select the [Save current setting before
replacement of VHMS controller] function.

D11-24 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


6. Select the [Use previous setting after 8. If the correct data is not showing, click the
replacement of VHMS controller] function. [Select File] button and choose the correct data.
Then click the [Next] button.

7. Verify that the data showing is the data to be 9. Enter the correct Time Zone, Date and Time
loaded and then click the [Next] button. information. Check [DST (Summer Time)] if the
truck's location uses Daylight Savings Time.
Click the [Apply] button.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-25


10. Click the [OK] button. Setting Date & Time, Satellite & Payload Meter
1. Select the [VHMS Setting] function, then click
the [Next] button.

11. Click the [OK] button. The Setting Tool Program


will close.

2. Select the [Set up only] function, then click the


[Next] button.

D11-26 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


3. After selecting one of the following choices, b. Satellite: Select the correct country location
click the [Next] button. from the drop-down menu, then click the
[Apply] button to change the setting.
• Date & Time
• Satellite
• Payload Meter

c. Payload Meter: Set Start Time to “0”, and


Interval to 1. Then click the [Apply] button to
a. Date & Time: Should be set to current date save the setting.
and time. If not correct, set the correct Time
Zone, Date and Time to current time zone,
date and time. Select [DST Summer Time)] if
it applies. Click the [Apply] button.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-27


Review Setting Information 2. Review the settings for accuracy. If something
1. Select the [Review setting information] function is not correct, click the [Back] button, select the
and then click the [Next] button. appropriate category and reset the information
to the correct settings. If everything is correct,
click the [Exit] button.

3. Click the [Yes] button to close the Setting Tool


Program.

D11-28 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


VHMS CONTROLLER CHECKOUT
Necessary Equipment
• Checkout procedure
• System schematic
• Laptop personal computer (PC)
• VHMS Technical Analysis Toolbox software
• VHMS Setting Tool software
• Tera Term Pro software
• Serial cable (RS232)
(male DB9 connector on one end, female
connector on the other end)

NOTE: Before performing this procedure, the


interface module must be fully functional and the
VHMS controller must be initialized and fully
functional.

Preliminary
1. Turn the key switch to the OFF position to stop
the engine. Verify that the seven segment LED
display on the VHMS controller is off.
2. Turn the key switch to the ON position, but DO
NOT start the engine. FIGURE 13-7. VHMS CONTROLLER
3. Allow the VHMS controller to boot up. Watch
1. VHMS Controller 7. Connector CN1
the red, two digit LED display on the VHMS
2. LED Display 8. Connector CN2A
controller to show a circular sequence of seven
3. Connector CN3B 9. Connector CN2B
flashing segments on each digit. After a short
4. Connector CN3A 10. PLM III Light
time the two digit display should start counting
5. Connector CN4B 11. OrbComm Light
up from 00 - 99 at a rate of ten numbers per
6. Connector CN4A
second.
4. Attach the VHMS serial cable to the truck's
VHMS diagnostic port (2, Figure 13-3) and the
other end to the laptop PC’s serial port.
5. Double-click on the VHMS Technical Analysis
Tool Box icon on the laptop PC's desktop.
6. Enter the appropriate User Name and
Password and click the [OK] button.
7. Check for any active fault codes. If any are
found, these circuits should be analyzed to
determine the cause of the fault and they must
be repaired before continuing.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-29


8. Start the VHMS Setting Tool program by 11. If any one of the following settings was
clicking on the icon on the laptop PC screen. changed, a new VHMS Initialization Form must
9. Select the [Review setting information] function be filled out and submitted to Komatsu America
and then click the [Next] button. Service Systems Support Team.
•VHMS controller replaced
•Engine or alternator replaced
•Adjusted time or time zone
12. Select [Apply] and exit the VHMS Setting Tool
program. Click [YES] when prompted to reset
the controller.
13. E-mail or fax the completed VHMS Initialization
form to Komatsu America Service Systems
Support Team.

VHMS Controller Checkout Procedure


1. Connect the serial cable from the PC to the
10. Review the settings for accuracy.
serial port of the VHMS controller.
• If everything is correct, click the [Exit] button. The 2. Start the serial communications software (Tera
checkout procedure is complete. Term).
• If a setting is not correct, click the [Back] button, 3. Setup the serial communications software by
select the appropriate category and reset the selecting the appropriate serial COM port, and
information to the correct settings. Then proceed baud rate equal to 19200.
to the next step.
4. After completing the setup, wait for 5 seconds
then while holding the CTRL key, type VHMS
(Notice that nothing will display on the screen
while typing).
5. After VHMS has been typed, some text followed
by a prompt, >, will be displayed. This confirms
that proper communication between the pc and
VHMS has been established.
6. At the prompt, >, type "ver". Something similar
to the following will be displayed:
>ver
VHMS OS Ver 1.6.5.1 Mar 01 2004 16:37:25
>

D11-30 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


7. At the prompt type "dispvhmsinf". Information 8. The VHMS controller also has two red LED
similar to the following will be displayed: lights (10 and 11, Figure 13-6). Verify the
connection status and repair any problems.
Light (10) PLM III communication
>dispvhmsinf
• OFF - No communication with the PLM III
controller. Troubleshoot and repair the
---- MACHINE INFORMATION -------- connection.
• ON - Communication with the PLM III controller
PRODUCT GROUP: Dumptruck
is good.
MACHINE_MODEL: 930E- Light (11) OrbComm
MACHINE_SERIAL: • OFF - No communication with OrbComm
ENG_MODEL: QSK60 controller. Troubleshoot and repair the
connection.
ENG_SERIAL_NO1:
• ON - Communication with OrbComm controller
ENG_SERIAL_NO2: is good.
PRG_NO1: 12000100100 • FLASHING - Satellite signal is established.
This may take as long as 15 minutes to occur.
PRG_NO2: 782613R290
---- DEVICES ------------------------
PLC NO CONNECTION
PLM23 Disabled
PLM3 CONNECTED
---- Condition --------------------
SMR: 90.0 H
DATE 04-10-25 TIME14:44:24
TIMEZONE: 0.0 H SUMMERTIME 0
----Controller Info -------------------
PartNumber: 0000000000
Serial No.: 000000
Compo Name: KDE1010
SilkyID: VA011740744
>
NOTE: Use the results of step 6 and 7 to confirm that
the correct software is installed in the VHMS
controller.

D11010 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11-31


ORBCOMM CONTROLLER Installation
The OrbComm controller receives data from the 1. Install the OrbComm controller. Connect the
VHMS controller and sends this data through the wire harnesses to the controller.
antenna to the Komatsu computer center. 2. Turn the key switch ON, but do not start engine.
Wait three minutes and watch for any error
messages on the VHMS controller LED lights
Removal that might indicate a problem with the
OrbComm controller or communications to the
1. Turn the key switch OFF. Disconnect battery
controller.
power by using the battery disconnect switches.
3. If there are no error messages, turn the key
2. Disconnect the wire harnesses from the
switch OFF. If there are error messages, refer to
OrbComm controller.
the VHMS Troubleshooting and Checkout
3. Remove the OrbComm controller. Procedures elsewhere in this section.
4. Fill out the “VHMS Initialization” form and send
it to Komatsu as instructed on the form. Failure
to submit the form to Komatsu will prevent
machine data from being sent to the Komatsu
computer center.
NOTE: The new controller should come with a
special Orbcomm Terminal Activation form that
includes space to list the failed controller serial
number and new controller serial number. Komatsu
must have this information to maintain accurate data.
5. It may take up to two weeks for Komatsu to
activate the new OrbComm controller. During
this time, a manual download of data must be
taken one time each week using a laptop PC.
This data must then be sent to WebCARE using
the FTP feature in VHMS Technical Analysis
Tool Box program. Keep downloading data and
sending it to WebCARE one time each week
until the new OrbComm controller has been
activated.

FIGURE 11-8. ORBCOMM CONTROLLER Komatsu will notify the person who performed
the controller replacement by e-mail when the
1. OrbComm Controller 3. Connector CN1B new controller has been activated and no more
2. Connector CN1A 4. Antenna Connector manual downloads will have to be performed.

D11-32 VEHICLE HEALTH MONITORING SYSTEM (VHMS) D11010


SECTION D12
INTERFACE MODULE
INDEX

INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-3

SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4

Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4

Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4

INTERFACE MODULE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5

Flashburn Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5

Interface Module Application Code Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6

Interface Module Realtime Data Monitor Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6

INTERFACE MODULE CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-7

Necessary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-7

Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-8

Check Digital Inputs To The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-9

Check Analog Inputs To The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-11

Check Serial Interfaces To The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-11

Check Outputs From The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-12

D12007 INTERFACE MODULE D12-1


NOTES

D12-2 INTERFACE MODULE D12007


INTERFACE MODULE
6. Turn the key switch OFF and wait one minute.
The interface module (IM) (1, Figure 12-1) collects
data from various sensors and sends this information 7. Turn the key switch ON, but do not start the
to the VHMS controller through the main wiring engine. Wait three minutes and watch for any
harness. error messages on the VHMS controller LED
lights that might indicate a problem in the
If a new interface module is purchased, the operating system.
system (software) has to be installed into the new
8. If there are no error messages, turn the key
interface module. To install the operating system, a
switch OFF. If there are error messages, refer to
laptop PC must be connected to the IM diagnostic
the VHMS & Interface Module Troubleshooting
port (1, Figure 12-5). Two software programs are
and Error Codes elsewhere in this section.
required to install the software: the operating system
and the program to perform the installation of the
software (flashburn).

Removal
1. Turn the key switch OFF. Wait three minutes to
allow the VHMS controller to process and store
data.
2. Disconnect the battery using the battery
disconnect switch.
3. Disconnect the wiring harnesses from the
interface module.
4. Remove the mounting hardware and remove
the interface module.

Installation
1. Install the interface module. Attach all wire har-
nesses to the interface module.
2. Refer to the VHMS Software instructions to
install the flashburn program on a laptop PC.
3. Connect the laptop PC to IM diagnostic port (1,
Figure 12-5).
4. Turn the key switch ON, but do not start the FIGURE 12-1. INTERFACE MODULE
engine. 1. Interface Module 3. Connector IM2
5. Run the flashburn program to install the 2. Connector IM1 4. Connector IM3
application code into the interface module.
Make sure the correct application code is
installed for the model and serial number range
(if any) of truck that is being serviced. After the
application code has been installed, proceed
with to Step 6.

D12007 INTERFACE MODULE D12-3


SENSORS Pressure Sensors

Temperature Sensors Four pressure sensors (Figure 12-3) have been


added to the truck to monitor various hydraulic
Temperature sensors (Figure 12-2) monitor the circuits. The four circuits are:
ambient air temperature and the hydraulic oil
temperature. An ambient air temperature sensor is • both inlets to the hoist valve
located on the left side of the air blower inlet duct for • steering supply circuit
the traction alternator. The hydraulic oil temperature
• front brake apply circuit
sensors are located at each wheel to measure the oil
temperature as it leaves each brake assembly.
The hoist pressure sensors are both located right at
the inlet of the hoist valve. The front brake apply
pressure sensor is located in the brake circuit
junction block in the hydraulic cabinet behind the
cab. The steering pressure sensor is located on the
bleeddown manifold in the port labeled “TP2”.

FIGURE 12-2. TEMPERATURE SENSOR

FIGURE 12-3. PRESSURE SENSOR

1. Pin 1, Input (Brown) 3. Sensor


2. Pin 2, Signal (Red)

D12-4 INTERFACE MODULE D12007


INTERFACE MODULE SOFTWARE The data files, application code and flashburn
software are only required if the interface module is
To work with the interface module, several special
being replaced. Replacement interface modules from
tools and software programs are required. Refer to
Komatsu do not have any software installed in them.
Tables 1 and 2 for detailed information on software
and tools. NOTE: NOTE: Be aware that the software and data
files are updated periodically. Check with the local
Refer to the following pages for detailed information
Komatsu distributor for the latest software versions.
on how to perform certain procedures using specific
software.

Table 1: Interface Module Software


Part Number Name Description Source
Interface Module
1.1.0.0 Install.exe Realtime Data Monitor Use to watch inputs and outputs in the
Komatsu Distributor
(or higher) Software Version interface module
1.1.0.0 Install.exe
To install application code in interface
EJ3055-2.exe Flashburn Program Komatsu Distributor
module
930E-4
EJ9098-2.exe Application code for interface module Komatsu Distributor
Application Code

Table 2: Interface Module Tools


Name Description Source
200 MHz or higher
64 MB RAM or more
Serial or USB Port
Laptop PC Purchase Locally
CD/DVD -Rom drive
Floppy Disk Drive
Windows 95/98/2000/ME/XP
Male DB9 connector at one end
Serial cable (RS232 port) Purchase Locally
Female DB9 connector at other end
USB port to RS232 serial port
Adaptor (If the laptop PC does not have an RS232 port, Purchase Locally
this adaptor is required.)

Flashburn Program Installation


The Flashburn program is used to install the
application code into the interface module controller.
1. Save the file EJ3055-2.exe to local drive on a
laptop PC.
2. Double click on the “EJ3055-2.exe” file to
extract the files to a directory (such as C:\temp).
3. Inside that directory, double click on
“Setup.exe” to install the Flashburn program.
4. Follow the on screen prompts to install the
program.

D12007 INTERFACE MODULE D12-5


Interface Module Application Code Installation Interface Module Realtime Data Monitor Software
The application code is truck specific software that is The Interface Module Realtime Data Monitor
installed into the interface module. Application code Software is used to display the data going into and
is installed using the Flashburn program. out of the interface module.
1. Using a laptop PC, save the application code
To install:
files to a folder on a local hard drive (such as
C:\temp). 1. Copy the file onto the laptop PC hard drive.
2. Double-click on the correct application code file 2. Double-click on the file and follow the screen
so it will extract the file. Chose a folder on a prompts to install the software.
local hard drive to save the file into (such as
C:\temp). To use:
3. Using a serial cable, connect the laptop PC to 1. Start the Interface Module Realtime Monitor
the IM-Diag connector located near the program.
interface module. 2. Click on the [Select Serial Port] menu item.
4. Start the Flashburn program. Select the correct communication port. It will
usually be Com1.
5. Select [Download Application to Product].
3. Click on the [Start/Stop] menu item and choose
[Start].
4. Click on the [Units] menu to select the desired
units to display the information.

6. Make sure that the power to the interface


module is off. Then click [Next].
7. Select the correct COM port. Then click [Next].
8. Select the correct “.KMS” file. Then click [Next].
Flashburn will now install the application code into
the interface module.

D12-6 INTERFACE MODULE D12007


INTERFACE MODULE CHECKOUT

If a new truck with VHMS is being assembled, or


a new VHMS system has just been installed, refer
to the VHMS System for instructions regarding
the VHMS Initialization Procedure. The initializa-
tion procedure and form must be completed
before the truck can be put into service.

Necessary Equipment
• System schematic
• Laptop PC
• Interface Module Real Time Data Monitor
software
• Serial cable (RS232)
• Jumper wire 77 mm (3 in.) or longer
• Volt Meter
• 300 to 332 ohm resistor
• 3/8 in. nut driver FIGURE 12-4. INTERFACE MODULE

1. Interface Module 3. Connector IM2


NOTE: The interface module must already have the 2. Connector IM1 4. Connector IM3
application code installed.

D12007 INTERFACE MODULE D12-7


Preliminary 7. Check for fault codes associated with the
interface module.
1. Turn the key switch to the OFF position to stop
the engine. a. Perform a VHMS download with the VHMS
2. Turn the key switch to the ON position, but DO Technical Analysis Toolbox program. Refer
NOT start the engine. to VHMS Download for detailed instructions
on performing a download.
3. Allow the VHMS controller to start up. This
should take about one minute. Verify the red b. In the download data, view the fault history
LED display starts counting up. and confirm that there are no fault codes
4. Attach the VHMS serial cable to the machine's associated with the interface module. If any
VHMS diagnostic port (2, Figure 12-5), and the are found, these circuits should be analyzed
other end to the laptop PC’s serial port. to determine the cause of the fault and
repaired.
c. Confirm that there are no fault codes associ-
ated with the communications between PLM
III, engine controller, interface module, drive
system controller or the Orbcomm controller.
If any are found, these circuits should be
analyzed to determine the cause of the fault
and repaired.
8. Attach the VHMS serial cable to the machine's
IM diagnostic port (1, Figure 12-5), and the
other end to the laptop PC’s serial port.
9. Start the Interface Module Real Time Data
Monitor program by double-clicking on the
shortcut. The program begins with a blank
window. On the menu bar, there are five items:
Select Serial Port, Start/Stop, Logging,
FIGURE 12-5. DIAGNOSTIC PORTS Screenshot, and Units.
10. Click on [Select Serial Port] in the menu bar.
1. IM Diagnostic Port 2. VHMS Diagnostic Port
Select the correct communication port. It will
usually be Com1.
11. Click on [Start/Stop] in the menu bar and select
5. Double-click on the VHMS Technical Analysis Start.
Tool Box icon on the computer's desktop.
12. The program should display data as shown in
6. Enter the appropriate User Name and
Figures 12-6 and 12-7.
Password and click the [OK] button.
NOTE: If any fault codes associated with the
interface module are found, these circuits should be
analyzed to determine the cause of the fault, and
they should be repaired.

D12-8 INTERFACE MODULE D12007


Check Digital Inputs To The Interface Module 6. Low Steering Precharge (IM2-W) - short wire
33KL to ground at TB44-P momentarily and
1. Hydraulic Tank Level (IM2-K) - short wire 34LL
confirm state change (one to zero).
to ground at TB35-N momentarily and confirm
state change (one to zero). 7. Pump Filter Switches (IM2-Y) - short wire 39L to
ground at TB44-N momentarily and confirm
2. No Propel / Retard - (IM2-N) short wire 75-6P to
state change (one to zero).
ground at TB26-C momentarily and confirm
state change (one to zero). 8. No Propel (IM2-p) - short wire 75NP to ground
at TB25-P momentarily and confirm state
3. Reduced Retard - (IM2-R) short wire 76LR to
change (one to zero).
ground at TB28-D momentarily and confirm
state change (one to zero). 9. Propel System Caution (IM2-t) - short wire 79W
to ground at TB26-D momentarily and confirm
4. Propel System Temp Caution - (IM3-A) short
state change (one to zero).
wire 34TW to ground at TB26-B momentarily
and confirm state change (one to zero). 10. Reduced Propel System (IM3-B) - short wire
5. Lamp Test (IM2-R) - actuate lamp test switch 72LP to ground at TB25-W momentarily and
and confirm state change (zero to one). confirm state change (one to zero).

FIGURE 12-6. INTERFACE MODULE REAL TIME DATA MONITOR

D12007 INTERFACE MODULE D12-9


11. Park Brake Set (IM2-M) - disconnect park brake 15. Starter Motor 1 Energized (IM3-R) - Disconnect
pressure switch in brake cabinet at CN240 wire 11SM1 from cranking motor to TB29-K at
momentarily and confirm state change toggles TB29-K. Momentarily short TB29-K to 24V and
continually (zero to one). confirm state change (zero to one). Reconnect
disconnected wire.
12. Park Brake Request (IM3-V) - Short the engine
oil pressure switch wire circuit 36 on TB26-L to 16. Starter Motor 2 Energized (IM3-S) - Disconnect
ground. Move shift lever from neutral to park wire 11SM2 from cranking motor to TB29-G at
position and confirm state change (one to zero). TB29-G. Momentarily short TB29-G to 24V and
Remove the ground from TB26-L. confirm state change (zero to one). Reconnect
disconnected wire.
13. Auto Lube Switch (IM3-Y) - short wire 68LLP1
to ground at TB24-T momentarily and confirm 17. Crank Sense (IM3-U) -Open the start battery
state change (one to zero). disconnect switch so that there is no battery
voltage to the starters. Momentarily short TB32-
14. GE Batt + (IM3-M) -- confirm this is a one.
M to 24V and confirm state change (zero to
one). After removing 24V short from TB32-M,
close the start battery disconnect switch.

FIGURE 12-7. INTERFACE MODULE REAL TIME DATA MONITOR

D12-10 INTERFACE MODULE D12007


Check Analog Inputs To The Interface Module 9. Right Front Brake Oil Temp [C] (IM3-R):
Disconnect right front brake oil temp sensor and
NOTE: Instead of using a resister in place of a
confirm fault A169, Hydraulic Oil Temp - Right
sensor for verifying pressure readings, a calibrated
Front Sensor Low, is active. Reconnect sensor.
pressure gauge can be installed in the hydraulic
circuit to compare system pressures with the 10. Left Front Brake Oil Temp [C] (IM3-T): Discon-
pressures displayed in the Interface Module Real nect left front brake oil temp sensor and confirm
Time Data Monitor program. fault A168, Hydraulic Oil Temp - Left Front Sen-
sor Low, is active. Reconnect sensor.
Verify that the used analog inputs are in the range of
the values listed below. 11. Hoist Pressure 2 [kPa] (IM3-Q): Short wire
33HP2 to ground at TB41-J momentarily and
1. Truck Speed [kph] (IM1-G, H): Use GE DID to
confirm fault A203, Hoist Pressure 2 Sensor
simulate vehicle speed and confirm reported
Low, is active.
speed matches vehicle speed set using GE DID
+/- 2 kph. 12. Hoist Pressure 1 [kPa] (IM3-S): Short wire
33HP1 to ground at TB41-A momentarily and
2. Steering Pressure [kPa] (IM3-D): Disconnect
confirm fault A202, Hoist Pressure 1 Sensor
steering pressure sensor and confirm fault
Low, is active.
A204, Steering Pressure Sensor Low, is active.
Reconnect sensor. 13. Battery Voltage 24V [V] (IMint): confirm reported
3. Ambient Air Temp [C] (IM3-E): confirm reported voltage is +/- 1 volt of actual measured battery
temperature matches ambient temperature voltage.
within 3 C.
4. Fuel Level [%] (IM3-G): confirm reported %
level matches actual fuel level in tank +/- 5%. Check Serial Interfaces To The Interface Module
5. Battery Voltage A [V] (IM3-H): confirm reported 1. Confirm fault A184, J1939 Not Connected, is
voltage is +/- 1 volt of actual measured 12 volt not active.
battery voltage. 2. Confirm fault A257, Payload CAN/RPC Not
6. Brake Pressure [kPa] (IM3-p): Disconnect Connected, is not active.
service brake pressure sensor located in brake 3. Confirm fault A275, GE RS232 Not Connected,
cabinet (reference circuit 33SP) and confirm is not active.
fault A205, Brake Pressure Sensor Low, is
active. Reconnect sensor.
7. Right Rear Brake Oil Temp [C] (IM3-M):
Disconnect right rear brake oil temp sensor and
confirm fault A167, Hydraulic Oil Temp - Right
Rear Sensor Low, is active. Reconnect sensor.
8. Left Rear Brake Oil Temp [C] (IM3-I):
Disconnect left rear brake oil temp sensor and
confirm fault A166, Hydraulic Oil Temp - Left
Rear Sensor Low, is active. Reconnect sensor.

D12007 INTERFACE MODULE D12-11


Check Outputs From The Interface Module 4. With circuit 528 at TB35-L still shorted to 24
volts, confirm that the Engine Start Fail lamp
NOTE: Note: Before performing these next steps, the
energizes.
key switch must be turned off for at least 7 minutes to
allow the IM to completely shutdown. Confirm that 5. With circuit 528 at TB35-L still shorted to 24
the IM has shutdown by verifying that the green LED volts, confirm that the Low Fuel lamp energizes.
on the IM controller has stopped flashing. While 6. Disconnect park brake pressure switch. With
performing the following IM output checks, ensure circuit 528 at TB35-L still shorted to 24 volts,
that no output short circuit fault codes are reported confirm that the Park Brake lamp energizes.
by the IM Realtime Data Monitor software. Reconnect pressure switch.
1. Turn the key switch ON and and place the 7. With circuit 528 at TB35-L still shorted to 24
directional control lever into NEUTRAL. volts, confirm that the Brake Oil Temp lamp
energizes. Remove 24 volts from TB35-L.
a. Confirm that park brake solenoid is ener-
gized by verifying that coil is magnetized. 8. Confirm that the voltage on circuit 33ES1 at
TB35-B is approximately 0 volts.
b. Use the GE DID panel to set the truck speed
9. Confirm that the voltage on circuit 33ES2 at
to a speed above 1 kph.
TB35-C is approximately 0 volts.
c. Shift into park. Confirm that the park brake
10. Check the Brake Oil Temperature gauge by
solenoid remains energized.
placing a 316 ohm resistor with a range of 300
d. Reduce the truck speed to 0 kph. Confirm to 332 ohms between circuit 5VIM on TB42-L
that the auto apply solenoid energizes. and 34BT3 on TB24-G. Verify that the gauge
Then, after 0.5 second, confirm that park needle moves clockwise. Do not remove the
brake solenoid de-energizes and, after resistor yet.
another 0.5 second, confirm that the auto
11. Confirm that the voltage on circuit 33ES1 at
apply solenoid de-energizes.
TB35-B is approximately battery volts.
2. Connect circuit 528 at TB35-L to 24 volts and
confirm that the Battery Charger Failure lamp 12. Confirm that the voltage on circuit 33ES2 at
energizes. TB35-C is approximately battery volts. Remove
the resistor between circuits 5VIM and 34BT3.
3. With circuit 528 at TB35-L still shorted to 24
volts, confirm that the IM Warning lamp
energizes.

D12-12 INTERFACE MODULE D12007


SECTION D13
INTERFACE MODULE AND VHMS TROUBLESHOOTING
INDEX

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-3

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4
Communications Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4
Coaxial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4


Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4
VHMS LED Display Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-5
Chassis Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-6
Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-9

FAULT TREE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-15


Unable to connect to VHMS from laptop PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-15
Flashing Error Code N4-23 (PLM III Communications Fault) . . . . . . . . . . . . . . . . . . . . . . . D13-16
Flashing Error Code N4-22 (Engine Communications Fault) . . . . . . . . . . . . . . . . . . . . . . . D13-17
No Data Received By WebCARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-18
Coaxial Cable Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-19

D13008 5/08 INTERFACE MODULE AND VHMS TROUBLESHOOTING D13-1


NOTES

D13-2 INTERFACE MODULE AND VHMS TROUBLESHOOTING 5/08 D13008


INTERFACE MODULE AND VHMS TROUBLESHOOTING
GENERAL For instructions on how to use VHMS software
programs, refer to VHMS Software elsewhere in this
The center of the Vehicle Health Monitoring System
section.
(VHMS) is the VHMS controller, which gathers data
about the operation of the truck from sensors and
other controllers installed on the truck. Refer to
Figure 13-1 for an overview of the VHMS system
components.

FIGURE 13-1. VHMS SYSTEM

D13008 5/08 INTERFACE MODULE AND VHMS TROUBLESHOOTING D13-3


TROUBLESHOOTING Effective troubleshooting of RF communications
systems can be complex and cannot always be
VHMS basically consists of five communications
reduced to a simple check of electrical resistance.
networks connected to the VHMS and OrbComm
However, a few basic troubleshooting procedures
modem controllers. Figure 13-1 shows the VHMS
may be helpful in identifying common problems. The
block diagram.
following steps can help identify a failed coaxial
cable. Repair or replace the cable if any of the
following is true:
Communications Networks
1. The center conductor is broken. There are more
Each RS232 network uses three wires: transmit, than two ohms of resistance when measuring
receive, and ground. Both transmit and receive are from one end of the coaxial cable to the other.
voltage signals, referenced individually to the ground 2. The outer shield is broken.
wire. The shield for the cable is grounded at one end
only. 3. There is an electrical connection between the
center conductor and the outer shield. There
Each CAN network uses two wires: CAN_High & are less than two megohms of resistance when
CAN_Low. The communications signal is a voltage measuring from the center conductor to the
differential measured between CAN_High and outer shield.
CAN_Low. The cable shields are connected at each
module through a high pass filter and grounded at
one point only on the truck. Both ends of each
network have termination resistors. FAULT CODES
Fault History
The fault history recorded in the VHMS controller can
Coaxial Cable
help identify a failure within VHMS and in the
The coaxial cable carries the Radio Frequency (RF) communications network to the engine, interface
communications signal between the OrbComm module and PLMIII. VHMS provides the following
modem and the antenna. The coaxial cable consists fault codes.
of an inner conductor and an outer shield (connected
to the connector shell) that are separated by a non-
conductive dielectric material. Table 1: Fault History
In an RF application such as VHMS, the Fault
Description
communications signal sent over coaxial cable is Code
very susceptible to changes in the cable. Physical DBB0KK Source Voltage Error
damage, as well as contaminants such as water, may
affect the ability of the cable to properly transmit the Abnormality in VBAT Voltage
DBB3KK
RF signal. Bending the coaxial cable into a small (VHMS VBAT <10V)
loop may also damage the inner conductor. DBBRKR Can-net System (J1939)
DBB0KQ VHMS Connector Mismatch
DAW0KR IM Stopped Real Time Data
Too Much Payload Data For Requested
7P70Kr
Period
7P70KR PLMIII Stopped Real Time Data
9843KM Truck Frame Number Changed
MFA0 Manual Trigger

D13-4 INTERFACE MODULE AND VHMS TROUBLESHOOTING 5/08 D13008


VHMS LED Display Fault Codes
The VHMS controller also indicates some faults on the two red LED digits on the top of the controller. Fault codes
are flashed as a two part sequence, as shown in the table below.

When no communication errors are occurring, the VHMS LED digits count from 00 - 99 continuously at a rate of ten
numbers per second.

Table 2: VHMS LED Display Error Codes


Fault Code Fault Condition VHMS LED Display
M101 Truck Frame Number Changed Alternates ‘n1’ and ‘01’
M801 Can-net System (J1939) Alternates ‘n8’ and ‘01’
M804 Can-net System (RPC) Alternates ‘n8’ and ‘04’
M806 IM Stopped Real Time Data Alternates ‘n8’ and ‘06’
M807 Too Much Payload Data For Requested Alternates ‘n8’ and ‘07’
Period
M808 PLMIII Stopped Real Time Data Alternates ‘n8’ and ‘08’
M809 Can-net System (QUANTUM) Alternates ‘n8’ and ‘09’
M80A Can-net System (CENSE) Alternates ‘n8’ and ‘0A’
M901 Source Voltage Error Alternates ‘n9’ and ‘01’
M902 VHMS 24V Source System Error Alternates ‘n9’ and ‘02’
M903 VHMS 12V Source System Error Alternates ‘n9’ and ‘03’
M904 VHMS 5V Source System Error Alternates ‘n9’ and ‘04’
M905 Abnormality in VBAT Voltage (VHMS Alternates ‘n9’ and ‘05’
VBAT <10V)
M990 Ethernet Power Short Alternates ‘n9’ and ‘90’
MC10 MEMORY CLEAR: Failure History Alternates ‘nc’ and ‘10’
MC31 MEMORY CLEAR: (Load Map) Alternates ‘nc’ and ‘31’
MC40 MEMORY CLEAR: (Trend Analysis) Alternates ‘nc’ and ‘40’
MC60 MEMORY CLEAR: (Snap Shot) Alternates ‘nc’ and ‘60’
MC91 MEMORY CLEAR: (Maintenance History) Alternates ‘nc’ and ‘90’
ME01 Change Service Meter Alternates ‘ne’ and ‘01’
ME02 Change Calendar Alternates ‘ne’ and ‘02’
ME03 Orbcomm Settings Alternates ‘ne’ and ‘03’
ME04 Other Settings Alternates ‘ne’ and ‘04’
ME05 MEMORY CLEAR: All Alternates ‘ne’ and ‘05’
ME06 Initialized Alternates ‘ne’ and ‘06’
MF11 VHMS Connector Mismatch Alternates ‘nf’ and ‘11’
MFA0 Manual Trigger Alternates ‘nf’ and ‘A0’

D13008 5/08 INTERFACE MODULE AND VHMS TROUBLESHOOTING D13-5


Chassis Fault Codes
Fault codes generated from the truck chassis, PLM III or GE are shown in Table 3.
NOTE: Not of the fault codes that are listed may be used for this truck.

Table 3: Chassis Fault Codes


VHMS Sent via Snapshot
VHMS Fault Description Source
Fault Code OrbComm Trigger
#A1 LF Pressure Sensor Signal High PLMIII
#A2 LF Pressure Sensor Signal Low PLMIII
#A3 RF Pressure Sensor Signal High PLMIII
#A4 RF Pressure Sensor Signal Low PLMIII
#A5 LR Pressure Sensor Signal High PLMIII
#A6 LR Pressure Sensor Signal Low PLMIII
#A7 RR Pressure Sensor Signal High PLMIII
#A8 RR Pressure Sensor Signal Low PLMIII
#A9 Inclinometer Sensor Signal High PLMIII
#A10 Inclinometer Sensor Signal Low PLMIII
#A13 Body Up Switch Failure PLMIII
#A14 Internal Checksum Failure PLMIII
#A16 Internal Memory Write Failure PLMIII
#A17 Internal Memory Read Failure PLMIII
#A18 RR Flat Cylinder Warning PLMIII
#A19 LR Flat Cylinder Warning PLMIII
#A20 Date/Time Change PLMIII
#A21 Manual Tare Reset PLMIII
#A22 Alarm Carry Back PLMIII
#A26 User Switch Select Failure PLMIII
#A27 User Switch Clear Failure PLMIII
#A101 Pump Filter Switches - Pressure High IM
#A103 Hydraulic Tank Temp Sensor Low IM
#A104 Hydraulic Tank Temp Sensor High IM
#A105 Fuel Level Sensor Low IM
#A107 Propel System Caution IM/GE X
#A108 Propel System Temp Caution IM/GE X
#A109 Propel System Reduced Level IM/GE X
#A115 Low Steering Precharge IM X
#A123 Reduced Retard Level IM/GE
#A124 No Propel/Retard IM/GE X
#A125 No Propel IM/GE X
#A126 Hydraulic Tank Level Low IM X

D13-6 INTERFACE MODULE AND VHMS TROUBLESHOOTING 5/08 D13008


Table 3: Chassis Fault Codes (continued)
VHMS Sent via Snapshot
VHMS Fault Description Source
Fault Code OrbComm Trigger
#A127 IM Sensor +5V Low IM X
#A128 IM Sensor +5V High IM X
#A139 Low Fuel IM
#A145 Brake Cooling RPM Advance 1 IM
#A146 Brake Cooling RPM Advance 2 IM
#A152 Starter Failure IM
#A153 Low Battery Voltage - Engine Running IM
#A154 High Battery Charge Voltage IM
#A155 Low Battery Charge Voltage IM
#A158 Fuel Level Sensor High IM
#A159 Battery Voltage, 12-Volt, System Sensing Low IM
#A164 Battery Voltage, 12-Volt, System Sensing High IM
#A166 Hydraulic Oil Temp - LR Sensor Low IM
#A167 Hydraulic Oil Temp - RR Sensor Low IM
#A168 Hydraulic Oil Temp - LF Sensor Low IM
#A169 Hydraulic Oil Temp - RF Sensor Low IM
#A170 Hydraulic Oil Temp - LR Sensor High IM
#A171 Hydraulic Oil Temp - RR Sensor High IM
#A172 Hydraulic Oil Temp - LF Sensor High IM
#A173 Hydraulic Oil Temp - RF Sensor High IM
#A182 System Battery 12V High IM
#A183 System Battery 12V Low IM
#A184 J1939 Not Connected IM
#A190 Auto Lube Switch IM X
#A194 High LF Brake Oil Temp IM X X
#A195 High RF Brake Oil Temp IM X X
#A196 High LR Brake Oil Temp IM X X
#A197 High RR Brake Oil Temp IM X X
#A198 Hoist Pressure 1 Sensor High IM
#A199 Hoist Pressure 2 Sensor High IM
#A200 Steering Pressure Sensor High IM
#A201 Brake Pressure Sensor High IM
#A202 Hoist Pressure 1 Sensor Low IM
#A203 Hoist Pressure 2 Sensor Low IM
#A204 Steering Pressure Sensor Low IM
#A205 Brake Pressure Sensor Low IM

D13008 5/08 INTERFACE MODULE AND VHMS TROUBLESHOOTING D13-7


Table 3: Chassis Fault Codes (continued)