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Manual de Reparacion Camion 930e Komatsu
Manual de Reparacion Camion 930e Komatsu
Shop
Manual
DUMP TRUCK
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.
NOTES
FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician become fully
knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per-
sonnel should read and understand the materials in this manual before performing maintenance and/or operational
checks on the truck. All safety notices, warnings and cautions should be understood and followed when accom-
plishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other gen-
eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major ser-
viceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator
group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire
mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed
repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict
a specific model.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to "Right",
"Left", "Front", or "Rear" are made with respect to the operator's normal seated position, unless specifically stated
otherwise.
Standard torque requirements are shown in torque charts in the general information section and individual torques
are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have
æ10% tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig-
nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
(Gross Vehicle Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers
represent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an
Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the original man-
ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo-
nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
(GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the
GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often
as practical.
Exceeding the allowable payload will reduce expected life of truck components.
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
HYDRAIR® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
GENERAL INFORMATION
INDEX
Read and follow all safety precautions. Failure to do so may result in serious injury or
death.
Safety Rules
• Only trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
• When working with another operator or a person on work site traffic duty, be sure all personnel understand all
hand signals that are to be used.
Safety Features
• Ensure all guards and covers are in their proper position. Have any damaged guards and covers repaired. (See
Walk-Around Inspection, Operating Instructions - Section 3)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• Never remove any safety features. Always keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.
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 modification.
Fire Prevention
• Thoroughly remove wood chips, leaves, paper and other flammable items
accumulated in the engine compartment, as they could cause a fire.
• Check fuel, lubrication, and hydraulic systems for leaks. Repair any leaks.
Wipe up any excess oil, fuel or other flammable fluids, and dispose of properly.
• Ensure a fire extinguisher is present and in proper working condition.
• Do not operate the machine near open flames.
The tire and rim assembly may explode if subjected to excessive heat. Personnel should move to a remote
or protected location if sensing excessively hot brakes, smell of burning rubber or evidence of fire near
tire and wheel area.
If the truck must be approached, such as to fight a fire, those personnel should do so only while facing the
tread area of the tire (front or back), unless protected by use of large heavy equipment as a shield. Stay at
least 50 ft. (15 m) from the tread of the tire.
In the event of fire in the tire and wheel area (including brake fires), stay away from the truck for at least 8
hours or until the tire and wheel are cool.
• Keep serviceable fire fighting equipment on hand. Report used extinguishers for replacement or refilling.
• Always have parking brake applied when the truck is parked and unattended. DO NOT leave the truck
unattended while the engine is running.
• Park the truck a safe distance away from other vehicles as determined by the supervisor.
• Stay alert at all times! In the event of an emergency, be prepared to react quickly and avoid accidents. If an
emergency arises, know where to get prompt assistance.
Traveling
• When traveling on rough ground, travel at low speeds. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is in motion, the emergency steering system will be activated.
Apply the brakes immediately and stop the machine as quickly and safely as possible (off of the haul road, if
possible).
The following actions are effective in preventing accidents while working near high voltages:
• Wear shoes with rubber or leather soles.
• Use a signalman to give warning if the machine approaches an electric cable.
• If the work equipment should touch an electric cable, the operator should not leave the cab.
• When performing operations near high voltage cables, do not allow anyone to approach the machine.
• Check with the electrical maintenance department about the voltage of the cables before starting operations.
When Loading
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
• Do not leave the operator's seat during the loading operation.
TOWING
When Towing, Fix Wire To Hook
• Improper towing methods may lead to serious personal injury and/or damage.
• Use a towing device with ample strength for the weight of this machine.
• Never tow a machine on a slope.
• Do not use tow rope that has kinks or is twisted.
• Do not stand astride the towing cable or wire rope.
• When connecting a machine that is to be towed, do not allow anyone to go between the tow machine and the
machine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing portion of the tow machine, and
secure it in position.
(For towing method, see the Operation and Maintenance Manual, Section 3, Operating Instructions - Towing.)
Proper Tools
• Use only tools suited to the task. Using damaged, low quality, faulty, or
makeshift tools could cause personal injury.
Attachments
• Place attachments that have been removed from the machine in a safe place and
manner to prevent them from falling.
Use Of Lighting
• When checking fuel, oil, coolant, or battery electrolyte, always use
lighting with anti-explosion specifications. If such lighting equipment is
not used, there is danger or explosion.
• Immediately after stopping operation, engine coolant and operating oils are
at high temperature and under high pressure. In these conditions, if the cap
is removed, the oil or water drained, or the filters are replaced, 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 in as
outlined in the service manual.
Waste Materials
• Never dump waste oil in a sewer system, rivers, etc.
• Always put oil drained from your machine in appropriate containers. Never
drain oil directly onto the ground.
• Obey appropriate laws and regulations when disposing of harmful objects
such as oil, fuel, coolant, solvent, filters, batteries, and others.
The tire inflation pressure and permissible speeds are general values. The actual values may differ depending on
the type of tire and the condition under 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 pres-
sure 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.
Any operating fluid, such as hydraulic oil or brake fluid escaping under pressure, can have sufficient force
to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper
medical treatment by a physician familiar with this injury is not received immediately.
Do not stand in front of a rim and locking ring when inflating a tire mounted on the machine. Observers
should not be permitted in the area and should be kept away from the sides of such tires.
Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of tire and rim.
14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation should
move the truck under its own power in the repair facility or during road testing after repairs are complete.
Before opening any cabinets or touching a grid element or a power cable, the engine must be shutdown
and the red drive system warning lights must not be illuminated.
Leave the drive system in the “rest” mode until the truck is to be moved.
10. Before leaving this position, look under the 19. Move around the fuel tank. Inspect the fuel
lower edge of the chassis to be sure the flexible quantity gauge, (this should agree with what will
duct that carries the air from the main blower to show on the gauge in the cab). Inspect the
the final drive housing is in good condition with attaching hardware for the fuel tank at the upper
no holes or breakage. Also look up at the main saddles, and then at the lower back of the tank
hydraulic pumps to see that there is no leakage for the security and condition of the mounts.
or any other unusual condition with pumps or Check hoist filters for leaks.
pump drive shafts. 20. Move in behind the right front wheel, and
11. Move on around the dual tires, check to see that inspect the steering cylinder. Check the greas-
all nuts/studs are in place and tight. Inspect ing and attaching hardware. Check suspension
wheel for any oil that would indicate brake leak- attaching hardware and suspension extension.
age or wheel motor leakage. Be sure the suspension protective boot is in
good condition. Inspect the hub and brakes for
Check dual tires for cuts, damage or bubbles. any unusual conditions. Check entire area for
Verify that inflation appears to be correct. If the leaks.
truck has been run on a "flat", the tire must be
cooled before moving the truck inside. 21. Move out and around the right front wheel;
Check for any rocks that might be lodged inspect that all nuts/studs are in place and tight.
between dual tires. Check rock ejector condi- 22. Move in behind the front of the right front wheel,
tion and straightness (so that it can not damage check hub and brakes for leaks and any
a tire). unusual condition. Inspect steering cylinder for
12. Inspect left rear suspension for damage and for security and for proper greasing. Inspect the
correct rod exposure. Check for leaks. Ensure engine compartment for any leaks and unusual
that the covers over the chrome piston rod are conditions. Inspect the fan guard and belts.
in good condition and inspect for proper greas- Check for any rags or debris behind radiator.
ing. 23. Inspect auto lube system. See Automatic Lubri-
13. Open rear hatch cover. Inspect for leaks around cation System in Section P, for specific details
the parking brakes. Inspect condition of cooling concerning the auto lube system.
air exhaust ductwork to be certain that it is intact 24. Move around to the right front of the truck, drop
and that there are no obstructions. the air cleaner pans to remove dirt, latch up,
14. While standing in front of the rear hatch, look up and secure. Inspect battery box cover for dam-
to see that rear lights are in good condition, age and be sure it is in place and secure.
along with the back-up horns. Look up at pan- 25. As you move in front of the radiator, inspect for
hard rod to see that it is getting proper greasing. any debris that might be stuck in front of the
Also look at both body hinge pins for greasing radiator and remove it. Check for any coolant
and any abnormal condition. Check hoist limit leaks. Inspect headlights and fog lights.
switch and clear any mud/debris from contacts.
If any of the red warning lights come on or if any 8. Check brake lock performance periodically for
gauge reads in the red area during truck opera- safe loading and dump operation.
tion, a malfunction is indicated. Stop the truck as 9. Proceed slowly on rough terrain to avoid deep
soon as safety permits, and shut down the ruts or large obstacles. Avoid traveling close to
engine. Have the problem corrected before soft edges and the edge of fill area.
resuming truck operation.
10. Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
operating the truck.
10. If the "emergency steering" light and/or "low b. When the lever is rotated to full "down"
brake pressure warning" light (if equipped) illu- (clockwise) position, it is in the full "ON/
minate during operation, steer the truck imme- Retard" position.
diately to a safe stopping area, away from c. For long downhill hauls, the lever may be
other traffic if possible. Refer to item 7 above. positioned to provide a desired retarding
11. Check tires for proper inflation periodically dur- effort. It will remain where it is positioned.
ing shift. If truck has been run on a "flat", or NOTE: The retarder control lever must be rotated
under-inflated tire, it must not be parked in a back to the OFF position before the truck will resume
building until the tire cools. the “propel” mode of operation.
In the event that the equipment is being worked in If engine does not shutdown with keyswitch,
consecutive shifts, any questionable truck perfor- use engine shutdown switch on operator cab
mance the operator may have noticed must be center console, and hold this switch down until
checked by maintenance personnel before the truck engine stops.
is released to another operator. 4. With keyswitch OFF, and engine stopped, wait
at least 90 seconds. Insure steering circuit is
1. The truck should be parked on level ground, if
completely bled down by turning steering wheel
at all possible. If parking must be done on a
back and forth several times. No front wheel
grade, the truck should be positioned at right
movement will occur when hydraulic pressure is
angles to the grade.
relieved. If the vehicle continues to steer after
2. The parking brake must be applied and/or shutdown, notify maintenance personnel.
chocks placed fore/aft of wheels so that the
5. Verify all link voltage lights are off (one on back
truck cannot roll. Each truck should be parked
interior wall of operator cab, two on electrical
at a reasonable distance from another.
cabinet, on deck), and notify maintenance per-
3. Haul roads are not safe parking areas. In an sonnel if remains illuminated longer than five
emergency, pick the safest spot most visible to minutes after the engine is shut down.
other machines in the area. If the truck
6. Close and lock all windows, remove key from
becomes disabled where traffic is heavy, mark
keyswitch and lock cab to prevent possible
the truck with warning flags in daylight or flares
unauthorized truck operation. Dismount truck
at night.
properly. Put wheel chocks in place.
The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrica-
tion and Service, in this manual for more complete lubrication instructions.
SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B FT. LBS. CODE (O.D.) UNF-2B FT. LBS.
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage
FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page A5-5 regarding Table usage
PSI 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page A5-5 regarding Table usage
PSI 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may 3. Multiply by 10:
be used as in the following example: 970 psi = 6688 kPa.
Example: Convert 975 psi to kilopascals (kPa). 4. Go to PSI row 0, column 5; read 34.475
psi = 34.47 kPa. Add to step 3.
1. Select Table X.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
2. Go to PSI row 90, column 7; read 668.8
97 psi = 668.8 kPa.
Multiply Multiply
To Convert 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
2 (cm2) 6.45 2) in.2 0.1550
sq. in. – in. sq. centimeters sq. centimeters (cm sq. in. –
sq. ft. – ft.2 sq. centimeters (cm2) 929 sq. centimeters (cm2) sq. ft. – ft.2 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. – ft.3 cu. meters (m3) 0.028 cu. meters (m3) cu. ft. – ft.3 35.314
cu. ft. – ft.3 liters (l) 28.3 liters (l) cu. ft. – ft.3 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. (force) 0.7376
ft. lbs. (force) kilogram.meters (kg.m) 0.138 kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters kilogram.meters (kg.m) Newton.meters (N.m) 9.807
Newton.meters (N.m) 9.807
(kg.m)
Kilopascals (kPa) psi (pressure) 0.1450
psi (pressure) kilopascals (kPa) 6.895
megapascals (MPa) psi (pressure) 145.038
psi (pressure) megapascals (MPa) 0.007 2 2
kilograms/cm (kg/cm ) psi (pressure) 14.2231
psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 2 2 kilopascals (kPa) 98.068
kilograms/cm (kg/cm )
ton (short) kilogram (kg) 907.2
kilogram (kg) ton (short) 0.0011
ton (short) metric ton 0.0907
metric ton ton (short) 1.1023
quart – qt. liters (l) 0.946
liters (l) quart – qt. 1.0567
gallon – gal. liters (l) 3.785
liters (l) gallon – gal. 0.2642
HP (horsepower) Watts 745.7
Watts HP (horsepower) 0.00134
HP (horsepower) kilowatts (kw) 0.745
kilowatts (kw) HP (horsepower) 1.3410
5. Clean the radiator; refer to Section C, Cooling 10. Exhaust openings and air cleaners should be
System, for the proper cleaning instructions. covered tightly with moisture barrier paper and
sealing tape.
6. The cooling system should be completely
drained, chemically flushed, and refilled with a 11. All lubrication points (grease fittings) should be
conditioned water/antifreeze solution suitable serviced with the prescribed lubricants.
for the lowest temperature anticipated. Refer to 12. Relieve tension from all drive belts. The engine
Section P, Lubrication and Service, for the manufacturer recommends insertion of heavy
proper anti-freeze and conditioner concentra- kraft paper between belts and pulleys to prevent
tions. After refilling the system, always operate sticking.
the engine until the thermostats open to circu-
late the solution through the cooling system. 13. All vandalism covers and locks should be in
place and secured.
NOTE: NEVER store a vehicle with a dry cooling
system.
The engine should be stored in a building which is An engine prepared in this manner can be returned
dry and can be heated during the winter months. to service in a short period of time by removing the
Moisture absorbing chemicals are available commer- seals at the engine openings, checking the engine
cially for use when excessive damage prevail in the coolant, fuel oil, lubricating oil, transmission oil and
storage area. priming the raw water pump (if used).
Temporary Storage (30 Days Or Less) Extended Storage (more Than 30 Days)
To protect an engine for a temporary period of time, To prepare an engine for extended storage, (more
proceed as follows: than 30 days), follow this procedure:
1. Drain the engine crankcase. 1. Drain the cooling system and flush with clean,
soft water. Refill with clean, soft water and add
2. Fill the crankcase to proper level with the rec-
a rust inhibitor to the cooling system.
ommended viscosity and grade of oil.
2. Remove, check and recondition the injectors, if
3. Fill the fuel tank with the recommended grade necessary, to make sure they will be ready to
of fuel oil. Operate the engine for two minutes at operate when the engine is restored to service.
1,200 rpm and no load. Shut down engine, do
not drain the fuel system or the crankcase after 3. Reinstall the injectors, time them and adjust the
this run. exhaust valve clearance.
4. Check the air cleaner and service, if necessary. 4. Circulate the coolant by operating the engine
until normal operating temperature is reached
5. If freezing weather is expected during the stor- 160° - 185° F ( 71° - 85° C).
age period, add an ethylene glycol base anti-
freeze solution in accordance with the 5. Stop the engine.
manufacturer's recommendations. 6. Drain the engine crankcase, then reinstall and
tighten the drain plug. Install new lubricating oil
filter elements and gaskets.
7. Fill the crankcase to the proper level with a 30-
weight preservative lubricating oil MIL-L-
21260C, Grade 2.
STRUCTURES
INDEX
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
1. Remove hardware attaching diagonal ladder (4, 1. Move hood and grille assembly (1, Figure 2-2)
Figure 2-1) to front bumper. from work area to truck and lift into place.
2. Attach lifting device to the ladder and lift struc- 2. Align mounting holes with brackets attached to
ture off truck. radiator assembly. Install side mounting cap-
screws (2).
3. Disconnect wiring harnesses and remove cable
clamps as necessary to allow hood removal. 3. Lift diagonal ladder into position over mounting
pads on front bumper. Align mounting holes and
4. Attach lifting device to the hood and grille
install hardware. Tighten capscrews to standard
assembly (1, Figure 2-2).
torque.
5. Remove all side mounting capscrews and lock-
4. Connect harnesses, hoses etc. that were
washers (2).
removed previously. Install all clamps removed.
6. Verify all harnesses, cables, hoses etc. are
removed.
7. Lift hood and grille assembly from truck and
move to work area.
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BODY UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FIGURE 3-7. ROCK EJECTOR INSTALLATION FIGURE 3-8. ROCK EJECTOR MOUNTING
BRACKET (Detail View)
1. Rock Ejector Arm 3. Rear Wheel Spacer 1. Rock Ejector Arm 3. Stop Block
2. Wear Plate Ring 2. Pin 4. Mounting Bracket
Inspection
1. The rock ejectors must be positioned on the
center line between the rear tires within 0.25 in.
(6.0 mm).
2. With the truck parked on a level surface, the
arm structure should be approximately 17.9 in.
(454.5 mm) from wheel housing (2). Refer to
Figure 3-10.
NOTE: With rock ejector arm (1, Figure 3-9) hanging
vertical as shown in Figure 3-10, there must be NO
GAP at stop block (3, Figure 3-9).
3. If arm (1) becomes bent, it must be removed
and straightened.
4. Inspect mounting brackets (4, Figure 3-9), pins
(2) and stops (3) at each shift change for wear
and/or damage, and repair as necessary.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-8
Installation
1. Clean mating surfaces, and install a new gas-
ket.
2. Reinstall the sender unit in the tank. Use care
and ensure that the float is oriented properly
and works freely in the vertical plane during
installation.
3. Reinstall the four socket head capscrews and
tighten to standard torque. Reconnect the wire
to the terminal.
4. Refill the tank and check for leaks.
Removal
Unscrew breather valve (5, Figure 4-1) from fuel tank
(1).
Installation
Screw breather valve (5, Figure 4-1) into fuel tank
(1).
Disassembly
1. Remove clamp (3, Figure 4-2).
2. Remove cover (2) and screen (1).
3. Remove ball cage (10), solid ball (11), and float
balls (12).
4. Unscrew end fitting (7) from body (4). FIGURE 4-2. BREATHER VALVE
5. Remove stem (8) and valve spring (5).
1. Screen 7. End Fitting
Assembly 2. Cover 8. Stem
3. Clamp 9. O-Ring
1. Clean and inspect all parts. If damaged compo- 4. Body 10. Ball Cage
nents are evident, replace the entire assembly. 5. Valve Spring 11. Solid Ball
2. Place valve spring (5) into position in body (4). 6. O-Ring 12. Float Ball
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
NOTE: This illustration represents a typical installation. Installation may vary depending on truck model.
Backflushing Procedure
1. Stop engine. Obtain a container to catch the
fuel drained in the following procedure.
2. Open the bleed screw to allow atmospheric
pressure into the filter. The dirt particles and
larger droplets of water will release from the
bottom of the filter element. Gravity will cause
the dirt particles to slowly fall to the bottom of
the bowl.
3. Open the drain valve. The clean fuel above the
filter will backflush through the filter element
releasing smaller dirt and water particles. Drain
the fuel until the dirt and water are removed
from the filter and bowl.
4. Close the drain valve.
5. Close the Bleed Screw (DO NOT OVER-
TIGHTEN).
6. Start engine. If engine stills lacks power, try
backflushing again.
7. If restriction (∆P) is still too high, change the fil-
ter element.
ENGINE
INDEX
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul) . . . . . . 11
• All removal, repairs and installation of It is not necessary to remove the radiator prior to the
propulsion system electrical components, removal of the power module. However, the coolant
cables etc. must be performed by an must be drained and the piping connected to the
electrical maintenance technician properly brake cooling heat exchanger removed. If radiator
trained to service the system. removal is desired or if only radiator repair is neces-
• In the event of a propulsion system sary, refer to Cooling System in this section.
malfunction, a qualified technician should
inspect the truck and verify the propulsion
system does not have dangerous voltage
levels present before repairs are started.
NOTE: Subframe rollers are supplied in the truck For further disassembly of the engine, alternator,
tool group and can be installed in the storage and radiator, refer to the appropriate section of this
position after use, as shown in Figure 2-6. manual.
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10
5. Unclamp and separate all upper tank lines (3) 10. Remove the upper radiator side support rods (4,
between the radiator and engine. Figure 3-2). Remove lower support rods (5).
6. Remove outlet elbows (2 & 4, Figure 3-4) at 11. Remove nuts, lockwashers, flat washers and
bottom tanks. Cap all coolant lines to prevent capscrews (2, Figure 3-6) from power module
contamination. subframe (3) at the lower radiator mounts.
7. Remove and cap hoses from radiator top tank
12. Verify all hoses and wiring harnesses have
and surge tank.
been removed. Lift radiator slightly with the
8. Remove capscrews and lockwashers to free fan hoist, move assembly forward until clear of
guard (3 & 5, Figure 3-5) from radiator shroud engine fan. Move radiator to work area for ser-
(2). The two halves of the fan guard may be dis- vice.
assembled and removed or the complete guard
may be moved to the rear to clear the fan
shroud during radiator removal.
9. Attach hoist to lift radiator and take up slack.
NOTE: The radiator and shroud assembly weigh
approximately 5,730 Lbs. (2,600 Kg.).
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Removal Service
Refer to instructions in previous sections for Complete instructions covering the disassembly,
removal instructions for the Power Module, alterna- assembly and maintenance of the engine and its
tor, and radiator assembly. components can be found in the engine manufac-
turer's service manual.
Installation
1. Align engine to subframe and install front
The engine weighs approximately 15,500 lbs. mounting capscrews and lockwashers (5, Fig-
(7020 kg) dry. Be sure lifting device is capable of ure 4-7). Align and install rear engine mounting
handling the load safely. capscrews and lockwashers (2) through cradle
1. Disconnect any remaining wiring or hoses structure, but do not tighten at this time.
between the engine and subframe. Tighten front mount capscrews to 345 ft.lbs.
2. Remove capscrews and lockwashers (5, Fig- (465 N.m) torque.
ure 4-7) securing front engine mount to sub- 2. Install alternator on engine following instruc-
frame. tions for "Engine/Alternator Mating".
3. Attach lifting device to front lift eyes and rear 3. Tighten rear engine mounting capscrews (2) to
lift eyes (6) on engine. Remove capscrews and 177 ft.lbs. (240 N.m) torque after alternator is
lockwashers (2) at rear engine mount securing installed.
engine to cradle structure (1).
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
1. Dust Cap 6. Wing Nut Gasket 10. Safety Filter Element 13. Clean Air Outlet
2. Dust Cap Gasket 7. Safety Element 11. Main Filter Element 14. Pre-Cleaner Gasket
3. Tube Indicator 12. Main Element Gasket 15. Safety Filter Element
4. Unfiltered Air Inlet 8. End Cover Gasket
5. Wing Nut
INDEX
NOTE: Electrical system wiring hookup and electrical schematics are located in Section “R” of this Manual.
DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNING AND CONTINUE
TO EXIST AFTER SHUTDOWN IF THE REQUIRED SHUTDOWN PROCEDURES ARE NOT FOL-
LOWED. Before attempting repairs or working near propulsion system components, the following
precautions and truck shutdown procedure must be followed:
•DO NOT step on or use any power cable as a handhold when the engine is running.
•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 those working in the areas of the deck, electrical cabinet, traction motors, and retarding grids. The
following procedures will ensure the electrical system is properly discharged before repairs are started.
AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR AND ITS
CIRCUITS TO DE-ENERGIZE.
Do not attempt to perform auxiliary blower motor or blower electrical circuit repairs until it has
been verified the system is de-energized.
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7
Troubleshooting
Two most common troubles that occur in the charg-
Lead-acid storage batteries contain sulfuric acid,
ing system are undercharging and overcharging of
which if handled improperly may cause serious
the truck's batteries.
burns on skin or other serious injuries to person-
nel. Wear protective gloves, aprons and eye pro- An undercharged battery is incapable of providing
tection when handling and servicing lead-acid sufficient power to the truck's electrical system.
storage batteries. See the precautions in Section
Some possible causes for an undercharged battery
A of this manual to insure proper handling of bat-
are:
teries and accidents involving sulfuric acid.
Sulfated battery plates
During operation, the storage batteries function as an Loose or corroded battery connections
electrochemical device for converting chemical Defective wire in electrical system
energy into the electrical energy required for operat-
ing the accessories when the engine is shut down. Loose alternator drive belt
A defective alternator
Overcharging, which causes overheating, is first indi-
BATTERIES cated by excessive use of water. If allowed to con-
tinue, cell covers will push up at the positive ends
Maintenance and Service and in extreme cases the battery container will
The electrolyte level of each cell should be checked become distorted and cracked.
at the interval specified in Lubrication and Service, Leakage can be detected by continual wetness of the
Section P, and water added if necessary. The proper battery or excessive corrosion of the terminals, bat-
level to maintain is 3/8 - 1/2 in. (10-13 mm) above the tery carrier and surrounding area. (A slight amount of
plates. To insure maximum battery life, use only dis- corrosion is normal in lead-acid batteries). Inspect
tilled water or water recommended by the battery the case, covers and sealing compound for holes,
manufacturer. After adding water in freezing weather, cracks or other signs of leakage. Check battery hold
operate the engine for at least 30 minutes to thor- down connections to make sure the tension is not
oughly mix the electrolyte. great enough to crack the battery, or loose enough to
allow vibration to open the seams. A leaking battery
should be replaced.
5 Minute Idle Contactor The AID system enables the indicating lights to be
flashing or constant. The AID also has the capability
The contactor (7) energizes the idle timer and main- of operating an audible alarm along with the light.
tains current flow to the engine "run" circuit if the The eight printed circuit cards are (refer to Figure 3-
operator turns the key switch off. 2):
5 Minute Idle Circuit Test • Diode Matrix (With Sound) Card (Slot 1)
Check 5 minute idle timer circuits as follows: • Diode Matrix (Without Sound) Card (Slot 2)
1. With the key switch ON, press the Engine Shut- • Hot Switch Inverter Card (Slot 3)
down switch firmly to the momentary position • Hot Switch Inverter Card (Slot 4) (Not Used)
and release (switch will return to the ON posi-
• Temperature Card (Slot 5) (Not Used)
tion).
2. Turn the key switch OFF and verify the follow- • Oil Level Card (Slot 6)
ing: • Temperature and Latch Card (Slot 7)
Circuit 712 (to ground) remains 24 volts for • Coolant Level and Flasher Card (Slot 8)
approximately 5 minutes. After 5 minutes,
the voltage drops to 0. NOTE: Each card is identified with a number which
corresponds with a mating number on the housing. If
The 5 minute idle indicator lamp on the cards are removed, make sure card numbers
overhead display is ON when circuit 712 correspond with housing numbers during installation
reads 24 volts.
(See Figure 3-2).
3. Repeat step 1. While monitoring voltage at cir-
cuit 712, turn the key switch OFF. Push the The following briefly describes each card and its
engine shutdown switch off. function. Refer to Section R for circuit components
described below.
Verify voltage at circuit 712 drops to 0 when
the shutdown switch is pushed to OFF.
The other half of the circuitry on the coolant level and Hot Switch Inverter
flasher card operates the coolant level light. The
water level probe connected to terminal B11 grounds The hot switch inverter card (Slot 3) is used to oper-
the 31L circuit when the coolant in the radiator is ate and test the service brake indicator light. In nor-
above the probe position. The coolant saturates the mal conditions Q4 transistor is off and the Indicator
probe and electrically grounds the circuit. When the Light is off. When the stoplight switch is activated, 24
circuit is grounded, Q6 transistor is off, resulting in no volts is sent to pin "E" of the hot switch iInverter card.
indication. When the coolant level drops below the Transistor Q4 is turned on by this voltage and, in
probe, 31L is no longer grounded and Q6 turns on to turn, grounds the service brake Indicator Light. There
ground the flasher through D5, ground the coolant is no alarm horn operation with this card.
level light through terminal D11, and ground the A second circuit on this card is used to operate and
alarm horn through D6. The light and alarm horn will test the retard speed control indicator light. When
operate intermittently as their 24 volt supply is from RSC is turned off, transistor Q7 is off and the indica-
circuit 12F, the flasher output. tor light is off. When RSC is turned on, 24 volts is
NOTE: Some electronic engine controls monitor sent to pin "J" of the card. This voltage turns on Q7,
coolant level. If the engine controls monitor the grounding the indicator light circuit.
circuit, a 2KW resistor is installed to replace the
probe and disable the AID system circuit.
Oil Level The diode matrix with sound card works very much
like the other diode matrix card, except that it con-
The oil level card is used to turn on the low oil level tains extra diodes to activate the alarm horn in addi-
indicator light to warn the operator engine oil/hydrau- tion to the flasher. The circuits connected to terminals
lic tank oil level is below acceptable levels. The oil A1 through A8 operate in the same manner.
float is connected to a variable resistor. As the oil
level decreases, the resistance goes down causing
Q3 to turn on, grounding the indicator light and alarm
Lamp Test
horn.
All of the card circuits are connected to the lamp test
switch on the overhead display area. In normal oper-
Temperature ation, these circuits are open and not functional.
When the operator pushes the lamp test switch, it
The temperature card (Optional) is used to turn on activates all the indicator circuits by grounding them.
the high oil temperature indicator light. The indicator This is used to verify that all lamps are functional.
light tells the operator that the hydraulic tank oil tem-
perature has exceeded acceptable levels. Normal
temperature setting is 250°F (121°C). As the temper-
ature goes up the resistance in the probe decreases
providing a ground path for the indicator light and
alarm horn.
Each relay board of this type is equipped with five To replace a circuit breaker:
green lights (9, Figure 3-6) and one red light (7). Four
green lights are labeled K1, K2, K3, or K4. These NOTE: Always replace a circuit breaker with one of
lights will be on only when that particular control cir- the same amperage capacity as the one being
cuit has been switched on and the relay coil is being removed.
energized. The light will not turn on if the relay board 1. Place battery disconnect switches in the off
does not receive the 24 volt signal to turn on a com- position.
ponent. Each relay board has a 5th green light that 2. Unplug all wiring harness(s) from relay board.
has a different function on each board. Remove four relay mounting screws and
The red "Breaker Open" light (if on) indicates that a remove relay board from truck.
circuit breaker (on that relay board) is in the off posi- 3. Remove four hold down screws (3) (one in each
tion. A light on the overhead display panel will also corner) in circuit breaker cover plate and all cir-
illuminate, informing the operator that a circuit cuit breaker screws. Remove cover plate from
breaker is in the off position. The red breaker open circuit breakers.
light will turn on whenever there is a voltage differ- 4. Remove nuts and star washer from back side of
ence across the two terminals of a circuit breaker. circuit board that holds the breaker in place.
If a control switch has been turned on and a green 5. Lift out circuit breaker. Retain flat washers that
(K) light is on, but that component is not operating, were between inner circuit breaker nut and
check the following on the relay board for that circuit: relay board.
Check for a circuit breaker that is in the off 6. Install one nut and two flat washers to each
position or a red (breaker open) light is on. pole on the circuit breaker. Nuts must be
If a circuit breaker is off, turn it on. Check adjusted to the same height as on the other cir-
operation of component. If it trips again, cuit breakers. This is necessary so when cover
check the wiring or component for cause of plate is installed, it will not press circuit breaker
overload. into, or pull up on, the circuit board. Install new
The contacts inside the relay may not be circuit breaker of the same capacity rating as
closing, or the contacts may be open, the one removed.
preventing an electrical connection. Swap 7. Install star washer and nut to circuit breaker
relays and check again. Replace defective poles (on the back side) and tighten nuts.
relays.
8. Install cover plate and all screws removed dur-
Check the wiring and all of the connections ing disassembly.
between the relay board and the
component for an "open" circuit.
Defective component. Replace component.
Poor ground at the component. Repair the
ground connection.
1. Relay Board
2. Main Harness Connector
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
13. Circuit Harness Connector
Operation
When the hoist cylinders approach maximum stroke,
and the body pivots on the pins, actuator arm (3)
moves close enough to the magnetically operated
switch to close the electrical contacts. When the con-
tacts close, an electrical signal is sent to the hoist-up
limit solenoid valve (located in the hydraulic compo-
nents 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 assem-
bly.
Adjustment
With body raised and hoist cylinders within 6 in. (152
mm) of maximum travel, make the following adjust-
ment.
1. Adjust limit switch to achieve an air gap (dimen-
sion "A") of 0.50 to 0.56 in. (12.70 to 14.30 mm)
between sensing area and actuator arm (3).
Retighten capscrews.
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE . . . . . . . . . . . . . . D5-3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-8
The Electronic Engine Control system provides an The following major components are required for
electronic method for determining engine fuel the system:
requirements and controlling engine speed. Engine
performance is continuously monitored by various
sensor inputs to microprocessors and compared to • Electronic Control Module
operating parameters stored in memory to provide • Electronic Unit Nozzles
engine operation controls. Operator demand for
• Engine and cooling system sensors
power is provided by an electronic foot pedal and/or
the drive system controller while engine mounted • Operator input controls
sensors provide information on engine crankshaft • Engine protection indicator lights/circuits
position, RPM, pressures, and temperatures. Exten-
sive operation and diagnostic information is stored • Wire harness/connector assemblies
and made available for troubleshooting engine prob- • Diagnostic Data Reader
lems and monitoring engine performance.
Electronic engine control eliminates the need for air
operated throttle pedals, cylinders, and mechanical
or hydraulic governors.
Two ECM's (6, Figure 5-2) are required for the 4000 Series engine, a primary and a secondary unit. The outboard
(primary) ECM controls fueling in the front 8 cylinders and the inboard ECM controls fueling in the rear 8 cylinders.
Fuel control information is sent across an electrical harness (data link) from the primary to the secondary unit.
The ECM electronics are cooled by passing engine fuel through a plate mounted on the ECM. Internal electronic
components are attached to this side of the ECM which acts as a heat sink to remove excessive heat.
PTO Counts
The throttle position sensor (2, Figure 5-7) is con-
tained in the electronic foot pedal control. When the
operator depresses the accelerator pedal, a variable
voltage signal is sent to the drive system controller
and based on other truck operating conditions inputs
to the panel (temperature, truck speed) the panel will
provide a frequency signal to the DDEC ECM's to
control engine speed. The drive system controller will
control the engine RPM for all operating conditions.
CLS
The coolant level sensor (CLS) (Figure 5-6) monitors
coolant level in the cooling system (1, Figure 5-4) top
tank. This sensor provides a signal to the ECM.
FIGURE 5-5. ELECTRONIC UNIT NOZZLE
1. Fuel Inlet 3. Valve Body
2. Solenoid Terminals 4. Nozzle
SEL
FIGURE 5-7. ELECTRONIC FOOT PEDAL The RED Stop Engine light will illuminate for approxi-
ASSEMBLY (EFPA) mately five seconds after the key switch is turned on.
If the Stop Engine light and Check Engine light turn
1. Connector Cable 2. Throttle Position on during operation, a potentially damaging condition
Sensor has been detected. Stop the truck as quickly as pos-
sible in a safe area. Apply parking brake. SHUT
EFPA DOWN THE ENGINE IMMEDIATELY.
The electronic foot pedal assembly (EFPA) (Figure 5- The following signals can cause the Stop Engine
7) is the accelerator pedal controlled by the operator Light to illuminate:
to vary the power demand.
• Low coolant level
• Low coolant pressure
TBS • High coolant temperature
The charge air pressure sensors (TBS) (4, Figure 5-2 • Low charge air cooler coolant pressure
& 2, Figure 5-4) monitor air inlet pressure from the • High charge air cooler coolant pressure
turbochargers and send voltage signals proportional
to pressures to the ECM. • Low oil pressure
• High oil temperature
• High crankcase pressure
OPS
The oil pressure sensor (OPS) (1, Figure 5-3) moni-
tors engine oil pressure. If one of the above conditions is detected, both lights
are illuminated and an alarm horn will sound, the
error code is logged and the ECM begins a pro-
grammed engine protection sequence. Maximum
engine speed is reduced to 1675 RPM and propul-
sion is interrupted. Retarding is available if it is
needed to slow or stop the truck.
A code is stored in the ECM and drive system con-
troller memory describing the fault. The DDR should
be used to determine which system caused the fault.
The problem should then be corrected.
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-10
Static Test - Engine OFF, Key ON, Battery Switch ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-11
Go To Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-11
Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17
Troubleshooting
2. Open battery disconnect switch. Remove bat- HIGH NORMAL Watch until amps decrease or
voltage exceeds 28.8 volts. If
tery cable from alternator B+ terminal. amps decrease and volts remain
Refer to Figure 10-2 for the following steps. Meters normal, system is OK. If voltage
exceeds 28.9 volts, regulator and/
should be installed directly at the alternator as shown or alternator defective. Go to
to eliminate variations in readings due to cable Static Test.
lengths etc.:
HIGH HIGH STOP TEST! Regulator and/or
3. Install the ammeter (negative lead) to the bat- alternator defective. Go to Static
tery positive cable removed in step 2. Install the Test.
ammeter positive lead to the alternator B+ ter- LOW LOW 1. Recheck voltmeter leads. If
minal. connections are OK, alternator
and/or regulator defective.
4. Install a voltmeter between the alternator B+
2. Perform Regulator Bypass Test
terminal (positive lead) and the ground terminal per instructions on following page:
(voltmeter negative lead). a. If volts and/or amps
5. Secure all test equipment leads to prevent dam- increase, alternator is OK but reg-
ulator is defective.
age or short circuits when engine is started.
b. If no effect, replace alternator
Reconnect battery disconnect switch.
LOW NORMAL Charging system is OK.
LOW HIGH STOP TEST! If battery and volt-
meter check is OK, regulator and/
or alternator defective.
DEFINITIONS
NOTE: Charge voltage and amp rates vary from B+ voltage is battery positive voltage, but does
battery type to battery type, based on battery not refer to a specific value as does battery volt-
construction technology and physical size of battery. age.
Low amps are the necessary amps that a bat- Surface charge is a higher than normal terminal
tery will take continuously over a period of time voltage a battery has when it comes off a
without damage to the battery when the battery charger or after extended time in vehicle opera-
is in an operating system and is constantly tion. The surface charge must be removed to
cycling. Batteries such as the Group-8D may determine true battery voltage.
accept rates up to 15 amps over several hours
without raising their internal temperature more
than a few degrees. Group-31 batteries may
accept rates up to 5 amps over several hours
with minimal temperature rise.
Remove strap between "R" and "E" terminal. NOTE: Alternator may not be turned on when engine
is operating. Go to "R" terminal test next, to prove if
Connect a 12 gauge jumper wire from the "B+" termi- vehicle "E" circuit will turn alternator on.
nal on alternator to the "E" terminal on alternator.
Vehicle Charging Circuit Test Is Now Complete: • If meter shows battery voltage, circuit is good.
Continue test.
Remove all jumper wires from alternator used to test
Insert "+" probe of voltmeter into "B" pin in connector.
charging circuit.
Insert negative probe of voltmeter into "B-" pin in
connector. (This is power circuit for voltage regula-
tor.)
Re-test Charging Circuit For Operation With The
Engine Running: • If circuit shows open (no voltage), alternator is
defective. Replace alternator.
Check charging system voltage with engine running.
• If circuit shows B+ voltage, regulator is
If no charge voltage, test for voltage at "E" defective. Replace the regulator, only.
terminal of alternator, with engine running.
NOTE: Turn key and battery switch OFF before
If no voltage on "E" terminal, shut engine installing new regulator. Turn battery switch and key
down and inspect link from "R" terminal to back on AFTER installing new regulator. Continue
"E". test.
Run engine and re-test charging circuit.
ALTERNATOR DIMENSIONS
1. Mounting Bolt - 1/2 UNC 6. Fan Nut; 50 ft.lbs. (68 N.m) torque
2. Mounting Bolt - 12/50 Dia; 65 ft.lbs. (88 N.m) torque 7. Slip Bushing
3. Ground Bolt, 3/8 - 16; 11 ft.lbs. (15 N.m) torque 8. Allowable Mounting Bracket Dimensional Span
Either Side; R.H. side shown 9. F+ Stud (NOTE: F+ Stud Not On All Models)
4. Locknut (5/16 - 18 UNF-2B) & Washer (to secure Pulley)
NOTE: (1) NOT SERVICED SEPARATELY - SUPPLIED ONLY IN BF1986 KIT.NOTE: (2) NOT SOLD
SEPARATELY
Preliminary Checks:
1. Check Belt Tension. Use Belt Tension Gauge
to measure belt tension: Poly V Belt Adjustment
(20 lbs./strand): 240 lbs. maximum for 12
groove Poly V-belt.
2. Check Battery.Batteries must be in good condi-
tion and fully charged. If any battery condition is
marginal, it should be replaced with one known
to be in good condition.
For split battery pack, dual voltage systems,
battery rest voltages should agree within 0.3 V.
When "12V" battery voltage is more than 0.3 V
lower than "24V" battery voltage, check the
"12V" battery circuit to verify adequate charge.
Polarity of battery and alternator must agree;
FIGURE 10-5.
reverse polarity will damage the alternator. The
alternator is NEGATIVE ground.
1. Alternator 3. Ammeter
3. Check electrical connections in charging circuit. 2. Voltmeter 4. Battery
Make sure all connections are clean, tight, and
free of corrosion. Battery connections are espe- 7. Attach meters as indicated by Figure 10-5, be
cially important. sure to measure voltage and amperage at alter-
4. Check Energize circuit.If alternator is not charg- nator, not at batteries or intermediate point.
ing, check for voltage at the alternator energize If an in-line ammeter is used, disconnect battery
terminal. Refer to Figure 10-5 for energize ter- ground cable before connecting ammeter. Then
minal location on the outside of the control box. reconnect battery ground cable. Ammeter con-
Check for battery voltage at the "E" terminal nections must carry rated output of alternator.
with engine running.
Test Procedure
Test Set-up
8. Start engine. Accelerate to high idle.
5. Discharge Battery as Follows:
d.Disable fuel system.
e.Turn all lights and accessories "ON". Crank
the engine for 10 - 15 seconds to discharge
If voltmeter reading exceeds 32V for 24V system,
battery, then stop cranking engine.
stop engine immediately and refer to Table 10-3.
f. Turn all lights and accessories off.
9. Watch meter reading.If battery is sufficiently
g.Enable fuel system. discharged, amps should be high within ± 10%
6. Determine setpoints of regulator. The setpoint of output specified by performance curve (refer
of the alternator is 28V. "Normal" range is within to SPECIFICATIONS, alternator RPM = engine
±0.2V of setpoint. RPM x pulley ratio). Volts should be within or
below the "normal" range as battery
approaches full charge. Amps should fall as
Volts rise. When amps and volts stabilize, note
readings and refer to Table 10-3.
ON-VEHICLE TEST
Bypass Test:
Disconnect plug between alternator and regulator
and momentarily touch "F-" terminal from alternator
plug to ground.
FIGURE 10-7.
1. F+ Stud (some units have F+ Stud & Phase taps)
Refer to Figure 10-8 for location of control box termi- Check to make sure that all phase leads are discon-
nal strip connections. Refer to Figure 10-7 for loca- nected from the heat sink (refer to Figure 10-10).
tion of control box external connections to regulator
and ignition circuit.
Table 10-8:
CONTROL BOX CONTINUITY CHECKS
OHMETER TERMINAL CONTROL READING
SCALE STRIP BOX
CONNECTION EXTERNAL
CONNECTION
(Figure 10-5)
x 10K F- GND* (B-) VERY
HIGH
x1 F- (F-) PIN ZERO
x1 F+ (F+) ZERO FIGURE 10-10.
TERMINAL
*GND connections are made to ground terminal 1. Positive Diode Studs 2. “S” Phase Terminal
located on outside of front housing.
NOTE: Heat sink diodes are de-rated for heavy duty
With regulator disconnected, test for continuity from performance. If diode failure is detected, the entire
"E" terminal on control unit to connector Energize charging system should be examined for loose
("E") pin on regulator harness (See Figure 10-9). connections (especially battery). If diode failure is
indicated, stator failure must also be suspected.
Stator Tests
NOTE: The front stator related Phase leads are "P1",
"P2", & "P3"; The rear stator phase leads are "P4",
"P5", & "P6"
The Alternator has two separate assemblies that will
be checked individually. Make sure all phase leads
are disconnected from the heat sink (Refer to Figure
10-6).
Fan Removal
1. Remove fan guard.
2. Use a 3/4" socket wrench to loosen nut attach-
ing fan to alternator. Keep shaft from rotating by
holding the pulley in a vise, jaws padded with
brass or aluminum (Figure 10-11).
3. Remove nut and hardened washer.
4. Remove fan assembly from alternator.
FIGURE 10-12.
FIGURE 10-11.
Pulley Removal
1. Use a 15/16" socket wrench on the pulley nut.
Clamp the pulley in a vise, jaws padded with
brass or aluminum, and loosed pulley nut (Fig-
ure 10-13).
2. Remove pulley nut and hardened washer.
3. With a gear puller remove the pulley from the
shaft.
4. Remove woodruff key from shaft.
5. Remove pulley bushing from shaft.
FIGURE 10-13.
FIGURE 10-16.
1. Machine Screws
Alternate Method
2b.Using an air hammer (air chisel) with a blunt
Rear Rotor Removal
tipped tool, vibrate the area around the
1. Remove six flanged locknuts from core studs or rotor element to rotor core attaching studs.
six self tapping screws (1, Figure 10-15). Scribe The vibrations should loosen any built up
location of stud or screw holes on rotor face rust in that area. Remove the rotor ele-
plate. ment. If resistance is still felt, use the
method described in "2a.", plus the air
hammer.
FIGURE 10-21.
1. Jack Screws
FIGURE 10-20.
FIGURE 10-24.
FIGURE 10-25.
1. Field Coil Bobbin Ear
FIGURE 10-27.
FIGURE 10-26.
FIGURE 10-28.
1. Tool (BF4818)
FIGURE 10-32.
FIGURE 10-37.
1. Bearing Seal 4. Fan Guard Screws
2. Bearing 5. Fan Mounting
3. Ring Seal Groove Hardware
FIGURE 10-39.
FIGURE 10-41.
FIGURE 10-40.
FIGURE 10-42.
FIGURE 10-43.
The field coil and shell studs must be removed from 11. Wrap a clean shop towel around the jack screw
the shell assembly before a stator can be removed. and lift the pressure plate/jack screw/top thrust
plate assembly. Insert the pressure plate into
REMINDER: A narrow, 1 - 3" wide, support ring is in and through the top stator assembly. Position
the tool package (not pictured). This ring is used the pressure plate in the space between the two
when necessary, to provide additional tool height to stators, where the field coil had been. Turn the
prevent the jack screw from protruding through the pressure plate to align the poles of the pressure
bottom thrust plate and preventing proper tool use. plate with the poles of the stator. This is easily
1. Position the bottom thrust plate in work area. done by grasping both the jack screw and guide
pin and twisting. The pressure plate will then
2. Place the first support ring on the bottom thrust
rotate. Before releasing the assembly, make
plate.Make sure the support ring seats in the
mating groove in the bottom thrust plate. sure the top thrust plate will once again rest on
the end of the guide pin, not the support ring.
3. Place the shell assembly on the support ring
with the stator to be removed, facing up. 12. Position the stator leads inside the support ring.
Firmly grab the top thrust plate at the outer
4. Place the second support ring on top of the
edge, twist slightly until the guide pin enters the
shell assembly.Reach inside the support ring
curved slot. Lower the top thrust plate onto the
and position the stator leads inside and away
support ring. The top of the support ring should
from the top of the shell assembly.
enter the mating groove in the top thrust plate.
Pressure Plate Set-up (Refer to Figure 10-46) 13. Thread the jack screw in, until the head of the
5. Thread the 3/8" diameter guide pin into the jack screw contacts the top thrust plate.
pressure plate, from the hub side of the pres- 14. Look through the large diameter holes (torque
sure plate. The threaded hub on the pressure arm holes) in the thrust plate to confirm the
plate faces up, toward the top thrust plate. proper seating of the pressure plate steps
6. Lay the top thrust plate on the pressure plate as against the stator. Adjust the pressure plate as
you pass the guide pin through the curved slot necessary.
in the top thrust plate.
NOTE: The pressure plate is properly seated when
7. After properly placing the thrust washer (not the outer edge of the pressure plate presses against
shown on drawing) on the jack screw, insert the the field coil mounting tabs on the stator. Make sure
jack screw through the top thrust plate and that ALL field coil mounting tabs are in contact with
thread the jack screw into the pressure plate the pressure plate.
about 1".
15. Continue threading the jack screw in, until sig-
8. Lift the top thrust plate up and off the guide pin.
nificant resistance is felt. Check position of the
Turn the top thrust plate so that the guide pin
pressure plate again.
Stator Installation
(Refer to Figure 10-45)
Shell Assembly Preparation
The bore that is to receive the new stator should be
clean and free from burrs.
1. Position the bottom thrust plate in the work
area.
2. Place the pressure plate, threaded hub facing
down, on the bottom thrust plate. Align the
smooth bored hole in the pressure plate with
the keyed hole in the bottom thrust plate. Insert
the correct length locating rod through the pres-
sure plate and into the bottom thrust plate.
NOTE: The correct length locating rod is a rod that
has a hole that will allow the locating pin to pass
through both the locating rod and shell drain hole.
3. Place new stator on the stator indexing pins on
FIGURE 10-44.
the bottom thrust plate.
NOTE: Proper placement of the stator is achieved
1. Bottom Thrust Plate 5. Locating Rod (Long)
when the single stator lead aligns with a stator slot
2. Stator Index Pins 6. Locating Pin
next to the other stator's single lead. The finished
3. Guide Pins 7. Locating Rod (Short)
shell assembly will have a slot arrangement of two
4. Jack Screw 8. Pressure Plate
leads-space, two leads-space, two leads-space.
The front stator is placed on the stator indexing
pins with the leads pointing down.
The rear stator is placed on stator indexing pins
with leads pointing up.
Position the stator leads so they will not be
damaged during stator installation.
INDEX
NOTE: Propulsion system electrical schematics are located in Section “R” of this manual.
Self-load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
The TCI panel provides the following functions: ›› 17FB144 CPU Card: Provides high speed
RS422 serial communications to PSC and
• Communicates with the Propulsion System
RS232 serial communication with the PTU.
Controller (PSC) to exchange propulsion control
system status and control data and to provide the
›› 17FB160 Analog I/O Card: Provides RS232
PSC with truck systems status data.
serial communications with Diagnostic Informa-
• Communicates with the Diagnostic Information tion Display and an optional Modular Mining
Display (DID) to exchange PSC and/or TCI Dispatch System. Provides RS422 serial com-
diagnostic and parameter data. munication with the Auxiliary Blower Sys-
• Communicates with the Auxiliary Blower System tem.Receives signals for front wheel speed,
to exchange diagnostic data. motor cooling and barometric air pressures,
accelerator, retard speed setting, payload,
• Communicates with a Portable Test Unit (PTU) to
exchange TCI data. ambient and hydraulic oil temperature, and
engine cranking voltage. Outputs drive cab
• Communicates with a Modular Mining Dispatch mounted temperature gauges etc.
System to exchange truck status data.
• Monitors engine control system, payload ›› 17FB104 Digital I/O Card: Receives operator
information, ambient and propulsion system control, engine and body-up signals. Provides
temperature, operator control inputs etc. engine start controls, drives cab mounted indi-
cator/warning lamps, etc.
• Controls the engine start sequence.
*NOTE: The 17FL373 Panel does not contain the
• Provides signals to activate many of the cab
17FB127 card.
mounted warning lamps and gauges. Controls
the park brake solenoid.
• Processes front wheel speed signals for the PSC
and speedometer.
In addition, the DID panel can be used by to perform No Propel “NO PROPEL" (red) light illuminates.
• No propulsion allowed
the self-load test.
• Retarding allowed
• Link power allowed
Speed Limit “PROPEL SYSTEM CAUTION"
(amber) light illuminates.
• Propel, retard and DC link power
still allowed.
• Speed is limited to 10 MPH
(16 KPH)
INV1 Disable Prohibits system from enabling
inverter #1 drive signal.
INV2 Disable Prohibits system from enabling
inverter #2 drive signal.
Engspd/RP Raises engine speed to account for a
possible stuck RP contactor. Closes
RP1
None No restrictions. Event is for informa-
tion purposes only.
000 NO FAULT None Displayed when all faults have been reset.
002 GROUND FAULT No power A ground fault is detected if leakage current to ground
(truck chassis) exceeds 145 mA for more than 0.05 sec-
onds.
003 FAILED DIODE No power Shorted diodes in main rectifier.
004 GFCO OPEN and not in REST None GF Cutout Switch is open with the system not in REST.
005 DRIVE SYSTEM OVERTEMP Temperature exceeds a limit for a sufficient time.
:01 auxiliary phase control Temperature exceeds a limit for a sufficient time.
:02 auxiliary inverter Temperature exceeds a limit for a sufficient time.
:03 afse Temperature exceeds a limit for a sufficient time.
:04 alternator Temperature exceeds a limit for a sufficient time.
:05 left stator Temperature exceeds a limit for a sufficient time.
:06 left rotor Temperature exceeds a limit for a sufficient time.
No Propel
:07 right stator Temperature exceeds a limit for a sufficient time.
:08 right rotor Temperature exceeds a limit for a sufficient time.
:09 chopper GTO Temperature exceeds a limit for a sufficient time.
:10 chopper diode Temperature exceeds a limit for a sufficient time.
:11 left GTO module Temperature exceeds a limit for a sufficient time.
:12 left diode Temperature exceeds a limit for a sufficient time.
:13 right GTO module Temperature exceeds a limit for a sufficient time.
:14 right diode Temperature exceeds a limit for a sufficient time.
:15 rectifier diode Temperature exceeds a limit for a sufficient time.
006 BOTH INVERTERS COMMUNICATION FAILED No power Lost Communication with both inverters.
008 DC LINK OVERVOLTAGE DC link voltage exceeds limit for a sufficient time.
:01 not in retard Occurs while not in retard, exceeds propel voltage limit.
No power
:02 in retard Occurs while in retard, exceeds retard voltage limit.
:03 instantaneous Occurs instantaneously in propel or retard, exceeds link
voltage limit.
009 ALT FIELD OVERCURRENT Alternator field current exceeds limit.
No power
:01 normal Exceeds current limit over time.
:02 instantaneous Exceeds current limit with no persistence.
011 RETARD LEVER BAD Incorrect input from retard lever.
None
:01 voltage too high Incorrect input from retard lever.
:02 voltage too low Incorrect input from retard lever.
012 RETARD PEDAL BAD Incorrect input from retard pedal.
:01 voltage too high None Incorrect input from retard pedal.
:02 voltage too low Incorrect input from retard pedal.
013 LINKV TEST FAILED No power Incorrect link volts
014 ANALOG SENSOR FAULT Incorrect input from a sensor.
:01 alt field amps Incorrect input from a sensor.
:02 link amps Incorrect input from a sensor.
:03 load box amps Incorrect input from a sensor.
:04 3 phase alt volts Incorrect input from a sensor.
:05 alt field volts Incorrect input from a sensor.
:10 PSC link volts Incorrect input from a sensor.
Speed limit
:11 inv1 link volts Incorrect input from a sensor.
:12 inv2 link volts Incorrect input from a sensor.
:13 A2D ground Incorrect input from a sensor.
:14 A2D gain Incorrect input from a sensor.
:15 fault current Incorrect input from a sensor.
:16 ATOC Incorrect input from a sensor.
:21 blower 1 amps Incorrect input from a sensor.
:22 blower 2 amps Incorrect input from a sensor.
015 ANALOG SENSOR FAULT (resrtictive) Speed limit Incorrect input from a sensor.
:02 link amps Incorrect input from a sensor.
016 PSC CPU CARD (FB147) Problem has occurred in the system CPU card.
:01 task_1
:02 task_2
:03 task_3
:04 task_4
:05 task_5 No power
:06 task_6
:07 maintenance task
:09 BRAM CRC CRC on BRAM does not match expected value.
:10 flash CRC Flash CRC computation did not match expected value.
:11 excess timeouts On power up, excessive timeouts occurred.
:12 invalid pointers On power up, the status of data in BBRAM is invalid.
017 DIGITAL I/O CARD FAULT (FB104) No power System CPU cannot communicate with digital I/O card.
018 ANALOG I/O CARD FAULT (FB143) System CPU cannot communicate with analog I/O card.
No power
:01 analog card no response Card missing.
:02 analog card timeout Read timeout.
019 RIDING RETARD PEDAL None Brake pedal applied while truck speed is >5 mph
020 LO SPEED HI TORQUE TIMEOUT No propel Torque limit exceeded
021 TCI COMM. FAULT No propel No serial data received from TCI over period of time.
022 PERSISTENT TCI COMM FAULT No power No serial data received from TCI and truck is stopped for
10 seconds.
023 TERTIARY OVERCURRENT No propel Current in alternator field tertiary winding exceeds limit
over time.
024 PSC CONFIG FILE INCORRECT Incorrect PSC configuration file.
:01 no file No configuration file selected
:02 bad CRC No power
:03 wrong version Wrong configuration file version
:04 overspeeds incorrect Incorrect overspeed values
025 AUX INVERTER FAULT Auxiliary Blower System fault.
:01 not ok or no speed feedback Aux speed feedback indicates no or incorrect blower
No power
speed.
:02 numerous shutdowns Aux ok goes low twice when speed command is greater
than running speed.
103/203 (cont.)
:21 link V too hi Link voltage too positive
:22 infilV too hi Input filter voltage too positive
:23 DB chop VCO hi High freq. on VCO DB chopper channel
:24 DB chopV too hi DB chopper voltage too positive
:25 VA VCO hi High freq. on VCO VA channel
:26 VB VCO hi None High freq. on VCO VB channel
:27 VC VCO hi High freq. on VCO VC channel
:28 VA volts too hi VA voltage too positive
:29 VB volts too hi VB voltage too positive
:30 volt scale C flt Scale C volts out of range 70%, 120%
:31 VC volts too hi VC voltage too positive
104/204 FIBER OPTIC CARD
:01 fo ps low Fiber optic power supply monitor
INV1 (INV2) off
:02 fo card disable Fiber optic card disabled
:03 fo card enable Fiber optic card enabled and no dir
105/205 POWER SUPPLY CARD
:01 P5V not ok +5 volt not in tolerance
:02 P15V not ok INV1 (INV2) off +15 volt not in tolerance
:03 N15V not ok -15 volt not in tolerance
:06 P24V not ok +24 volt not in tolerance
:07 N24V not ok -24 volt not in tolerance
106/206 DC WIRING
INV1 (INV2) off
:01 DC pwr conn open DC power connection open
:02 link V phase V mismatch Link and phase voltage mismatch
107/207 GDPS FAILURE
:01 gate dr ps off No power to gate drive power supply or it failed
INV1 (INV2) off
:02 gate dr ps off S No power to gate drive power supply or it failed with
enable/DC volts
:03 multiple GTO not off S Multiple GTOs not off with enable/DC volts
109/209 LINK VOLTS SENSOR
:01 linkV sensor flt INV1 (INV2) off Link voltage sensor failed
111/211 INPUT VOLTS SENSOR
INV1 (INV2) off
:01 Vfil not ok Filter voltage outside limits
113/213 (cont.)
:29 C volt hi Adn Phase C volt too high while phase A down on
:30 C volt lo Aup Phase C volt too low while phase A up on
:31 C volt hi Bdn Phase C volt too high while phase B down on
:32 C volt lo Bup Phase C volt too low while phase B up on
:33 C volt hi Cdn Phase C volt too high while phase C down on
:34 C volt lo Cup Phase C volt too low while phase C up on
:35 Aup fault cur Phase A fault current when phase A up on
:36 Adn fault cur Phase A fault current when phase A down on
:37 Bup fault cur Phase B fault current when phase B up on
:38 Bdn fault cur Phase B fault current when phase B down on
:39 Cup fault cur Phase C fault current when phase C up on
INV1 (INV2) off
:40 Cdn fault cur Phase C fault current when phase C down on
:48 A volt hi off Phase A voltage high with all GTOs off
:49 A volt lo off Phase A voltage low with all GTOs off
:50 B volt hi off Phase B voltage high with all GTOs off
:51 B volt lo off Phase B voltage high with all GTOs off
:52 C volt hi off Phase C voltage high with all GTOs off
:53 C volt lo off Phase C voltage high with all GTOs off
:54 phase short pos Possible phase to DC+ short
:55 phase short neg Possible phase to DC- short
:60 linkV too hi PTL Link volts above PTL
:70 Aph neg I low Phase A negative current low (unbalance)
:71 Bph neg I low Phase B negative current low (unbalance)
113/213 (cont.)
:72 Cph neg I low Phase C negative current low (unbalance)
:73 Aph neg I hi Phase A negative current high (unbalance)
:74 Bph neg I hi Phase B negative current high (unbalance)
:75 Cph neg I hi Phase C negative current high (unbalance)
:76 Aph pos I low Phase A positive current low (unbalance)
INV1 (INV2) off
:77 Bph pos I low Phase B positive current low (unbalance)
:78 Cph pos I low Phase C positive current low (unbalance)
:79 Aph pos I hi Phase A positive current high (unbalance)
:80 Bph pos I hi Phase B positive current high (unbalance)
:81 Cph pos I hi Phase C positive current high (unbalance)
:82 no current w run No current while running
114/214 INVERTER, GENERAL (NR)
:22 IA VCO lo Low frequency on IA channel
:24 IB VCO lo Low frequency on IB channel
:26 linkV VCO lo Low frequency on VCO link filter V channel
:28 infilV VCO lo Low frequency on VCO in filter V channel
:38 LinkV too lo Link voltage too negative
:40 infilV too lo Input filter voltage too positive
None
:46 DB chop VCO lo Low frequency on VCO DB chopper channel
:48 DB chopV too lo DB chopper voltage too negative
:50 VA VCO lo Low frequency on VCO VA channel
:52 VB VCO lo Low frequency on VCO VB channel
:54 VC VCO lo Low frequency on VCO VC channel
:56 VA volts too lo VA voltage too negative
:58 VB volts too lo VB voltage too negative
:61 VC volts too lo VC voltage too negative
624 BODY UP AND PAYLOAD INDICATION Speed Limit Full payload and body up signal received at same time.
625 DUMP BODY UP WITH SPEED None Dump body raised while truck is moving.
626 LOAD BRAKE APPLIED WITH SPEED None
628 CONNECTED BATTERY VOLTS One of the connected batteries' volts incorrect with engine
speed above low idle.
:01 control battery low Control battery voltage below minimum limit
None
:02 control battery high Control battery voltage above maximum limit.
:03 crank battery low Cranking battery voltage below minimum limit.
:04 crank battery high Cranking battery voltage above maximum limit.
629 BAROMETRIC PRESSURE SIGNAL Barometric pressure signal outside operational limits.
:01 low None Voltage below minimum operational limit.
:02 high Voltage above maximum operational limit.
630 MOTOR BLOWER PRESSURE Motor inlet and outlet pressure signal outside operational
limits.
:01 no cooling air No voltage signal feedback
Speed Limit
:02 low Voltage feedback below minimum operational limit.
:03 high voltage Voltage above maximum operational limit.
:04 sensor reversed
631 AMBIENT TEMPERATURE Ambient temperature signal outside operational limits.
None
:02 high Voltage above maximum operational limit.
632 TCI CONFIGURATION DATA No propel Problem with TCI configuration file.
:01 no file No propel No configuration file loaded.
:02 bad CRC No propel
:03 version incorrect No propel Wrong version of file loaded.
633 BBRAM CORRUPTED None Battery backed RAM has failed.
634 TRUCK OVERLOADED - RESTRICTIVE Speed limit The over-payload signal is on, speed is reduced.
635 TRUCK OVERLOADED - NON-RESTRICTIVE None The over-payload signal is on, propulsion allowed.
636 AUX INVERTER None An Auxiliary Blower Control failure has occurred.
:01 buss volts low None Low dc bus detected during powerup.
:02 buss volts high None High dc bus detected during powerup.
:03 overcurrent None Overcurrent condition detected during operation.
:04 battery loss None Loss of blower control battery voltage has occured.
:05 high dc buss when running None High dc bus voltage detected during operation.
:06 high dc buss after pc powerup None High dc bus voltage detected after phase controller
powerup.
:07 Low dc buss after pc powerup None Low dc bus voltage detected after phase controller
powerup.
:08 high dc buss when running None High dc bus voltage detected during operation.
:09 overcurrent after pc powerup, current overload None Overcurrent condition detected after phase controller
power up.
:10 current overload None Sustained current overload exists.
:11 low dc buss overcurrent None Overcurrent due to low dc bus voltage.
:12 low dc buss current overload None Sustained current overload due to low dc bus voltage.
:13 gate drive trip None IGBT protection circuit detected overload.
:14 no input voltage None Zero input voltage detected.
638 ENGINE CRANKING TIMEOUT None
639 ENGINE START REQUEST WHILE RUNNING None
640 ACCEL PEDAL TOO HIGH No Propel Accelerator pedal voltage high
641 ACCEL PEDAL TOO LOW None Accelerator pedal voltage low
642 ENGINE STARTED USING OVERRIDE None
696 UNEXPECTED TCI CPU RESET None TCI CPU reset without request.
698 DATA STORE None A data snapshot has been manually initiated.
Ready State:
STATE MANAGEMENT Ready state is the default powered state. The system
will be in this state whenever the engine and control
State Machine system are ready to provide power, but none is
As part of the total software package, a particular requested.
group of regulatory software commands is included Ready state also is the state where the DC link is dis-
called a "state machine". The state machine controls charged in preparation for Shutdown, Rest, or in
the various functions of truck operation. reaction to certain event conditions. Therefore,
The software implements the state machine by keep- Ready state should not be considered strictly a pow-
ing track of which state the truck is in, and which ered state (as are Propel and Retard described
state the truck is allowed to move into if the operator below).
requests a different mode of operation. Each soft-
ware state is defined as follows:
Rest State:
Rest is an unpowered state whose purpose is to con-
Startup/Shutdown State: serve fuel while the truck idles for an extended period
The purpose of this state is to ensure the system is in of time. Rest state also provides an environment
a desired known state upon startup or shutdown. where maintenance personnel can control the engine
This is an unpowered state. without causing power to be applied to the DC link.
The system will transition from Rest state to Test 1. Overspeed is not active.
state upon release of the TCI rest request. 2. At least one of the following conditions is true:
NOTE: A transition directly from Rest state to Ready a. The retard pedal or lever is not pressed or is
state is not allowed because the system is essentially pressed such that an insignificant amount of
off and should be brought back on-line and checked retarding effort is requested.
out before Ready state is entered. b. Truck speed is such that retard is not
allowed.
Transition from Propel State to Ready State: 3. At least one of the following conditions exists:
The system will transition from Propel state to Ready a. Retard speed control is not selected.
state if all of the following conditions exist: b. Truck speed is low enough such that retard
1. The accel pedal is not pressed. speed control is not active.
2. The retard pedal or lever is not pressed or is c. The accel pedal is pressed, and the truck is
pressed such that an insignificant amount of configured such that the accel pedal over-
retarding effort is requested. rides retard speed control. This allows the
3. Truck speed is less than the motor overspeed configuration constant to determine if press-
limit. ing on the accel pedal kicks the truck out of
retard, even if retard speed control is still
4. At least one of the following conditions is true:
active.
a. Retard speed control is not selected.
4. The retard torque control logic exit sequence is
b. Truck speed is below the set retard speed, complete.
and acceleration is such that no retard effort
is (currently) required to maintain this condi-
tion.
The Auxiliary Blower Control regulates the tempera- Three power-on tests are executed once every time
tures of the AFSE, auxiliary blower system, rectifier power is applied to the PSC. They are as follows:
diodes, phase modules, chopper modules, and trac- 1. CPU Card Checks - Upon powerup, the PSC
tion motors by controlling the speed of the auxiliary will confirm the integrity of its CPU card hard-
blower. Additionally, this software function checks for ware before transferring execution control to
faults in the auxiliary blower. the application program residing in its FLASH
This software function is performed using the follow- memory.
ing process: 2. Battery-backed RAM (BBRAM) Test/Adjustable
Parameter Initialization - A battery backed RAM
1. The commanded auxiliary blower speed will be
(BBRAM) check will be performed to check for
calculated to control all system temperatures.
BBRAM data integrity. If the check fails, all TCI/
The control priorities will be:
PTU-adjustable parameters will be initialized to
a. Keep all temperatures below allowable maxi- their default values.
mums. 3. Inverter Powerup Tests - The purpose of these
b. Keep the GTO temperatures as constant as tests is to verify that each inverter sub-system is
possible. functional:
2. If the aux blower system status (AUXOK) indi- a. Enabling Inverter Powerup Tests - The pow-
cates the aux blower system is not okay, a reset erup tests for a given inverter will be enabled
pulse will be sent. Additional reset pulses will be if all of the following conditions are true:
sent at periodic intervals if the aux blower sys-
tem does not respond. 1.) The system is in Test state for the purpose
of powerup.
4. DC Link Capacitance Test - Test will run once NOTE. Limp Home mode is a state which is entered
every 24 hours when conditions allow, normally when the truck has suffered a failure and is not able
after a VI-test during normal powerup to continue normal operation but is still capable of
sequence. This test can also be run from the "limping" (getting either back to the maintenance
DID panel to aid in troubleshooting. During test area or at least out of the way of other trucks).
execution, engine speed is set to 1500 rpm and Event Restrictions associated with a given event are
the link is charged to 1200VDC. The engine is listed in Table I, page E2-5.
then returned to idle while the link is allowed to
discharge to 100 volts.Total link capacitance is
then calculated using the time it took to dis-
charge. If capacitance is getting low, but still
OK, event 70 logs. If capacitance is below the
EVENT LOGGING AND STORAGE
minimum allowable level, event 71 logs and the
truck is restricted to 10 MPH. If test is not able This software function is responsible for the record-
to complete after numerous attempts, event 72 ing of event information. There are two basic levels
logs, indicating a problem in the truck's ground of event storage: event history buffer and data packs.
detection circuit, and truck speed is limited to 10 The event history buffer provides a minimum set of
MPH. information for a large number of events, while data
packs provide extensive information for a limited
number of events.
The following requirements apply to both data packs
and the event history buffer:
The following Tables list component abbreviations The GE part number for major components is shown
used in schematics and system description informa- in parentheses. A short description of the compo-
tion. Refer to Figures 2-3 through 2-8 for the location nent's primary function is also listed.
on the truck of components listed in the "Ref. No."
column.
REF.
NO. COMPONENT FUNCTION
AFSE 36 Alternator Field Static Exciter Panel Regulates current in the alternator field based on firing
(17FM466) pulses from the PSC.
Alternator Field Voltage Divider Attenuates high voltage output from the AFSE to an
AFVLT 21 Panel (17FM363) acceptable level for use by the Analog I/O card in the
PSC.
ALT Alternator (5GTA34) Main alternator, propulsion and control system.
ANALOG I/O CARD System analog input/output card Provides signal conditioning for analog signals to and
(17FB143) from the TCI and PSC.
REF.
NO. COMPONENT FUNCTION
BATFU 19 System Fuse Provides overload protection for control equipment and
the System Batteries.
BATTSW Battery Disconnect Switch Connects and disconnects the 12 VDC and 24 VDC cir-
(System Batteries) cuit batteries (located at right front corner of truck).
BDI 68 Battery Blocking Diode Works in conjunction with BFC and BLFP to maintain
battery voltage to CPU.
BFC 67 Battery Line Filter Capacitor Additional capacitance for BLFP to prevent nuisance
CPU resets.
BLFP 10 Battery Line Filter Panel Reduces voltage ripples in System Battery power sup-
(17FM311) plied to the PSC.
BM1, 2 63 Grid Blower Motors 1 and 2 DC motors driving blowers to provide cooling air for the
(5GY19) retarding grids.
BM1I 65 Current Sensing Module Monitors current flowing through grid blower motor #1
BM2I 66 Current Sensing Module Monitors current flowing through grid blower motor #2
CCLR1, 2 20 Capacitor Charge Resistor Panels Connected across the DC link to provide a voltage atten-
1 and 2 uated sample of the DC link voltage to the Capacitor
Charge Indicating lights.
CCL1, 2 61 Capacitor Charge Indicating Lights Illuminated when 50 volts or more is present on the DC
1 and 2 link (the DC bus connecting the Alternator output, Chop-
per Module/Resistor Grid circuits and traction Inverters).
CIF11, 12, 13, 14, 40 Inverter 1 Filter Capacitors Stores the Inverter 1 DC bus voltage to provide instanta-
15, 16 neous power when the PM1 GTO Phase Modules first
turn on.
CIF, 21, 22, 23, 24, 41 Inverter 2 Filter Capacitors Stores the Inverter 2 DC bus voltage to provide instanta-
25, 26 neous power when the PM2 GTO Phase Modules first
turn on.
CLSW 59 Cabinet Light Switch Controls electrical cabinet interior lights.
CMAF 27 Alternator Field Current Sensing Detects amount of current flowing through the Alternator
Module field winding.
CMT 28 Alternator Tertiary Current Sensing Detects amount of current flowing through the Alternator
Module tertiary winding.
CM1, 2 5, 6 Chopper GTO Phase Module 1 and Controls the DC voltage applied to the grids during
2 (17FM630) retarding.
CM1A, 1B 45 Current Sensing Modules, Phase Detects amount of current flow through the A and B
1A and 1B phases of Traction Motor 1.
CM2A, 2B 44 Current Sensing Modules, Phase Detects amount of current flow through the A and B
2A and 2B phases of Traction Motor 2.
CPR 53 Control Power Relay (17LV66) Picks up when the Key Switch and Control Power Switch
are closed.
CPRD Dual Diode Module Allows two separate voltages to control the CPR coil.
CPRS Control Power Relay Suppression Suppresses voltage spike when CPR coil is de-ener-
Module gized.
REF.
NO. COMPONENT FUNCTION
Detects amount of current flow through the Alternator ter-
CT 34 Battery Boost Current Transformer tiary winding. Signal turns off the AFSE battery circuit
when the tertiary winding voltage level is able to excite
the Alternator field.
CTR CT Voltage Limiting Resistor Provides a resistive load for the CT.
GDFU1, 2 1 Gate Driver Power Source Fuse 1 Provide overload protection for the Gate Drive Power
and 2 Supply.
GDPC1 17 Gate Drive Power Converter 1 Converts 19 to 95 VDC from the Gate Drive Power Sup-
(17FM670) ply to 25 kHz, 100 VRMS, square wave power to drive
Inverter 1 GTO Phase and Chopper Modules.
GDPC2 16 Gate Drive Power Converter 2 Converts 19 to 95 VDC from the Gate Drive Power Sup-
(17FM670) ply to 25 kHz, 100 VRMS, square wave power to drive
Inverter 2 GTO Phase and Chopper Modules.
GDPS 18 Gate Drive Power Supply Provides a 19 to 95 VDC output, at approximately 3kW,
(17FM645) from one of two input power sources; either the main
Alternator or the System Batteries.
GF 49 Alternator Field Contactor Connects the AFSE to the Alternator field.
(17CM53)
GFCO 62 Generator Field Contactor Cutout Disables Alternator output.
Switch
GFIP 22 Ground Fault Current Panel Reduces Alternator field voltage input to provide a low
(17FM363) voltage signal for use by the PSC. Used to provide
ground fault warning.
GFM 8 Gate Firing Module (17FM415) Receives pulses from the Analog I/O card in the PSC,
amplifies the pulses, and then splits the pulses to drive
two SCR circuits in the AFSE.
REF.
NO. COMPONENT FUNCTION
GFR 52 Alternator Field Relay (17LV66) Picks up with GF contactor and applies B+ to the AFSE
(battery boost) during initial acceleration phase.
GFRS 50 Alternator Field Relay Coil Sup- Suppresses voltage spikes when GF coil is de-ener-
pression Module gized.
Inverter 1 Central Processing Unit Generates Phase Module turn-on/turn-off commands for
INV1 TMC CARD Card and Input/Output Card the Inverter 1.
Monitors voltages and currents from various areas for
(17FB172) Inverter 1. Monitors Traction Motor 1 speed.
Inverter 2 Central Processing Unit Generates Phase Module turn-on/turn-off commands for
INV2 TMC CARD Card and Input/Output Card the Inverter 2.
Monitors voltages and currents from various areas for
(17FB172) Inverter 2. Monitors Traction Motor 2 speed.
I1CO 57 Inverter 1 Cut Out Switch Cuts out inverter 1 when in the "cutout" position. Located
on switch/LED panel, left front corner of electrical cabi-
net.
I2CO 58 Inverter 2 Cut Out Switch Cuts out inverter 2 when in the "cutout" position. Located
on switch/LED panel, left front corner of electrical cabi-
net.
KEYSW Key Switch Connects battery voltage to CPR and control circuits
when closed. (Located on instrument panel.)
LDBXI 48 Load Box Current Sensing Module Monitors current during load box test.
LED's indicate status of the following:
CPR: Illuminated when CPR is energized.
SYS RUN: Illuminated when the PSC power-up
sequence has completed successfully and control logic
LEDP 60 Light Emitting Diode Panel is executing.
NAFLT: When illuminated, indicates a fault has occurred
that prevents propulsion or retarding.
TEST: Illuminated when system is in the Test state.
REST: Illuminated when system is in Rest state and there
is essentially no voltage on the DC link.
LINKI 7 Link Current Sensing Module Detects amount of current flow through the DC link.
LINKV 3 Link Voltage Measuring Module Attenuates the high voltage from the DC link to a level
(17FM458) acceptable to the electronics on the Analog I/O card in
the PSC.
L1, 2, 3 Cabinet Lights Provide interior cabinet illumination.
REF.
NO. COMPONENT FUNCTION
PSC 32 Propulsion System Controller The PSC is the main controller for the AC drive system.
(17FL320) All propulsion and retarding functions are controlled by
the PSC based on internally stored software instructions.
PM1A+, 1B+, 1C+ 13 GTO Phase Modules (17FM628) Provide positive driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 1.
PM1A-, 1B-, 1C- 12 GTO Phase Modules (17FM629) Provide negative driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 1.
PM2A+, 2B+, 2C+ 15 GTO Phase Modules (17FM628) Provide positive driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 2.
PM2A-, 2B-, 2C- 14 GTO Phase Modules (17FM629) Provide negative driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 2.
RD 2 Rectifier Diode Panel (17FM528) Converts Alternator 3-phase, AC voltage to DC voltage to
power the two Inverters.
RG1A, 1B, 1C, 2A,
2B, 2C, 3A, 3B, 3C, 64 Retard Grid Resistors Dissipate power from the DC link during retarding, load
box testing, and Inverter Filter Capacitor discharge oper-
4A, 4B, 4C, 5A, 5B, ations.
5C
When closed, connects Grid Resistors to the DC link dur-
RP1, 2, 3 47 Retard Contactors 1, 2 and 3 ing retarding, load box testing, and Inverter Filter dis-
charge operations.
(17CM55) Note: Some trucks do not have RP3 installed.
RP1S, 2S, 3S 55 Suppression Modules Suppresses voltage spikes in coil circuit when RP con-
tactors are de-energized.
RSN1, 2 Snubber Resistors Provide a current path for the associated Chopper Mod-
ule filter capacitors.
RS1A, 1B, 1C, 2A, Snubber Resistors Provide a current path for the associated Phase Module
2B, 2C filter capacitors.
R1 51 Battery Boost Resistor Limits surge current in the Alternator field circuit when
GFR contacts first close.
AUX SNUB 25 Snubber Suppresses voltage spikes in Aux Blower Motor circuit.
REF.
NO. COMPONENT FUNCTION
TCI Truck Control Interface Provides the main interface between the various truck
(17FL349 or 17FL373) systems, controls, and equipment and is used in con-
junction with the DID by maintenance personnel.
TH1 54 Alternator Field Thyrite (Varistor) Discharges the Alternator field when the AFSE is first
turned off.
VAM1 46 Voltage Attenuation Module Attenuates the three high voltage outputs applied to each
(17FM702) phase winding of Traction Motor 1 to a level acceptable
for use by the Analog I/O card in the PSC.
VAM2 46 Voltage Attenuation Module Attenuates the three high voltage outputs applied to each
(17FM702) phase winding of Traction Motor 2 to a level acceptable
for use by the Analog I/O card in the PSC.
Battery and Control Checks of System WITH Battery Power OFF. . . . . . . . . . . . . . . . . . . . . . E3-6
Battery and Control Circuit Checks of System With Battery Power ON . . . . . . . . . . . . . . . . . . E3-9
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-36
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-43
DANGEROUS VOLTAGE LEVELS ARE PRESENT • If weld repairs are required, the welding
WHEN THE ENGINE IS RUNNING AND CONTINUE ground electrode should be attached as close
TO EXIST AFTER SHUTDOWN IF THE REQUIRED as possible to the area to be welded. NEVER
SHUTDOWN PROCEDURES ARE NOT FOLLOWED. weld on the rear of the Electrical Control Cabi-
Before attempting repairs or working near propul- net or the retard grid exhaust air louvers.
sion system components, the following precau- Power cables and wiring harnesses should be
tions and truck shutdown procedure must be protected from weld spatter and heat.
followed:
• Prior to welding, disconnect Engine Control
• DO NOT step on or use any power cable as a System (ECS) harnesses and ground wire
handhold when the engine is running. (MTU engine). If equipped with DDEC or
Komatsu engine, disconnect ECM harnesses.
• NEVER open any electrical cabinet covers or GE cards should be pulled forward far enough
touch the Retarding Grid elements until all to disconnect card from backplane connector.
shutdown procedures have been completed.
• Some power cable panels throughout the
• ALL removal, repairs and installation of pro- truck are made of aluminum or stainless steel.
pulsion system electrical components, cables They must be repaired with the same material
etc. must be performed by an electrical main- or the power cables may be damaged.
tenance technician properly trained to service
the system.
APPROX.
CIRCUIT LOCATION NOTES
VALUE
11B1 * ∞ * Measure at the 12VDC insulator in the Electrical Interface Cabinet
*Measure at the 24VDC insulator in the Electrical Interface Cabinet.
11 * ∞
All devices listed for 11A circuit reading must be OFF.
15V TB21 ∞
71GE TB22 120Ω
71TCI TB23 120Ω 17FL349 Panel Only (Not applicable on 17FL373 Panel.)
439 TB25 ∞
10V TB28 ∞
11SL TB28 ∞ Engine service lights turned OFF.
11ST TB28 ∞
15PV TB29 ∞
11S TB30 ∞ Ground level engine shutdown switch open
The following must be turned OFF:
Brake cabinet service light, operator cab light, passenger seat com-
11A TB30 ∞ partment service light, hazard lights, headlights, ground level engine
shutdown switch, engine governor heater switch (MTU 396 only - in
Electrical Interface Cabinet), left and right side engine service lights.
Engine governor heater switch in Electrical Interface Cabinet open.
11T TB30 >36Ω
(MTU 396 engine only)
11FR TB30 ∞ (MTU 396 engine only)
11HTR TB30 ∞ (MTU 396 engine only)
712 TB32 ∞ The Electrical Interface Cabinet service lights must be switched OFF.
71 TB32 ∞
11L CB30 ∞ Measure at circuit breaker CB30 in cab.
12M ∗ >10Ω *Measure at AID Module terminal B-13 under passenger seat in cab.
12F ∗ >200Ω *Measure at AID Module terminal B-12 under passenger seat in cab.
BE SURE TO VERIFY LINK VOLTAGE IS DIS- BE SURE TO VERIFY LINK VOLTAGE IS DIS-
CHARGED BEFORE PERFORMING THE FOLLOW- CHARGED BEFORE PERFORMING THE FOLLOW-
ING PROCEDURES. ING PROCEDURES.
1. Disconnect Circuits 21SS and 21SR, and insulate 1. Disconnect Circuits 21SS and 21SR and insulate
from engine starter if equipped with MTU 396 from engine starter if equipped with MTU 396
engine. If MTU/DDC 16V4000 or Komatsu engine engine. If MTU/DDC 16V4000 or Komatsu engine
is installed, disconnect and insulate 21B circuits is installed, disconnect and insulate circuit 21B at
at starter solenoids. Apply park brake and brake the starter solenoids. Apply park brake and brake
lock. lock.
a. Connect the serial communication cable from a. Connect the serial communication cable from
the PTU to the TCI port located behind the the PTU to the PSC port located behind the
center console in the cab on the passenger center console in the cab on the operator’s
side. side.
b. Be certain the Rest Switch in the cab is in the b. Be certain the Rest Switch in the cab is in the
REST position. REST position.
2. Turn the key switch ON. 2. Turn the Key Switch ON.
To program the 17FB144 CPU card: To program the 17FB147 CPU card:
Highlight “PROGRAM TCI PANEL” {enter} Highlight “PROGRAM PSC PANEL” {enter}
Cursor to the appropriate configuration file for Cursor to the appropriate configuration file for
the truck being programmed from the list of con- the truck being programmed from the list of con-
figuration files {enter} figuration files {enter}
3. Cycle keyswitch or CPS when requested on 3. Cycle keyswitch or CPS when requested on
screen. screen.
4. Verify the Object Code and Configuration file 4. verify the Object Code and Configuration file
shown on the screen for downloading is correct. shown on the screen for downloading is correct.
BE SURE TO VERIFY LINK VOLTAGE IS DIS- BE SURE TO VERIFY LINK VOLTAGE IS DIS-
CHARGED AND ENGINE IS NOT RUNNING CHARGED BEFORE PERFORMING THE FOLLOW-
BEFORE PERFORMING THE FOLLOWING PROCE- ING PROCEDURES.
DURES.
1. Disconnect Circuits 21SS and 21SR, and insulate
1. Open the right door on the Electrical Control Cab- from engine starter if equipped with MTU 396
inet and connect the serial communication cable engine. If MTU/DDC 16V4000 or Komatsu engine
from the PTU to one of the two ports located to is installed, disconnect and insulate 21B circuits
the right of the PSC Panel. (RS11 is used for the at starter solenoids. Apply park brake and brake
inverter card in slot No. 09, RS12 is used for the lock.
inverter card in slot No. 11.)
Log on to the TCI panel:
To program the Inverters:
2. Connect the serial communication cable from the
PTU to the TCI port located behind the center
c:\>ACNMENU {enter}
console in the cab on the passenger seat side.
Highlight “PROGRAM INVERTERS” {enter} Turn control power ON.
Cursor to “TCI Real Time Data” {enter} Verify the PTU is communicating on this screen
by observing a blinking cursor on the screen.
Verify PTU display indicates:
• COMMLINK=OK {escape} {escape}
{escape} {escape}
Notes: Only 4 command numbers are supported
On the PSC PTU: through this port.
When the PTU starts, it sends out 3 or 4 commands
Move the cursor to “Normal Operation” {enter} that the TCI will not respond correctly to. At the top TCI
screen, press the space key a number of times when
Cursor to “PSC Real Time Data” {enter} the screen indicates a mismatch until reaching the Real
Time Data screen.
Verify PTU display indicates:
• COMMLINK=OK
{escape} {escape}
1. Verify analog values and functions highlighted on the PTU are similar to the examples below:
Note: Actual values shown in illustrations will vary from those displayed on truck being serviced:
2. Press {enter} to display “TCI SERIAL LINK DATA” screen shown below:
LOCATION
STEP DO NAME DESCRIPTION
(Fig. 3-3)
1 RESTLT Rest Light B6
2 PSCNOTRDY Propel System Not Ready Light C6
3 REDUCELT Reduced Propulsion Level Light D6
4 LINKONLT Link ON light, DID Panel (Behind Operator's Seat)
5 TEMPWARNLT Propulsion System Temperature Warning Light C5
6 NORETARDLT No Retard, No Propel Light A5
7 NOPROPELLT No Propel Light A6
8 PSCWARNLT PSC Warning Light B5
9 RTRDCONTLT Reduced Retarding Light E6
10 HYDBHOTLT Hydraulic Brake Fluid Hot Light D5
Verify park brake switch is applied:
11 PKBRKON Measure Circuit 52CS @ TB26 to ground: Verify 0.0 volts A3
Press {enter} to turn PKBRKON on: Verify approx. 24 volts
12 RETARDLT Retard Light (on overhead display) D3
13 RETARDXLT Retard light (on top of cab and rear of truck)
Battery Separate Relay
14 BATSEPC Measure Circuit 21BSR @ TB28 to ground
With BATSEPC highlighted, press {enter}: Verify 0.0 VDC
15 SPEED1 not used
16 SPEED2 not used
17 REVERSELT Activates backup horn and backup lights B4
Refer to TCI Digital Output Test procedure step 5. before performing the following test:
18 ENGCRANK Engine Crank Signal
13. Release the key switch. B2* Autolube Low Pressure Amber
C2* Circuit Breaker Tripped Amber
14. Apply parking brake.
D2* Hydraulic Oil Filter Restricted Amber
E2* Low Fuel Amber
A3* Park Brake Applied Amber
AUX ERROR CODE Check:
B3* Service Brake Applied Amber
1. With the PTU still on the TCI Real Time Data C3* Body Up Amber
screen, check the AUX_ERROR_CODE at the
D3* Dynamic Retarding Applied Amber
upper right of the screen:
E3 STOP ENGINE Red
Value should be blank or (001)
A4* Spare
Note: A Value of (-01) may indicate the TCI is not B4* Manual Back-Up Lights Amber
communicating with the aux inverter.
C4* 5 Minute Shutdown Timer Amber
D4* Retard Speed Control Amber
E4* CHECK ENGINE Amber
A5 No Propel/Retard Red
B5 Propulsion System Caution Amber
C5 Propulsion System Temp. Caution Amber
D5 High Brake/Hydraulic Oil Temp. Red
E5* STOP ENGINE (Komatsu engine only) Red
A6 No Propel Red
B6 Propulsion System at Rest Amber
C6 Propulsion System Not Ready Amber
D6 Propel System at Reduced Level Amber
E6 Retard System at Reduced Level Amber
8. Press {enter}. Verify PTU screen values are similar to Figure 3-6.
10. Press {enter}. Verify the values on the PTU are similar to Figure 3-8 below:
Cursor to “Engine Stopped Tasks” {enter} Cursor to “Engine Stopped Tasks” {enter}
Cursor to “Manual Test Mode” {enter} Cursor to “Manual Test Mode” {enter}
Highlight GD1E on the digital output section and Highlight GD2E on the digital output section and
press {enter}. press {enter}.
When performing the following procedures, never When performing the following procedures, never
look directly into the fiber optic light. Eye damage look directly into the fiber optic light. Eye damage
could result. could result.
18. Carefully remove the grey plug on the top of each 26. Carefully remove the grey plug on the top of each
Phase Module for Inverter 1. Phase Module for Inverter 2.
Without looking directly into the plug on each Without looking directly into the plug on each
Phase Module, verify that a red light is Phase Module, verify that a red light is
present. present.
19. Carefully remove the grey plug on the top of 27. Carefully remove the grey plug on the top of
Chopper Module 1. Chopper Module 2.
Without looking directly into the plug on Chop- Without looking directly into the plug on Chop-
per Module One, verify that a red light is per Module 2, verify that a red light is present.
present. 28. Reconnect plug on each Phase Module 2 for
20. For step 15 (GD2E) in the PSC Digital Output Test inverter 2 and Chopper Module 2.
Table, use an AC voltmeter to check for 90 to 100
volts AC between the pins on each round connec-
tor removed in step 3 (cable side) to Inverter 2
(bottom row).
21. Use an AC voltmeter to check for 90 to 100 volts
AC between the pins on the round connector on
the top of Chopper Module 2 (CM2 G-X) removed
in step 3.
Press {enter} to go to TCI Analog Input Chan- On TCI Communication Menu, cursor to Exit
nels screen {enter} {enter} to return to Main Menu.
From the Main Menu, highlight “DOWNLOAD 7. With Retard Speed Control knob pulled up and
PSC PANEL” {enter} the knob turned fully clockwise, verify the follow-
ing is displayed:
Highlight “SELECT PSC SETUP” {enter} RSCMPH = 37 (see note below)
Cursor to configuration desired {enter} Note: In step 7, truck configurations 07E and 13E will
indicate 31 (instead of 37) for 38.1 gear ratio.
Highlight “DOWNLOAD PSC PANEL” {enter}
3. Place the Rest Switch in the REST position. 4. Connect one serial communication cable from the
PTU to the PSC port.
4. Make sure the wheels are chocked, and the park
brake switch is ON. C:\>ACNMENU {enter}
5. Remove the locking bar from the right side of the Highlight “PTU TCI & PSC” {enter}
auxiliary blower behind the inspection cover.
Type your name {enter}
6. Install locks on the three front doors of the electri-
Type your password {enter}
cal cabinet. Also secure the 3 top covers.
Cursor to “Normal Operation” {enter}
Preload Checks
Cursor to “PSC Real Time Data” {enter}
Alternator Speed Sensor Check: 5. Verify the analog values and the functions high-
1. Connect an AC voltmeter to circuits 74X (TB22) lighted on the PTU are similar to Figure 3-10.
and 74Z (TB22). 6. Connect a second serial communication cable
2. Place the GF Cutout Switch in the CUTOUT posi- from the PTU to the TCI port.
tion (down). C:\>ACNMENU {enter}
3. With Rest Switch in the REST position, start the Highlight “PTU TCI & PSC” {enter}
engine and operate at low idle.
Verify approximately 4 VAC on the meter. Type your name {enter}
Verify tach (in cab) reads approximately 700 Type your password {enter}
RPM. Cursor to “Normal Operation” {enter}
4. Shut down the engine. Remove voltmeter. Cursor to “TCI Real Time Data” {enter}
Battery Boost Check: 7. Verify the analog values and the functions high-
lighted on the PTU are similar to Figure 3-11.
8. Start the engine.
9. Place the GF Cutout Switch in the NORMAL posi-
tion (up).
THE BATTERY BOOST CHECK MUST BE PER- 10. While observing the voltmeter installed in step 1,
FORMED EXACTLY AS DESCRIBED BELOW. FAIL- place the Rest Switch in the OFF position.
URE TO DO SO MAY RESULT IN SERIOUS INJURY. The voltmeter will momentarily show about 18
• The contactors in the cabinet with the R1 volts and then drop to zero
resistor may be energized with the engine run- 11. Place the Rest Switch in the ON position.
ning. DANGEROUS VOLTAGES ARE
12. Place the GF Cutout Switch in the CUTOUT posi-
PRESENT INSIDE THE CABINET.
tion.
• Engine must be OFF during setup prepara-
13. Shut down the engine.
tion.
• Rest switch in the cab must be in REST. 14. Verify ALL lights indicating link voltage are OFF.
• GF cutout switch must be in the CUTOUT 15. Remove the voltmeter and lock the cabinet door.
position, (down).
• ALL Link Voltage lights must be OFF.
5. Without touching them, check for air flow from the Press the {F2} key
grid blowers as follows:
Cursor to “record” and press {enter}
a. Increase engine RPM until two RP contactors
pickup. Type a filename and press {enter}
Hot air should be felt from one front section of
the grid.
b. Reduce RPM to idle and then increase RPM 11. Note the “ENGLOAD” value On the screen:
to pickup two RP contactors. If the value is 5 volts during load testing, load-
Hot air should be flowing from the other front ing is satisfactory.
section of the grid. If the value is below 5 volts, the electrical sys-
6. Warm-up engine with two RP contactors picked tem needs to remove horsepower loading.
up until the engine coolant temperature stabilizes. (This is an indication of a weak engine.)
7. Compare values displayed on the Loadbox Test If the value is above 5 volts, the electrical sys-
Screen with the sample screen in Figure 3-18. tem needs to load the engine more.(This is an
indication of a strong engine.)
8. Fully depress the accelerator pedal to pickup all
three RP contactors.
Note: Some trucks have RP1 & RP2 only
5ms/20ms = .25 X 10 = 2.5VDC If the GE drive system follows the signal and with
c. Verify circuit 0 is connected to ground. 5VDC the system can produce full power, but cannot
function normally, troubleshoot engine boost or fuel
d. If the signal “908M” is correct and the supply injection system.
voltage (15SIM) to the PVM is correct, but out-
put is incorrect, replace the PVM module.
2. Move cursor to the appropriate GD1E or GD2E To Remove the Phase Modules:
signal in the digital output area and turn it ON.
1. Open the battery disconnects to disconnect the
(GD1E turns on all Inverter 1 phase modules and
truck batteries.
chopper module 1. GD2E turns on all Inverter 2
phase modules and chopper module 2.) 2. Short out the DC link by installing jumpers from
(+) to (-) next to the AFSE and then to ground.
3. Disconnect the GRAY fiber optic cable on the
phase module or chopper module being checked. 3. Remove the front cabinet supports between the
doors.
4. Disconnect the fiber optic cables and the plug at
the top of each Phase Module. Tuck the removed
cables under the blue loom to protect the cables
In the following step, DO NOT look directly at the when the modules are pulled out.
red light. Eye damage could occur.
5. With a 15/16” inch socket, remove the four
4. There should be red light visible out of the GRAY mounting nuts on each Phase Module.
receptacle on the gate drive module.
6. Cut the tyrap by the capacitor on top of each
5. If there IS red light, the phase module or chopper Phase Module.
module is OK.
7. Partially pull out each Phase Module. Using a
6. If red light IS NOT visible, disconnect the round 7/16” inch socket, remove the snubber wire
power supply harness from the gate drive mod- behind the top capacitor.
ule.
8. Remove each Phase Module which weighs 65
7. Check the AC voltage in the two pins in the har- pounds (29.5 Kg). Mark each Module so that it
ness; There should be 100 VAC square wave on will be put back in the same location that it was
the harness. The actual reading on the VOM will removed from.
depend on the meter and how it is designed to
measure AC voltage. Most meters read less than
100 volts. Normally, there will either be proper
voltage on the harness or NO voltage at all on the
harness.
5. Remove the four screws holding the resistor to 5. Reconnect the fiber optic cables and the plug at
the base. (These screws have been installed and the top of each Phase Module.
retained with Loctite®, and will require extra force 6. Replace the front cabinet supports between the
to remove.) doors.
6. Remove the rubber grommet along with the resis- 7. Remove the ground jumpers from the DC link.
tor cables. 8. Close battery disconnect switches to reconnect
7. Remove the resistor from the base and remove the truck batteries.
and discard the gaskets.
Description: A low DC bus voltage was detected after Description: A high DC bus voltage was detected dur-
the phase controller power up sequence. ing operation.
1. Check the 3-phase input connections and fuses 1. Check Capacitor Bank and Controller connec-
F1 and F2. tions.
2. If no problem was found in step 1, use an ohm- 2. Check DC Sense connection (connector J13 to
meter to check for short circuits between AM101, IV+ (red wire) and IV- (black wire)).
AM201, and AM301 wires and between IV+ and
3. If problem still exists, replace controller.
IV-.
3. If no problem was found in step 1 or 2, replace
the controller.
Description: An overcurrent condition was detected Description: A sustained overload exists due to low
after the phase controller power up sequence. DC bus voltage.
1. Check Capacitor Bank and Controller connec- 1. Check the 3-phase input connections and fuses
tions. F1 and F2.
2. Verify the inductor connections match-up 2. Check Capacitor Bank and Controller connec-
(+ and -) from the Auxiliary Inverter and to the tions.
Auxiliary Capacitor bank (PH+ to IV+ and PH- to
3. After performing checks in step 1 and 2, attempt
IV-).
to restart.
3. If a problem was found and corrected in step 1 or 4. If problem still exists, replace the controller.
2, restart and check operation again.
4. If problem still exists, disconnect AM101, AM201
and AM301 wires connecting the Auxiliary
Inverter to the blower motor. Subcode 13:
5. Using an ohmmeter, check for shorts between Description: IGBT protection circuit detected an over-
blower motor cables and between blower motor current condition.
cables and chassis ground.
1. Disconnect AM101, AM201 and AM301 wires
6. Using an ohmmeter, check for shorts between connecting the Auxiliary Inverter to the blower
AM101, AM201 and AM301 wires and between motor.
IV+ and IV-.
2. Using an ohmmeter, check for shorts between
7. If no problem was found in above steps, replace blower motor cables and between blower motor
the Controller. cables and chassis ground.
3. Using an ohmmeter, check for shorts between
AM101, AM201 and AM301 wires and between
Subcode 10: IV+ and IV-.
4. If no problem was found in above steps, replace
Description: A sustained current overload exists that the Controller.
is below component safe operating range.
1. Verify the inductor connections match-up
(+ and -) from the Auxiliary Inverter and to the
Auxiliary Capacitor bank (PH+ to IV+ and PH- to Subcode 14:
IV-).
Description: Zero input voltage detected.
2. Check the blower fan for blockage or damage.
1. Check the 3-phase input connections and fuses
3. If no problem was found in step 1 or 2, the blower F1 and F2.
motor may be damaged.
2. If no problems were found in step 1, replace the
controller.
Subcode 11:
The Auxiliary Capacitor Panel remains charged for 9. Disconnect the blower motor cables from AM101,
at least 15 minutes after engine shutdown. Be cer- 201, & 301 (4) and megger the Aux Blower motor
tain LED’s D1 and D2 (4, Figure 3-22) are OFF and its wiring. Be sure to reconnect properly to
before working on Auxiliary Blower Control cir- assure proper rotation direction.
cuits. 10. Check the Gate Drive Power Supply AC input
fuses GDFU1 & 2 and replace if necessary.
The following items should be checked if an auxiliary
Inverter failure is suspected. 11. Disconnect the main rectifier Filter Panel wires
T103, T203, & T303 at the rectifier bus bars.
1. Observe the two LED’s on top of the Auxiliary Using an analog VOM on the ohms scale, mea-
Power Filter Capacitor Bank (AXCAP); Both sure between T103 & T203, between T203 &
LED’s should be ON (lit) when the Aux. Inverter is T303, and between T303 & T103. A capacitance
running and OFF after the circuit has discharged. deflection should show on each measurement.
2. Check for loose wires and check resistance 12. Disconnect the main rectifier from the circuits and
between the terminals on the Aux Snubber panel. perform a standard diode check with a VOM and
Measurements from 1 to AF1, 2 to AF2, & 3 to back-bias each diode with a 1000 volt megger.
AF3 should all be 0 ohms. Measurements from 1
to either AF2 or AF3 and similarly from 2 & 3 13. After all checks are made, and repairs completed
should be 2 ohms. if required, reconnect all wiring to their proper ter-
minals and reinstall fuses.
3. Check continuity from PH+ to INV+ and from PH-
to INV-. These circuits connect the Aux Phase
Control, Aux Inductor, Aux Capacitors, & Aux
Inverter. The resistance should be 0 ohms for
these two measurements to verify continuity
through the Aux Inductor.
4. Check the fuses on the Aux Capacitor panel.
(The fuses must be removed from the circuit to
check.)
5. Check for loose connections on all wires associ-
ated with the Aux Inverter circuits.
6. Check Aux Inverter Phase Control SCR’s (see
Table below). Measure between AC input termi-
nals 1, 2, & 3 and DC output terminals PH+ & PH-
A reading of less than 100 ohms indicates a
shorted SCR. Good SCR’s will measure more
than 100K ohms. Replace at least the connected
pair of SCR’s if one is shorted (preferably replace
all 6 SCR’s).
Measurement Points
INDEX
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Wheel Motor Mounting Flange 6. Inner Tire Inflation Hose 11. Double Spud
2. Inner Wheel Rim 7. Flanged Nut 12. Outer Tire Inflation Hose
3. Disc Brake Assembly 8. Adaptor Ring 13. Outer Wheel Rim
4. Wheel Hub 9. Capscrew 14. Wheel Motor Transmission
5. Flanged Nut 10. Hardened Washer
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TOE-IN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal
Refer to the "Front Tire and Rim Removal" instruc-
tions and remove front tire and rim assembly.
1. Close hydraulic pump shut-off valves.
2. Disconnect speed sensor cable(s) (5, Figure 3-
1) at connector. Tie cables back away from
spindle to prevent damage during spindle
removal.
NOTE: The left brake assembly has two speed
sensors installed.
3. Disconnect disc brake cooling oil hoses (4) at
inlet and outlet ports on brake housing. Also
disconnect brake apply line. Cap hoses and
ports to prevent contamination. Remove the oil
in the brake housing and hub bearings by
removing the hex plug (2) and draining into a
suitable container.
4. Remove lubrication lines from tie rod and steer-
ing cylinder.
FIGURE 3-1. FRONT WHEEL & SPINDLE
INSTALLATION 5. Disconnect tie rod and steering cylinder rod
from spindle being removed. Refer to "Steering
1. Spindle 4. Brake Cooling Hose Cylinder and Tie Rod Removal" in this section.
2. Brake Housing Drain 5. Speed Sensor
3. Disc Brake Housing Connector
The front spindle, brake and wheel hub assembly a. Refer to Figure 3-5 (spindle removal tool )
weighs approximately 10,250 lbs. (4654 Kg). Be and remove the capscrews in the steering
certain lifting device is capable of lifting the load. arm designated by an an "X".
b. Remove the capscrews using a circular pat-
tern in torque increments of 500 ft. lbs. (678
6. Position a fork lift under the wheel hub and N.m). Do not attempt to remove each cap-
spindle assembly as shown in Figure 3-2. Use screw in one sequence!
blocking as necessary to prevent applying pres-
9. Run a tap (1.25" UNF) in the threads after cap-
sure to disc brake housing when assembly is
screws are removed.
lowered from suspension.
7. Remove capscrews and washers (1, Figure 3- 10. Using several 1.25" UNF x 8.00" long , grade 8
3) securing retainer plate (2) to spindle structure capscrews and hardened flatwashers (see Fig-
and suspension. To prevent thread damage, ure 3-4 for Komatsu part numbers), install the
loosen capscrews in a circular pattern, in torque pusher tool on the bottom of the steering arm.
increments of 500 ft. lbs. (678 N.m). Remove Lubricant, such as chassis, is recommended for
retainer plate. use on the washers and threads of the cap-
screws.
FIGURE 3-4. SPINDLE REMOVAL TOOL 13. Tighten the capscrews again to the maximum
INSTALLATION specified torque, and using a large hammer and
heat, as specified in the previous step, carefully
1. Capscrew 3. Removal Tool
tap the top surface of the spindle.
(Part No. KC7095) 4. Steering Arm
2. Hardened Washer 5. Spindle NOTE: In extreme cases, it may be necessary to
(Part No. WA0366) 6. Suspension Piston remove additional steering arm retaining capscrews
and use additional pusher capscrews to apply more
force.
NOTE: The capscrews installed in step 3 will secure 15. Remove capscrews (31) and hardened flat-
the seal carrier and face seal assembly to the brake washers (32). Remove brake adapter and dis-
housing during brake removal. card O-rings (22 & 25).
DO NOT ROTATE WHEEL HUB. 16. Remove inner bearing cone (28) and retainer
4. Disconnect speed sensor cables. Loosen sen- pin (41).
sor clamping capscrews and remove speed 17. Remove bearing spacer (27).
sensors (16).
5. Remove capscrews (20) and hardened flat-
washers (21) securing brake adapter (19) to Cleaning and Inspection
brake housing.
1. Clean all metal parts in fresh cleaning solvent.
6. Remove cover (5) and discard O-ring seal.
2. Inspect wheel hub studs (2, Figure 3-6) and
7. Remove capscrews (11) and hardened flat-
replace if damaged or broken.
washers (12). Remove bearing retainer (13)
and shims (8). NOTE: If new studs are installed, coat the hole in the
8. Attach a lifting device to the wheel hub/brake hub and serrated portion of the stud with an anti-
assembly and carefully lift it straight up and off seize compound prior to installation. DO NOT coat
the spindle. Remove outer bearing cone (7) and threads.
retainer pin (42). 3. Inspect tapped hole threads and re-tap if neces-
9. Rotate hub vertically 180° and place on block- sary.
ing to prevent damage to wheel studs and 4. Inspect bearing seating surfaces in hub and on
machined surfaces. spindle. Inspect bearing spacer. Use a stone to
carefully dress high spots that may interfere
10. Remove capscrews (14) and washers (15)
with re-assembly.
securing seal carrier (37) sensor gear (35) and
shims (36) to wheel hub. 5. Inspect all other machined surfaces for dam-
age.
6. Always use new O-ring seals during assembly.
1. Wheel Hub 12. Hardened Washer 23. Capscrew 34. Socket Head Capscrew
2. Stud 13. Bearing Retainer 24. Hardened Washer (Temporary)
3. Capscrew 14. Capscrew 25. O-ring 35. Speed Sensor Gear
4. Washer 15. Washer 26. Spindle 36. Shims
5. Cover 16. Speed Sensor 27. Bearing Spacer 37. Seal Carrier
6. Outer Bearing Cup 17. Sensor Bracket 28. Inner Bearing Cone 38. O-ring
7. Outer Bearing Cone 18. Disc Brake Assembly 29. Inner Bearing Cup 39. Spacer (Optional)
8. Shims 19. Brake Adaptor 30. Seal Assembly 40. Capscrew and Washer
9. O-ring 20. Capscrew 31. Capscrew 41. Bearing Retainer Pin
10. Spindle Cap 21. Hardened Washer 32. Hardened Washer 42. Bearing Retainer Pin
11. Capscrew 22. O-ring 33. Drain Plug 43. O-ring
The brake assembly should not be installed at NOTE: Measure the shims individually for accuracy.
this time in order to facilitate the bearing adjust- The above procedure results in a shim pack which
ment procedure. will provide a nominal 0.020 in. (0.508 mm) preload
8. Install a new O-ring (9) onto spindle cap (10). for the bearings after assembly.
Lubricate the O-ring with clean hydraulic oil.
Install the cap into the end of spindle (26). The
tapped holes on the spindle cap must face the
outside for disassembly purposes.
e. Align hub and seal carrier (37) mounting NOTE: The hoist must be rigid enough to prevent
holes and lower brake assembly onto hub. "springing" or "jerking" as the hub and brake
assembly is lowered into position.
NOTE: Do not remove shipping bars until inner gear
ring of brake assembly is attached to hub 22. Lift hub over spindle and slowly lower, aligning
the brake mounting holes with the alignment
f. Install capscrews (14) and washers (15) from studs.
under hub flange to secure the seal carrier
and gear. Tighten capscrews to standard a. When the brake piston housing is approxi-
torque. mately 0.50 in. (13 mm) from the adapter,
install four capscrews (20) and flatwashers
g. Align the brake hub holes with the wheel hub (21) spaced evenly in between the alignment
and install hardened flatwashers (24) and studs.
capscrews (23). Tighten capscrews to 1995
ft. lbs. (2705 N.m) torque. b. Carefully pull the brake and wheel hub
assembly into position by tightening the cap-
h. Remove shipping bars from brake assembly. screws evenly and in small increments.
18. Install a new O-ring (25) to brake adapter (19). c. DO NOT allow the assembly to "cock" (stick
Place the assembly into position on the spindle. at an angle). If the assembly is cocked, lift
19. Install hardened flatwashers (32) and cap- the assembly, and inspect O-ring (22) for
screws (31). Tighten capscrews to 1995 ft. lbs. damage. Replace the O-ring if necessary,
(2705 N.m) torque. and repeat the assembly procedure.
PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANTI-SWAY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal
1. Position frame and rear axle housing to allow
use of a puller arrangement to remove anti-
sway bar pins (4, Figure 4-3) on the rear axle
housing and the frame.
2. Block securely between frame and axle hous-
ing.
3. Disconnect lubrication lines. Position a fork lift
or attach lifting device to anti-sway bar (11) for
removal from truck.
4. Remove capscrews (9) and locknuts (10) at
each mount.
5. Attach puller and remove pin (4) from each end
of anti-sway bar.
6. Remove anti-sway bar from mounting brackets.
7. Remove bearing spacers (6).
Installation
1. Start pin (4, Figure 4-3) in through the front of
the frame mount and one spacer (6). Rotate pin
to align retaining capscrew (9) hole with the FIGURE 4-4. ANTI-SWAY BAR ASSEMBLY
hole in the mounting structure (1).
1. Mounting Structure 7. Retainer Ring
2. Raise the anti-sway bar into position and push 2. Capscrew 8. Bearing
pin through spherical bearing, insert second 3. Lockwasher 9. Capscrew
spacer and continue pushing into other ear of 4. Pin 10. Locknut
bracket. If necessary, realign pin with retainer 5. Sleeve 11. Anti-Sway Bar
capscrew hole. Install capscrew (9) and locknut 6. Bearing Spacer
(10).
3. Repeat above procedure to install remaining
pin, spacers, capscrew and locknut at opposite Disassembly
end of bar. Start the pin into the bore of the axle
1. Remove retainer rings (7, Figure 4-3) from
housing mount from the rear of the truck.
bores of both ends of anti-sway bar (11).
4. Attach lubrication lines. Pump grease into bear-
2. Press out spherical bearings (8).
ing to verify line and system is operational.
Cleaning and Inspection
5. Remove blocking.
6. If necessary, recharge suspensions. Refer to 1. Inspect bearing bores of anti-sway bar. If bores
Section “H” for charging procedure. are damaged, repair or replace anti-sway bar.
2. Inspect bearing spacers (6) for damage or
wear.
Assembly
1. Press in new bearings.
2. Install retainer rings. Be certain rings are prop-
erly seated in grooves.
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filtering Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11. Open access covers inside axle housing. 17. Remove automatic lube system hoses and
clamps attached to housing. Secure hoses to
12. Disconnect parking brake supply line (13). Dis-
frame to prevent interference during axle hous-
connect and remove RH parking brake supply
ing removal.
line at tee.
18. Remove rear suspensions. Refer to Section
13. Disconnect air sensor hose from duct.
"H".
14. Remove wheel motor cooling air exhaust duct
19. Remove anti-sway bar as described in this
(5) from between wheel motors.
Section.
15. Disconnect wheel motor power cables (7) at
20. Remove pivot pin as described in this Section.
wheel motor terminals. Remove cable clamps
and pull cables from axle housing. 21. Remove wheel motors as described in this
Section.
16. Disconnect air pressure sensor/rear light har-
ness (8) inside axle housing and remove 22. Attach overhead hoist or crane to lift eyes on
clamps. Disconnect speed sensor harness (9) rear axle housing and move from rear of
connectors and remove clamps. Pull both har- frame.
nesses from axle housing.
MASTIC SEALANT
Vendor Product Name:
• Uniseal 310S Sealant
Punch Marks
Description:
• 2.00 in. wide x 0.125 in. thick x 120 in.
long roll
Vendor Source:
• Uniseal
1800 W. Maryland Street
Evansville, IN 47712
• Other sources may be available
FIGURE 5-4. AXLE HOUSING DIMPLE MARKINGS throughout the world.
Spectrographic oil analysis results should be exam- A gradual rise of elements between oil samples is
ined prior to sun pinion gear inspection. The trends of normal. Only when a sharp increase occurs is there
element parts per million (ppm) or sudden ppm ele- evidence that a mechanical failure is imminent. Lev-
ment changes can estimate the present condition of els of elements that indicate mechanical stress differ
the wheel motor and also predict the immediate from element to element. Additionally, oil sampling
future of the mechanical components within the criteria established for each element may differ at
wheel motor. each mine site due to factors such as uphill or down-
hill hauling, grades, and speeds.
While examining oil sample history, the most impor-
tant characteristic to look for is a rapid increase in the Elements for the wheel motor that can be detected
presence of an element in the oil such as iron (Fe). with oil analysis are iron (Fe), chromium (Cr), nickel
Rapid changes in element content indicate that a (Ni), copper (Cu), silicon (Si), phosphorus (P), zinc
component(s) may be deteriorating. In many cases (Zn), and calcium (Ca). Monitoring and plotting levels
oil analysis can help detect which component may be of these elements should aid in identifying opera-
deteriorating and the cause of the failure. tional status of the wheel motor. Rapid changes or
high levels of these elements are indicators that
Oil sampling must be done every 250 hours of opera- problems exist in the mechanical components.
tion. The sample must be taken within a half an hour
of truck shut down and within an hour of actual truck As stated above, some guidelines for analyzing oil
operation. Oil samples that are not taken under this samples can be given, but specific levels should be
stipulation will not convey an accurate measurement established at the operating mine site. The element
of wheel motor condition. type, maximum ppm, maximum spike allowable
between 250 hour interval oil samples, oil sample
When taking an oil sample, position one of the mag- indicators, and possible causes and actions are
netic plugs in the six o’clock position on the wheel. listed in the following charts. These charts provide
Oil samples should be taken from this plugged hole basic guidelines for analysis of oil sampling informa-
using a flexible tube that is 18 inches (457 mm) in tion.
length. The tube must be inserted downward exactly
12 inches (305 mm) toward the bottom of the torque
tube.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
If iron levels are high and other "Soft" iron contamination. Sources are likely to
200 elements are slightly elevated: be casting material.
Iron (Fe) 600
If iron levels are high and other "Hard" iron contamination. Sources are likely
100
elements ppm's are rising rapidly: to be bearing, gears, etc.
Action: A sun pinion and magnetic plug inspection should be done immediately. The magnetic plugs should be
inspected for metal chips and shavings. The sun pinion and low speed planet gears should be inspected for wear
or spalling per GE Transportation Systems AC Wheel (GDY85) Transmission Gear Use Criteria. If the low speed
planet gears fail to meet the inspection criteria the wheel should be removed, disassembled, and gears replaced. If
the low speed planet gears meet the re-use criteria, but the sun pinion fails to meet the reuse criteria, then replace
the sun pinion. Once the sun pinion has been replaced drain the oil and replace with fresh oil. This wheel should
then be monitored closely and replaced if the iron level spikes again.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
Chromium If chromium is high and iron is high: A bearing failure is likely in progress.
10 7
(Cr)
Action: The oil should be resampled immediately and a gear train inspection completed. If resampling shows high
chrome, the wheel should be removed from service, disassembled, and the bearings and gears inspected.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
If nickel is high and iron is high or rising: Nickel is likely from one or more of the gears.
Nickel (Ni) 10 5
Action: This could indicate a condition such as gear tooth pitting or spalling. The oil should be resampled immedi-
ately and a gear train inspection completed. If the resampling of the oil shows high nickel and chromium, the wheel
should be removed from service, disassembled, and the bearings and gears inspected.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
If copper is high with iron high: High iron will produce high copper from the thrust
15
washers and bearings.
Copper (Cu) 50 If copper is high with other elements A thrust washer is rapidly wearing with the likely cause
20 low: of the sun pinion gear thrusting inboard or outboard.
Action: This often indicates a normal wear condition such as minor thrust washer wear. It can also be an indicator
of bearing wear. If bearing wear is a concern review the chromium readings in conjunction with the copper read-
ings. If both the copper and chromium readings spike; remove the wheel from service, disassemble the wheel, and
inspect the bearings. If the only elevated reading is that of copper or lead; remove the sun pinion and check the
outer thrust washer for wear. If the outer thrust washer has worn less than the depth of the oil lubricating grooves
then reassemble the sun pinion, filter the oil and continue to monitor. If the outer thrust washers have worn more
than the depth of the oil lubricating grooves then replace the outer thrust washers, reassemble the sun pinion, filter
the oil and continue to monitor.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
Zinc (Zn) 75 40 If zinc, phosphorus, and calcium are high: Hydraulic oil has entered the drive train.
25 If zinc is high without high calcium and High mechanical wear of components is
phosphorus: occurring.
Action: If zinc and calcium increase proportionally then look at the oil viscosity. If the oil viscosity is below the 53
cSt at 100° C (212° F) or 588 cSt at 40° C (104° F) condemning limit, the oil should be resampled immediately. If
the resampling still shows a spike in calcium and low viscosity remove the wheel, disassemble, and replace the
internal brake seals. The oil removed from a low viscosity wheel should be disposed of and not reused under any
circumstances. If the oil viscosity is above 53 cSt at 100° C (212° F) or 588 cSt at 40° C (104° F) then monitor the
wheel for any further changes in viscosity.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
Phosphorus If phosphorus, zinc, and calcium are Hydraulic oil has entered the drive train.
400 150
(P) high:
Action: If the oil viscosity is below the 53 cSt at 100° C (212° F) or 588 cSt at 40° C (104° F) condemning limit, the
oil should be resampled immediately. If the resampling still shows a spike in phosphorus and low viscosity, remove
the wheel, disassemble, and replace the internal brake seals. The oil removed from a low viscosity wheel should
be disposed of and not reused under any circumstances. If the oil viscosity is above 53 cSt at 100° C (212° F) or
588 cSt at 40° C (104° F) then monitor the wheel for any further changes in viscosity.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
20 If silicon is high with other elements high: High wear of components.
Silicon (Si) 50 If silicon is high with other elements low: Dirt has entered the drive train. Flush wheel
25
motor.
Action: Flush the wheel motor and monitor element levels.
To fully utilize oil sampling analysis, complete information should be kept with the truck. Necessary information
includes: the truck identification number at the mine site, truck serial number, side of truck the wheel motor is on,
dates when wheel motors are changed (include serial numbers of wheels), the type of oil, viscosity of the oil, sam-
ple date, hours on wheel, hours on oil, and element count. Refer to the chart below. Information in this format can
be easily sent to equipment manufactures and gives required information to analyze the results of oil samples.
Separate records for each wheel motor should be kept in this format.
Contamination can reduce sun pinion gear life significantly, as well as the rest of the drive train. Additional
component (sun pinion gear, etc.) inspections may be required, in addition to normal maintenance interval
inspections, if oil samples from a wheel motor show elements are above normal or rapidly elevating.
HYDRAIR® II SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
When using a cleaning agent, follow the manu- NOTE: The use of dry threads in this application
facturer's instructions for use, proper ventilation is not recommended. Due to the high tightening
and/or use of breathing apparatus. forces required to load these capscrews, dry
threads may cause damage to tools.
REAR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIGURE 3-5. SUSPENSION PIN REWORK 10. Install the nitrogen charging kit and add nitrogen
to raise frame off stands or cribbing, or use a
lifting device if available.
11. Connect lubrication lines and pressure sensor.
12. Service the suspension. For instructions, refer
to HYDRAIR® II "Oiling and Charging Proce-
dure", this section.
13. Install piston rod shield (2, Figure 3-1) with the
capscrews, flat washers, and lockwashers.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
For best results, Hydrair® II suspensions should be FIGURE 4-1. HYDRAIR® CHARGING KIT
charged in pairs (fronts together and rears together).
If rears are to be charged, the fronts should be NOTE: Arrangement of parts may vary from
charged first. illustration above, depending on charging kit P/N.
NOTE: For longer life of suspension components, a 1. “T” Handle Valve
friction modifier should be added to the suspension 2. Charging Valve Adapter
oil. See Specifications Chart, Figure 4-5 at the end of 3. Manifold Outlet Valves (from gauge)
this chapter. 4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
NOTE: Set up dimensions specified in the charts
6. Manifold
must be maintained during oiling and charging
7. Charging Pressure Gauge (Suspensions)
procedures. However, after the truck has been
8. Dry Nitrogen Gas (Specifications Figure 4-5)
operated, these dimensions may vary.
REAR SUSPENSION DIMENSIONS (EMPTY) 3. Install the Hydrair® charging kit and a bottle of
pure dry nitrogen. Refer to Installation of Charg-
TRUCK MODEL OILING CHARGING *CHARGING
ing Kit in this section.
& OPTIONS HEIGHT HEIGHT PRESSURE
In. (mm) In. (mm) psi (kPa) 4. Charge the suspensions with nitrogen gas to 2
in. (50.8 mm) greater than the charging height
930E-1, 1.0 (25.4) 7.5 (190) 215 (1482) listed in Figure 4-4.
930E-2,
930E-3 5. Slowly release gas until the suspensions match
the charging height listed in Figure 4-4.
* Note: Charging pressures are for reference only and may vary
depending on body weights.
BRAKE CIRCUIT
INDEX
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WARNING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Actuator Cap
2. Adjustment Collar
3. Nut
4. Actuator Plunger
5. Wiper Seal
6. Poly-Pak Seal Assembly
7. Glyde Ring Assembly
8. Regulator Springs (B1)
9. Plunger Return Spring
10. Spring Seat
11. Spool Return Spring (B1)
12. Regulator Sleeve (B1)
13. Regulator Spool (B1)
14. Reaction Plunger (B1)
15. Base Plate
16. Reaction Plunger (B2)
17. Regulator Sleeve (B2)
18. Regulator Spool (B2)
19. Spool Return Spring (B2)
20. Regulator Springs (B2)
21. Staging Seat
NOTE:
B1 - Rear Brakes
B2 - Front Brakes
Rebuild Criteria
If any one of the following conditions exist, the brake FIGURE 3-1. BRAKE ACCUMULATOR BLEED
valve should be removed and repaired: DOWN
13. Remove controller from vice. 27. Remove the wiper seals (23), poly-pak seals
(25), and the orange back-up rings (24) from
14. Remove the four capscrews (34, Figure 3-4) the actuator section of the valve and discard.
and washers (33) from the base of the valve.
15. Remove the base plate (32).
16. With the valve upright, the retaining plug (31)
should fall out. If the plug does not fall out,
lightly tap to dislodge the plug.
Assembly
FIGURE 3-8. DIFFERENTIAL PRESSURE SWITCH
1. Install plug (11, Figure 3-8). Tighten plug to 190
1. Differential Pressure 7. Screw Plug
- 210 in. lbs. (21.5 - 23.7 N.m) torque.
Switch Assembly 8. Spring
2. Lightly lubricate Glyde rings on spool assembly 2. Valve Body 9. Piston
(10) and carefully insert in body (4) until it bot- 3. Switch Assembly 10. Spool Assembly
toms on plug (11). 4. Body 11. Plug
3. Install plug (5). Tighten plug to 190 - 210 in. 5. Plug 12. O-Ring
lbs. (21.5 - 23.7 N.m) torque. 6. Plug
NOTE: Shut off valves (8) for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1, B2 Cylinders must be capable of a 10 cubic inch maximum displacement.
Table I - Differential Pressure Switch Adjustment NOTE: The "Final Test and Adjustment" procedure
can also be performed with the brake valve installed
Pressure - Switch Contacts Closing in the truck. To perform final test with brake valve
Spring "B1" Valve Spool "B2" Valve Spool mounted in the truck, install valve per instructions in
Color "Installation". Install 3000 psi (20 682 kPa) gauges at
Red 300 ± 30 psi 300 ± 30 psi the "B1" and "B2" diagnostic test connectors in the
(2 068 ± 207 kPa) (2 068 ± 207 kPa) brake cabinet. Follow steps 21. - 33. below for final
Green 600 ± 50 psi 600 ± 50 psi test.
(4 137 ± 345 kPa) (4 137 ± 345 kPa) 21. Reinstall brake valve (with actuator pedal
attached) on the test stand following Steps 2
14. Release plunger and depress again while through 9 under "Test Setup Procedure".
observing "B1" gauge and ohmmeter to verify 22. With test stand pump adjusted for 2750 psi
switch contacts close at the pressure in Table I. (18,960 kPa) or with engine running and brake
If not, repeat step 13. system supply pressure at or above 2750 psi
15. Insert pry bar under pivot pin to actuate the "B2" (18, 960 kPa), depress the pedal as quickly as
section of valve. possible. The pressure on the output circuits
must reach the minimum pressure listed below
16. Slowly depress plunger while observing ohm-
at port "B1" and port "B2" within 1.0 second.
meter; switch contacts should close at the pres-
Measurement of time begins the moment force
sure in Table I on the "B2" gauge. A slight
is applied to move the pedal.
adjustment may be necessary.
Rear Brake - "B1": 2400 ± 75 psi
17. Slowly depress both plungers equally from mini- (16,545 ± 517 kPa)
mum to maximum application pressure. Switch
contacts must remain open. Front Brake - "B2": 2400 ± 75 psi
(16,545 ± 517 kPa)
18. Install plug (6) and tighten to 90 - 100 in. lbs.
(10.2 - 11.3 N.m) torque. 23. With "B1" and "B2" plugged into a strip chart
recorder, (if available) check the modulation by
19. Shut down the test bench and relieve all slowly applying pressure until the maximum
hydraulic pressure from the lines. pressure is reached. Make sure the pressure
increase is smooth and no sticking of the spools
is observed. Fully depress the pedal. Pressures
must remain within specification at "B1" and
"B2" for 20 seconds.
Avoid spillage and contamination! Avoid contact
24. Adjust set screw (21, Figure 3-10) until the set
with hot oil if the machine has been operating.
screw is not touching the actuator cap. Apply
The oil will be at very high pressure.
Loctite® 242 to the adjustment screw prior to
Hydraulic fluid escaping under pressure can setting the deadband.
have sufficient force to enter a person's body by
25. Set the deadband by placing a 0.010 in (0.254
penetrating the skin and cause serious injury and
mm) thick shim at location (9) between the
possibly death if proper medical treatment by a
pedal structure and return stop boss on pivot
physician familiar with this injury is not received
structure.
immediately.
26. Adjust the set screw (21) until the set screw is
just touching the cap.
20. Remove hoses from valve and remove valve
from test stand. Refer to instructions below for
pedal actuator installation prior to final test.
1. Brake Valve 9. Place 0.010 in. Shim Here 17. Brake Pedal Actuator
2. Retainer Clip 10. Jam Nut 18. Spring Pivot (Lower)
3. Pivot Shaft 11. Capscrew 19. Spring
4. Bushings 12. Pedal Structure 20. Spring Pivot (Top)
5. Shims 13. Pad 21. Set Screw
6. Retainer Clip 14. Nut 22. Jam Nut
7. Nylon Bearing 15. Capscrew 23. Differential Pressure Switch
8. Pivot Shaft 16. Electronic Retard Pedal Assembly
• Pressure gauges (4), 0-to-3000 psi (20,680 Port "T": . . . . . . . . . 1 1/16 in., #12 SAE O-ring.
kPa). • Ohmmeter or continuity tester
• Hydraulic pressure supply, regulated to 2750 psi NOTE: It is possible to check the pressures with the
(18,960 kPa). dual relay valve installed on the truck by using the
• Hydraulic test stand, Refer to Figure 3-12. brake treadle valve to modulate pilot pressure and
monitoring brake apply pressure in the appropriate
brake apply pressure lines.
Removal
1. Place the selector switch in NEUTRAL, turn the
rest switch ON. Turn key switch OFF and allow
at least 90 seconds for steering accumulator oil
to drain back to tank.
2. Open needle valves (6 & 7, Figure 3-1) on
brake manifold (5) and allow the four brake sys-
tem accumulators to bleed completely.
3. Remove charging valve guard (2, Figure 3-25)
and loosen small hex on charging valve (3) FIGURE 3-25. CHARGING VALVES
three complete turns. Depress the valve core 1. Accumulator 3. Charging Valve
until all nitrogen pressure has been relieved. 2. Charging Valve
Guard
Installation
1. Lift accumulator into position on the mounting
bracket. Accumulator should be positioned with
the anti-rotation block positioned between the
two stop blocks on the lower mounting bracket.
2. Secure the accumulator to the mounting
bracket using mounting bands (4, Figure 3-26)
and associated hardware. Do not overtighten
nuts, as this could distort the accumulator.
FIGURE 3-26. BRAKE ACCUMULATOR
3. Reconnect oil line (5) to the bottom of the accu- INSTALLATION
mulator.
1. Rear Brake Circuit 3. Capscrews, Washers
4. Precharge both accumulators with pure dry
Accumulator & Nuts
nitrogen as outlined in Accumulator Charging
2. Front Brake Circuit 4. Mounting Bands
Procedure (Frame Mounted).
Accumulator 5. Oil Line
EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Operator's Cab 5. To Brake Valve, Port "P1" 8. To Rear Axle Junction Block,
2. Hoses to Brake Valve & Steering 6. To Brake Valve, Port "B1" Port "P1"
Control Valve 7. To Rear, Frame Mounted Brake 9. To Front, Frame Mounted Brake
3. Hydraulic Components Cabinet Accumulator Accumulator
4. To Brake Valve, Port "P2" 10. To Brake Valve, Port "B2"
TROUBLE: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected. Check plumbing.
TROUBLE: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system. Check wiring.
Brake accumulator bleeding down. Valve Open; close valve.
Differential pressure switch defective. Check brake valve and dual relay valves; replace
switch assembly.
Brake warning relay defective. Replace relay.
Brake valve out of balance (not tracking). Adjust collars according to instructions.
Differential pressure switch is defective or improp- Check the switch and replace if defective.Check dif-
erly adjusted. ferential pressure switch adjustment. Refer to Table
I - Differential Pressure Switch Adjustment.
NOTE: If the differential pressure switch is O.K. and
the differential pressure is 300 ± 30 psi (2 068 ± 207
kPa), replace "red" spring in Differential Pressure
Switch Assembly with "green" spring and re-adjust
differential pressure to: 600 ± 50 psi (4 137 ± 345
kPa).
Accumulator precharge/leak. Check accumulators and recharge if necessary.
Problem in brake valve subassembly. Remove, disassemble, clean, and inspect brake
valve assembly or replace it.
Dual relay valve defective Inspect and repair dual relay valve(s)
Air in one brake circuit. Bleed brakes.
Small leak in one circuit. Inspect brake system and repair leaks.
Brake warning delay timer defective Replace timer.
TROUBLE: A Low Brake Pressure Warning Occurs When Brakes are Applied
Leak or other malfunction in one brake circuit. Inspect brake system and repair leaks.
Brake valve balance is out of adjustment. Adjust collars according to instructions.
Differential pressure switch is defective or improp- Check the switch and replace if defective.Check dif-
erly adjusted. ferential pressure switch adjustment. Refer to Table
I - Differential Pressure Switch Adjustment. See
NOTE: above.
A dual relay valve is defective Inspect and repair dual relay valve(s)
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open. Close valve, check precharge.
Accumulator precharge is low. Recharge accumulator
Leak in one circuit. Check plumbing.
Malfunction in brake valve. Remove, disassemble, clean, reassemble; or
replace.
TROUBLE: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in brake valve assembly. Remove, disassemble, clean, reassemble; or
replace.
Damage in brake valve assembly. Repair or replace brake valve assembly.
Dual relay valve malfunctioning Repair or replace dual relay valve assembly.
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component. Check all steering and brake system components.
Steering accumulator precharge too high or too low. Check steering accumulator precharge.
Brake Valve plumbed incorrectly. Correct plumbing.
Internal leakage in brake valve assembly. Replace brake valve assembly.
Internal leakage in dual relay valve assembly. Rebuild or replace dual relay valve
Steering/Brake pump is worn. Rebuild or replace pump.
Pump unloader or compensator not adjusted cor- Adjust pump pressure controls.
rectly.
STEP 2 _______________ All brake Accumulators charged to 1400 psi (9.65 MPa).
Refer to appropriate Service Manual procedures and Bleed brakes; Bleed park brakes.
STEP 15 ______________ Left rear brake pressure within one second (LBP).
______________ Right rear brake pressure within one second (RBP).
______________ Brake pressures remain above 2375 psi (16,375 kPa) minimum for 20 seconds.
STEP 45 ______________ Front brake pressure at which differential switch actuates low brake pressure buzzer
and lamp.
STEP 51 ______________ Rear brake pressure at which differential switch actuates low brake pressure buzzer
and lamp.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation
The ring gear (4, Figure 5-1) is internally splined to
retain the dampers (8) and separator plates (12). The
separator plates are alternately placed between the
friction faced discs (7) which are splined to the inner
gear (6). The inner gear mounts directly to the wheel
hub on the front wheel brakes. On the rear, the inner
gear requires an adapter hub which mounts on the
wheel hub on the wheel motor.
The inboard side of the assembly contains the piston
(9) which is activated by hydraulic pressure supplied
by the dual relay valves (controlled by the brake
valve). As hydraulic pressure is applied, the piston
moves to compress the rotating friction faced discs
against the stationary steel discs. The friction forces
generated resist the rotation of the wheels. As
hydraulic pressure increases, friction forces are
increased and wheel rotation is slowed until maxi-
mum force is reached and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The low pressure cooling circuit is completely iso-
lated from the high pressure, piston apply circuit. FIGURE 5-1. WET DISC BRAKE ASSEMBLIES
Cooling oil flows from the hydraulic tank to the hoist
1. Hub Adapter 6. Inner Gear
pump, through the hoist circuit high pressure filters,
(Rear Only) 7. Friction Disc
through the hoist valve, and into the brake housings.
2. Capscrew & Lock- 8. Damper
A parallel circuit from the hoist valve outlet is con-
washer 9. Piston Assembly
nected to relief valves at the hydraulic tank which
3. Socket Head Screw 10. Seal Carrier
limit brake cooling circuit pressure to 35 psi (241
(Temporary) 11. Back Plate
kPa). Oil routed to the front brakes passes through
4. Ring Gear 12. Separator Plate
the oil cooler before entering the front brake hous-
5. Capscrew & Hard-
ings. In addition, the brake cooling oil provides lubri-
ened Washer
cation for the front wheel bearings. Oil exiting the
brake housings returns to the hydraulic tank.
1. Inspect seal surfaces and mounting cavities for Both ramps must be dry. Use clean, lint-free cloths
rough tool marks or nicks that may damage rub- or lint-free paper towels for wiping.
ber seal rings. Hone smooth and clean, if NOTE: Oil from adjacent bearing installations or seal
required. Remove any oil, dust, protective coat- ring face lubrication MUST NOT get on the ramp or
ing or other foreign matter from the metal seal toric until after both seal rings are together in
rings, the toric rings, and both the housing and their final assembled position.
seal ring ramps. Use tri-chloroethane #111
which is a non-petroleum base, rapid drying sol-
vent leaving no film. Allow surfaces to dry com- 2. Install the rubber toric on the seal ring.
pletely. Use clean, lint-free material such as
"Micro-Wipes #05310" for cleaning and wiping.
ALTERNATE PROCEDURE:
After positioning the seal squarely over the retaining
lip, thoroughly lubricate the ring by spraying with tri-
chloroethane #111.
DO NOT USE Stanosol or any other liquid that
leaves an oily film or does not evaporate quickly.
4. With all surfaces of toric ring wet, use installa-
tion tool to position seal ring and toric ring 7. Toric can twist if it is dry on one spot or if there
squarely against the seal housing. are burrs or fins on the housing retaining lip.
APPLY SUDDEN AND EVEN PRESSURE to pop A bulging toric or cocked seal can contribute to
(push) toric under housing retaining lip. eventual failure.
PARKING BRAKE
INDEX
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
1. Apply the parking brake, put selector switch in 6. Connect a clear plastic hose to the parking
NEUTRAL, place the rest switch in the ON brake bleeder screw. Place the other end of
position, turn the key switch OFF to shut down hose in a container.
the engine, and allow approximately 90 sec- 7. Slowly open bleeder valve and allow hydraulic
onds for the steering accumulators to bleed fluid to run until clear and free of bubbles. Close
down. Confirm the steering pressure is bleeder screw securely.
released by turning the steering wheel - no
movement should occur. Block the truck 8. Repeat Steps 6 & 7 for the other parking brake.
wheels. 9. Shut down engine.
2. Block the truck wheels securely to prevent 10. Remove brake bleed equipment, close axle
movement when the parking brake is released. housing cooling air ducts and reinstall duct tube
3. Open the rear axle housing access door, at door.
remove the cooling air duct tube and open
access covers.
4. Be certain the brake accumulator bleeddown
valves are closed.
5. Start the engine and allow the steering system
to fully charge (pump unloads). Turn the parking
brake to the OFF position.
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection Of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Attach a suitable lifting or support device to the The hoist pump weighs approximately 310 lbs
hoist pump capable of handling approximately (140 kg). The hoist and steering pump together
250 lbs (113 kg). Attach a support to the front weigh approximately 560 lbs (254 kg). Use a suit-
end of the steering pump to hold it in place dur- able lifting or support device that can handle the
ing removal of the hoist pump. load safely.
9. Remove the four capscrews (2, Figure 3-2) 2. Attach a suitable lifting or support device to the
securing the hoist pump to the front support hoist pump capable of handling approximately
bracket. Remove the six capscrews holding the 250 lbs (113 kg). Move pump into position in
support bracket to the pump module support. truck.
Remove support bracket. 3. Lubricate the steering pump spline shaft and
10. Make sure the lifting and support devices are in align with coupling (9). Install hoist pump to
place on both pumps. Loosen (but do not steering pump and install capscrews (10) with
remove) the rear support bracket (7) capscrews hardened washers and tighten to standard
holding the steering pump. Lower the pumps torque. Raise pumps up into position.
allowing hoist pump to come down further than 4. Attach front support bracket to the pump mod-
steering pump. ule support structure and to the pump with cap-
screws, lockwashers and nuts. Tighten
11. Remove the four steering/brake pump mounting
capscrews to standard torque.
capscrews (4, Figure 3-2). Slide hoist pump for-
ward to disengage the splines of drive coupling 5. Connect hoist pump drive flange to drive shaft
(9, Figure 3-3) from the steering pump. with capscrews, lockwashers and nuts. Tighten
to standard torque.
12. Move pump to a clean work area for disassem-
bly. 6. Tighten steering pump support bracket (7, Fig-
ure 3-2) capscrews to standard torque. Install
outlet tube (8) support clamp.
7. Uncap inlet and outlet hoses and install to
pumps using new O-rings. Tighten capscrews
securely.
8. Service the hydraulic tank with C-4 type hydrau-
lic fluid. Refer to Hydraulic Tank this section for
filling instructions.
9. Open the three suction line shut-off valves.
Loosen capscrews (at the pump) on suction
hoses to bleed trapped air. Then loosen cap-
screws (at the pump) on pressure hoses to
bleed any trapped air. Tighten all capscrews
securely.
NOTE: If trapped air is not bled from steering pump,
possible pump damage and no output may result.
10. Reinstall blower duct and support bracket.
1. Drive Gear & Shaft 10. Connector Plate 19. Dowel 28. Snap Ring
2. Seal 11. O-ring 20. Bearing Plate 29. Coupler
3. Idler Gear 12. Bearing Plate 21. Dowel 30. Steel Ring
4. Stud 13. Gear Plate 22. Transition Plate 31. Backup Ring
5. Steel Ball 14. Connector Plate 23. O-ring 32. O-ring
6. Flange 15. Washer 24. (Not Used) 33. Pressure Plate
7. Dowel 16. Nut 25. Coupler 34. Isolation Plate
8. Gear Plate 17. Stud 26. O-ring 35. Plug
9. O-ring 18. Idler Gear 27. Drive Gear (Rear) 36. Snap Ring
NOTE: To aid in shaft seal removal place the flange FIGURE 3-8. SHAFT SEAL REMOVAL
on two small wooden blocks as shown in Figure 3-7.
1. Flange 3. Bearings
2. Punch
1. Shut down the engine and the key switch "Off" Installation
for at least 90 seconds. 1. Install suction strainers and secure in place with
capscrews and lockwashers. Tighten cap-
screws to standard torque.
2. Using new cover gasket move cover (2, Figure
3-19) into place and install capscrews and lock-
washers (3). Tighten capscrews to standard
torque.
3. Install pump suction hoses.
4. Fill the hydraulic tank; refer to Hydraulic Tank
Filling Instructions. Open both suction line shut-
off valves (4).
5. Loosen suction line connections at both pumps
to bleed any trapped air. Tighten hose connec-
tions.
6. Bleed trapped air inside steering pump. Refer to
FIGURE 3-19. STRAINER REMOVAL "Steering and Brake Pump Installation", this
1. Hydraulic Tank 4. Shutoff Valve Section, for air bleeding procedure.
2. Cover 5. Pump Suction Hoses NOTE: If trapped air is not bled from steering pump,
3. Capscrews & possible pump damage and no output may result.
Lockwashers
STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bleeddown Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
No Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
• Pilot operated check valve (19) After approximately 90 seconds, the solenoids will
de-energize to close the return port to tank. By this
The bleeddown manifold receives oil from the steer- time all the oil in the accumulators should be
ing/brake pump through a high pressure filter and returned to tank. At start-up, the steering circuit will
directs oil to the accumulators, brake circuit, and be charged, including the brake circuit. The Low
flow amplifier. Oil supply for the steering control Steering Pressure light and buzzer will turn on until
valve and steering cylinders is supplied via the flow steering pressure reaches 2300 psi (15.9 MPa). This
amplifier. is controlled by the steering pressure switch, located
The relief valves and accumulator bleed down sole- on the frame mounted manifold (7, Figure 4-1).
noids are factory preset and cannot be rebuilt indi-
vidually.
Neutral Position:
Neutral position (Figure 4-12) results when the con-
trol piston (1) centers the swashblock (4). The
swashblock angle is now zero and swashblock face
is now parallel to cylinder face. Therefore, no inward
or outward motion of the pump pistons exists as pis-
ton shoes rotate around the swashblock face. The
lack of inward and outward motion results in no fluid
being displaced from the piston bores to the cres-
cents in the valve plate and subsequently no delivery
FIGURE 4-12. PUMP IN NEUTRAL POSITION
from pump ports.
1. Control Piston 3. Piston
2. Housing 4. Swashblock
INDEX
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-4
Installation
1. Lubricate external splines of stub shaft (11, Fig-
ure 5-1) with a molybdenum disulphide or multi-
purpose NLGI grease.
2. Place steering control unit (9) into position on
the mounting bracket. Install capscrews and
washers (7) and tighten to standard torque. It
may be necessary to loosen capscrews (10) to
ease in the alignment of the stub shaft and the
control unit.
3. With capscrews (3) loosened, allow steering
column to slide downward until stub shaft (11)
splines bottom in steering control unit (9). When
the stub shaft is at rest at the bottom of the input
collar, slide column out to obtain 0.08 to 0.120
FIGURE 5-1. STEERING CONTROL UNIT in. (2 to 3 mm) clearance between end of stub
INSTALLATION shaft and steering control unit. Tighten cap-
screws (3) to standard torque.
1. Steering Column 7. Capscrews & Washers
2. Trim Cover 8. Front Access Cover NOTE: The gap in Step 3 can be measured by
3. Capscrews & Washers 9. Steering Control Unit etching a line across saddle bracket (5) and the
4. Capscrews & Washers 10. Capscrews & Washers bracket mounting face while the stub shaft is at rest
5. Saddle Bracket 11. Stub Shaft in the control unit. Pull the column away from the
6. Capscrew & Nut* control unit until the correct gap exists between the
mark on the bracket and the mark on mounting face.
FIGURE 5-12. CHECK BALL INSTALLATION 19. Tighten cover capscrews in a criss-cross pat-
tern to 2 ± 0.4 ft. lbs. (3 ± 0.5 N.m) torque.
1. Check Ball hole 3. O-Ring
2. Check Ball 4. Housing
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLOW AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal
NOTE: It may not be necessary to remove the
bleeddown manifold from the truck for component
replacement. If the problem area has been isolated,
simply remove inoperative component and replace
with a new one. FIGURE 6-1. BLEEDDOWN MANIFOLD VALVE
1. Perform normal truck shutdown procedures. 1. Valve Body 10.Return From Flow
Turn keyswitch "Off" and allow 90 seconds for 2. Return To Tank Amplifier
the accumulators to bleed down. Manually 3. Supply from Steering 11.Bleeddown Solenoid
bleed brake system accumulators located in Pump & Filter 12.Pressure Test Port
hydraulic components cabinet. 4. Diagnostic Test Port 13.To Front Accumulator
5. Bleeddown Solenoid 14.To Rear Accumulator
2. Disconnect wires at the bleeddown solenoids (5
6. Relief Valve, 500 psi 15.Brake Circuit Supply
& 11, Figure 6-1).
7. Check Valve 16.From Steering
3. Disconnect, identify and plug each hydraulic 8. Supply to Flow Pressure Switch
line to prevent contamination. Amplifier 17.Check Valve
4. Remove mounting capscrews and remove the 9. Return From Hoist 18.Relief Valve, 4000 psi
bleed down manifold. Pilot Valve
5. Clean exterior of manifold before starting disas-
sembly.
Installation
NOTE: Adjustment of the relief valves is not
1. Install bleeddown manifold. Secure in place necessary or recommended. Relief valves are
with capscrews. Tighten capscrews to standard factory preset. Do not attempt to rebuild or repair if
torque. relief valves are defective. Replace as a unit. The
2. Unplug lines and attach. Tighten connections check valves are also replaced only as units.
securely.
3. Attach electrical leads to the bleed down sole-
noids. If check valves or relief valves were
removed, replace using new O-ring seals.
4. Start the engine and check for proper operation
and leaks. Check steering and brake applica-
tion.
Installation
1. Lift accumulator into position on the mounting
bracket. Accumulator should be positioned with
the anti-rotation block positioned between the
two stop blocks on the lower mounting bracket.
2. Secure the accumulator to the mounting
bracket using mounting bands (3, Figure 6-3),
capscrews, lockwashers and nuts. Do not over-
tighten nuts, as this could distort the accumula-
tor.
3. If pressure switches were removed, install at
this time. Connect electrical wiring to pressure
switches and reconnect oil line to the bottom of
the accumulator.
4. Precharge both accumulators with pure dry
nitrogen as outlined in "Steering Accumulator
Charging Procedure".
FIGURE 6-3. ACCUMULATOR INSTALLATION
1. Accumulator 3. Mounting Band
2. Pressure Switch
1. Capscrew 7. Bearing
2. Cover 8. "T" Ring Seal
3. Charging Valve 9. Housing
4. Gland 10. Plug (or Adaptor) FIGURE 6-5. GLAND REMOVAL TOOL
5. O-ring & Backup Ring 11. Plug (Fabricate Locally)
6. Piston
Installation
1. Install a new O-ring on pump mounting flange.
2. Make certain the steering pump splined coupler
is in place (inside hoist pump) prior to steering
pump installation.
1. Back-Up Ring 4. O-Ring NOTE: The valve plate is a slight press fit into pump
2. O-Ring 5. Back-Up Ring housing. Make sure pilot diameter on valve plate is
3. Back-Up Ring aligned with mating diameter on the pump housing
prior to assembly.
32. Insert bias control piston springs (1, Figure 6-
14) into control piston (11). Use four capscrews
43. Insert four capscrews (8, Figure 6-15) and alter-
(1, Figure 6-15) to fasten control cover cap to
nately tighten until valve plate is drawn up to the
back of valve plate. Tighten capscrews evenly
pump housing. Tighten capscrews evenly to
to 138 ft.lbs. (187 N.m) torque.
244 ft.lbs. (330 N.m) torque.
33. Install O-ring (10) in rear of valve plate. Use four
44. Install cover plate (9) with new O-ring (10) and
capscrews (7) to fasten cover plate (9) over
capscrews (7).
opening in valve plate.
45. Install O-rings (2, 3 and 4, Figure 6-16) in
34. Pull free end of control link (17, Figure 6-14)
proper location on top of valve plate. Install
toward back of pump housing until the open
block (10) to valve plate with socket head cap-
hole in the link lines up with open ports on sides
screws (12) and tighten to 183 in lbs (20.7
of pump case.
N.m) torque.
35. Install stroke adjuster assembly (Figure 6-17) to
46. Install 4-way valve (11), and compensator valve
hold swashblock in place.
(16).
Valve Plate Group 47. Install 0.062 in (1.575 mm) diameter orifice (9)
36. Be sure driveshaft bearing (13, Figure 6-15) is and plug (7) with new O-ring (8) in side of com-
in place. Using assembly grease (to hold pensator block as shown in Figure 6-15. Install
desired position), place valve plate gasket (12) 0.032 in (0.813 mm) diameter orifice (15), plug
in position on valve plate (11). (7) and O-ring (8) in top of block.
37. Support valve plate assembly from an overhead 48. Install remaining plugs with new O-rings.
hoist (lifting lug holes are provided) in prepara- 49. Install unloader module (18) on compensator
tion for mating to the pump housing. block with new O-rings (19) and socket head
38. Assemble one control link retainer ring (14, Fig- capscrews (17). Tighten capscrews to 87 in lbs
ure 6-14) and one control link washer (15) onto (9.8 N.m) torque.
the threaded hole side of the control link pin 50. Install plugs (9 & 24, Figure 6-13) and O-rings
(16). Then thread a 1/4 in - 20 UNC capscrew (10 & 25) in pump housing.
into pin to ease holding.
51. Measure pump rotation torque. Rotation torque
should be approximately 15 ft. lbs. (20.4 N.m).
TROUBLE: Slip - a slow movement of steering wheel fails to steer front wheels
Leakage of steering cylinder piston seals Repair or replace steering cylinder
Worn steering control unit meter Replace steering control unit.
TROUBLE: Free wheeling - steering wheel turns freely with no back pressure. Front wheels do not steer.
Splines of steering column/steering control valve Repair or replace steering column or coupling.
coupling may be disengaged or damaged
No flow to steering control valve; can be caused by:
1. Low oil level 1. Add oil and check for leakage.
2. Ruptured hose 2. Replace hose.
3. Broken steering control valve gerotor drive pin 3. Repair or replace steering control valve.
TROUBLE: Steered wheels turn in opposite direction when operator turns steering wheel
Lines connected to wrong cylinder ports Inspect and correct line connections.
(STEERING PUMP)
TROUBLE: No pump output
Air trapped inside steering pump Bleed air from pump and/or system.
Broken pump drive shaft Inspect hoist and steering pump, replace drive
shaft.
Excessive circuit leakage Check for external leaks, internal system pressure
loss.
No oil to pump inlet Check hydraulic tank oil level. Make certain pump
inlet shut-off valve is open.
Incorrect relief valve pressure setting Check and correct relief valve setting.
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inlet Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Spool Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Snubber Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Pump
The hoist system hydraulic pump is a tandem, gear
type pump driven by a drive shaft on the end of the
traction alternator. The pump has a total output of FIGURE 7-2. HOIST VALVE
246 GPM (931 l/m) at 1900 RPM and 2500 psi (17, 1. Inlet Section 4. Inlet Section
235 kPa). 2. Work Ports Spool 5. Inlet Port
A smaller, piston type, pressure compensated pump Section 6. Outlet Port
rated at 66 GPM (250 l/m) @ 1900 RPM, coupled to 3. Tank Ports Spool 7. Spool Section Cover
the hoist pump, supplies oil to the steering system Section
and brake apply system.
Hoist Valve
Hoist pressure is limited to 2500 psi (17,235 kPa) by
internal relief valves located in the hoist control valve The hoist valve (Figure 7-2) is mounted on a modular
inlet sections. assembly containing the hoist valve, manifold, and
both hydraulic pumps. This assembly is bolted to
brackets attached to the frame rails behind the main
alternator.
High Pressure Filters
The hoist valve is a split spool design. (The term
Hoist pump output oil is directed to the high pressure "split spool" describes the spool section of the valve.)
filters, mounted on the inboard side of the fuel tank. The hoist valve precisely follows differential pressure
The filter assemblies are equipped with a bypass input signals generated by the hoist pilot valve as the
valve which permits oil flow if the filter element operator moves the hoist control lever while raising
becomes excessively restricted. and lowering the dump body.
Flow restriction through the filter element is sensed
by an indicator switch. This switch will turn on a cab Inlet Sections
mounted red warning light to indicate filter service is Each of the front and rear inlet sections of the hoist
required. The indicator light will illuminate when valve contains of the following components:
restriction reaches approximately 40 psi (276 kPa). • Flow control valve and main relief valve
Actual filter bypass will result when the filter element
• Secondary Low pressure relief valve
restriction reaches approximately 50 psi (345 kPa).
• Anti-void check valve
• Load check valve
The flow control portion of the flow control and main
relief valves allows pump flow to the service brake
cooling circuit unless the body is being raised or low-
ered. The relief portion of the valve is direct acting
and has the capacity to limit the working pressure at
full pump flow.
The rear spool section of the hoist valve consists of When the operator moves the lever, the pilot valve
the following components: spool moves and directs pilot flow to the appropriate
pilot port on the hoist valve. The pilot flow causes the
• Pilot ports main spool to direct oil flow to the hoist cylinders.
• Main spools The hoist pilot valve is equipped with a one way load
• Work ports check valve which allows free flow from the center
passage to bridge core and prevents reverse flow.
• Check poppets
The valve also contains the power down relief valve
The pilot ports are located in the spool section cover. (2), used to limit power down pressure to 1500 psi
These ports provide connections for a pilot line to the (10.4 MPa).
hoist pilot valve. Each work port has a corresponding
pilot port.
The work ports provide for a line connection between
the spool section and the hoist cylinders. One main
spool for each work port is spring biased at both ends
to block the work port from the high and low pressure
cores when there is no flow through the spool cross
holes.
When there is flow through the pilot ports to the
spools, a positive differential pressure at the top of
the spool will overcome the bottom spring bias and
the spool will shift to connect the work port to the
high pressure core.
When there is flow from the main valve work port to
the pilot port through the cross-holes, a positive dif-
ferential pressure at the bottom of the spool will over-
come the top spring bias and the spool will shift to
connect the work port to the low pressure core.
The check poppets located in the spool section per-
mit free flow from the work port to the pilot port and
restrict flow from the pilot port to the work port. These FIGURE 7-3. HOIST PILOT VALVE
check poppets control spool response and spool
movements during void conditions. 1. Hoist Pilot Valve 4. To Hoist Valve
2. Relief Valve (Rod End)
3. Supply Port 5. To Hoist Valve
(Base End)
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INLET SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Quill Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INLET SECTION
Disassembly
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Disconnect the external tube (7, Figure 8-2) at
the cover end and remove. Remove capscrews
(14, Figure 8-5), remove cover (13). Remove
springs (12), poppets (11) and O-rings (10).
NOTE: Inlet section shown removed from main valve
body for clarity.
3. Remove capscrews (1) and cover (2). Remove
springs (3 & 5) and main relief valve (4).
Remove sleeve (6), low pressure relief (7) and
O-rings (8). The main relief valve (4) is factory
preset at 2500 psi (17.2 MPa). Replace as a
complete assembly only.
NOTE: If restrictor poppet removal in cover (2, Figure
8-5) is required, refer to step 4 and figure 8-6.
Disassembly
NOTE: It is not necessary to remove the inlet
sections (1 or 4, Figure 8-2) to accomplish spool
section disassembly and repair.
1. Match mark or identify each spool in respect to
its mating bore when removed.
2. Remove capscrews and lift spool section cover
(4, Figure 8-12) from housing.
3. Remove and discard O-rings (5 & 6).
4. Remove capscrews and remove bottom cover
(9) from spool housing. Remove and discard O-
rings.
5. Remove springs (8). Push spools (7) out of
housing bores.
FIGURE 8-11. SPOOL INSTALLATION
1. "V" Groove 3. Work Ports Spool
2. Spool Assembly Section Cleaning and Inspection
1. Discard all O-rings. Clean all parts in solvent
and blow dry with compressed air.
2. Inspect springs for breaks or distortion.
8. If used, install O-ring (2, Figure 8-8) and backup
3. Inspect housing bores and surfaces of spools
ring (3) on restrictor poppet (1). Install poppet in
for nicks, scoring or excessive wear.
spool housing as shown in Figure 8-9.
9. Install new O-rings (4, 5 & 10).
10. Install new O-ring (and backup ring if used) on Assembly
poppet (6, Figure 8-9). Make certain the small
steel ball (7) is installed in poppet. Install poppet 1. Lubricate spools (7, Figure 8-12) with clean
in cover (1). hydraulic oil and re-install their original bores.
Install springs (8).
11. With new O-rings (4, 5 & 10) installed, position
2. Lubricate O-rings (5 & 6) with clean hydraulic
cover (1) over spool housing. Secure cover in
oil. Install O-rings in bottom of spool housing.
place with capscrews. Tighten capscrews to 60
Install bottom cover (9) and secure in place with
ft. lbs. (81 N.m) torque.
capscrews. Tighten capscrews to 60 ft. lbs. (81
N.m) torque.
3. Lubricate O-rings (5 & 6) and install in top of
spool housing. Install top cover (4) and secure
in place with capscrews. Tighten capscrews to
60 ft. lbs. (81 N.m) torque.
4. If removed, install plugs (2) with new O-rings
(3).
FIGURE 8-16. HOIST PILOT VALVE REASSEMBLY FIGURE 8-17. TIE ROD NUT TORQUE
1. Spool Housing 4. O-ring 1. Nut 4. Tie Rod
2. Check Poppet 5. Outlet Housing 2. Tie Rod 5. Outlet Housing
3. Spring 3. Nut
Quill Installation
1. The plugs (3, Figure 8-22) and the check balls
(4) in the quill should be checked during any
cylinder repair to insure the plugs are tight and
ball seats are not damaged. Refer to "Installa-
tion of Check Balls and Plugs in Quill".
2. Secure cap assembly (1) in a sturdy fixture.
Make certain threads in cap and threads on quill
are clean and dry (free of oil and solvent).
3. Using Loctite "LOCQUIC®" Primer "T"
(Komatsu part number TL8753, or equivalent),
spray mating threads of both cap assembly (1)
and quill assembly (2). Allow primer to dry 3 to 5
minutes.
4. Apply Loctite Sealant #277 (Komatsu part num-
ber VJ6863, or equivalent) to mating threads of
both cap assembly and quill assembly.
5. Install quill and use SS1143 tool to tighten quill
to 1000 ft. lbs. (1356 N.m) torque. Allow parts
to cure for 2* hours before exposing threaded
areas to oil.
* Note: If "LOCQUIC®" primer "T" (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
6. Tack weld quill in 2 places as shown in Figure
8-21.
7. Remove all slag and foreign material from tack
weld area before assembly of cylinder.
Hookup
Be certain there is an adequate, clear area to dump
the loaded box. When the good truck is in position,
shut down the engine and allow the hydraulic system
to bleed down. Be certain pressure has bled off
before connecting hoses. FIGURE 8-25. PUMP MODULE, HOSE HOOKUP
1. With the good truck parked as close as possible
to the disabled truck, attach a hose from the 1. Hoist Valve
power up quick disconnect (4, Figure 8-25) to 2. Hoses to LH Hoist Cylinder
the power down circuit of the disabled truck. 3. Power Down Quick Disconnect; Connect to
(Hose must be rated to withstand 2500 psi (17 power up circuit of "disabled" truck
MPa) or greater pressure. 4. Power Up Quick Disconnect; Connect to power
down circuit of "disabled" truck
NOTE: The power down circuit will use a smaller
diameter hose (tube) than the power up circuit.
2. Connect another hose from the power down b. Remove the cap from the Hoist Pilot Valve
quick disconnect (3) to the power up circuit of relief valve located in the hydraulics compo-
the disabled truck. nents cabinet behind the cab. While counting
the number of turns, slowly screw the relief
NOTE: If both trucks are a Model 930E, the hoses valve adjustment screw clockwise until it bot-
will be installed at the quick disconnects shown in toms.
Figure 8-25 and will be crossed when connected.
5. Repeat step 4 to dump the disabled truck.
INDEX
Hydraulic fluid escaping under pressure can 1. Indicator Switch 6. Filter Element
have sufficient force to enter a person's body by 2. Setscrew 7. Bowl
penetrating the skin and cause serious injury and 3. Head 8. O-Ring
possibly death if proper medical treatment by a 4. Pressure Tap 9. Drain Plug
physician familiar with this injury is not received 5. O-Ring
immediately.
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12. Steer the truck slowly again while observing the Maximum permissible leakage is 10 cubic
steering pressure feedback gauge. inches (164 ml) per minute.If leakage is
excessive, the steering control valve should
The pump must reload when pressure be repaired or replaced.
drops to 2750 psi (18,960 kPa) minimum.
*Record on Data Sheet
*Record on Data Sheet 6. Shut down engine and allow accumulators to
13. If minimum reloading pressure in step 12 is not bleed down completely. Steer the truck to verify
correct, repeat unloader valve adjustment, all pressure has bled off. Reinstall all hoses to
steps 11 and 12. their proper location.
NOTE: The critical pressure setting is the 2750 psi
(18,960 kPa) when the pump loads. The unloading
pressure follows the loading pressure adjustment
and should occur at approximately 3025 psi (20,855
kPa).
Bleeddown Manifold Leakage Test
14. Tighten jam nut to lock pressure adjustment.
1. Disconnect the hoist pilot valve return hose (9,
15. Steer truck to cause system to cycle several Figure 10-2) located on the side of the bleed-
times to verify system pressure begins to down manifold. Cap the open fitting on the man-
increase (pump cycles from unload to load) ifold.
once pressure has dropped to 2750 psi (18,960
kPa).
16. Shut down engine and allow accumulators to
bleed down completely. Turn the steering wheel
to verify no pressure remains.
17. Remove gauges and cap test ports.
Adjustment
1. If power down relief pressure is not within spec-
ifications, adjust as follows:
a. Remove cap from power down relief valve
(2, Figure 10-6).
FIGURE 10-6. POWER DOWN RELIEF VALVE
1.) To increase power down relief pressure,
1. Spool Housing 2. Relief Valve
turn adjusting screw in (clockwise).
2.) To decrease power down relief pressure,
turn adjusting screw out (counter-clock-
wise).
2. Recheck power down relief pressure (step 3)
after valve adjustment. Install cap on relief
valve.
3. Shut down engine, allow accumulators to bleed
down. Remove gauges, hoses etc.
Operate hydraulic steering system to obtain proper operating temperature. Refer to Check-out
Procedures.
Operate hydraulic system to obtain proper operating temperature. Refer to Check-out Proce-
dures.
INDEX
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-3
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Placing the Electric Detection & Actuation System Into Service . . . . . . . . . . . . . . . . . . . . . . . M2-9
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-10
Control Module
(Figure 2-4):
Provides the electrical connections necessary
between the power lead and the linear detection
wire to the power lead supplying electrical power,
via the squib, to the actuator. Also provides a visual
check of power availability - pressing the switch but-
ton will illuminate the green indicator light if electri-
cal power is available in the system. FIGURE 2-4. CONTROL MODULE
FIGURE 2-11. LINEAR DETECTION WIRE Do Not install squib to power lead at this time
CONNECTOR (Figure 2-13).
! CAUTION !
Remove jumper to prevent fire suppression sys-
FIGURE 2-14. INSTALL JUMPER tem from discharging when squib is installed in
electric detection and actuation system.
2. The Linear Detection Wire
a. Using the furnished text kit, proceed to the
end of the last length of detection wire.
Remove the plugged blank connector (Fig-
ure 2-14) and install the jumper assembly.
NOTE: Retain plugged connector to be reinstalled
after testing is completed.
b. With jumper in place, screw squib connector
into receptacle on test module (Figure 2-15).
Test module light should immediately illumi-
nate. This test confirms that the wire is prop-
erly installed and will function as designed. If
test module light does not illuminate on test
module, refer to the "Troubleshooting" sec- FIGURE 2-16. REMOVE JUMPER ASSEMBLY
tion.
FIGURE 2-19.
Daily
The machine operator should manually test system
power by pushing the button and noting illumination
of indicator light. This confirms battery power is avail-
able. If light is not illuminated, refer to "Troubleshoot-
ing" covered in this section.
FIGURE 2-23. ATTACH INDICATOR LIGHT 14. Install actuation cartridge back into lower actua-
ASSEMBLY (Test Module) tor body and tighten firmly by hand.
TROUBLE: Green Indicator Light on Control Module Does Not Go On When Button is Depressed.
Dimen-
Description 930E-1 Refer to Section G, Drive Axle, Spindles, and Wheels,
sion
for information on using the spindle tool to properly
Plate Bolt 1.37 in. remove the spindles from the machine.
"A"
Hole Diameter (34.8 mm)
21.62 in.
"B" Plate O.D.
(549.2 mm)
2.00 in.
"D" Plate I.D.
(50.8 mm)
1.37 in.
"E" Plate Thickness
(34.8 mm)
Other Data
This display indicates the status of If the truck engine is started before the preceding
the Inclinometer for the PLM II™, where "Power-up Process" is completed, the display will
shift to normal operation.
"CL : - -" indicates Inclinometer Not Used, and
"CL : oo" indicates Inclinometer Is Used. If the engine is running when the payload meter
starts up, only "o:XXX" and "d:XXX" will display
5. The display will show: before switching to normal operations.
NOTES:
1. The Option Code is set to "0" for trucks not
equipped with Modular Mining System (MMS)
(Except 530M/HD1500).
2. The 530M/HD1500 with Powertrain Manage-
ment Control (PMC) system uses "10" as the
setting for the Option Code.
3. For trucks with Modular Mining System (MMS)
or Scoreboard, the Option Code is "12".
This function will erase all of the cycle data, engine If there are no faults or warnings,
ON/OFF data, and fault/warning data. Total payload the display will show for 6 sec-
and the overall number of cycles will not be cleared. onds.
If there are current faults or warnings, the
IMPORTANT - Before clearing the data, download codes will be displayed in order of their priority,
the data to a personal computer. the highest priority first. Each code will flash for
To begin, the shift lever should be in the "N" position, 6 seconds.
the brake lock set, the hoist control lever should be in 5. After the current codes have been displayed,
the "FLOAT" position and the body in the down posi- past history codes that have been reset will be
tion. displayed. Each code will flash for 3 seconds.
1. Press and hold the MODE If there are no history codes or
switch until "Cd:dP" is displayed. after all history codes have been
2. Press the MODE switch once. shown, the display will show for 3
The display will show: seconds:
3. Press and hold the CAL/CLR The system will then proceed to the following
switch until "A.CLE" is flashing. displays: Refer to Page 25 for details.
4. Press the CAL/CLR switch again
and the memory will be cleared. The meter will
then return to normal operation. • Condition of the shift selector on mechanical
trucks or brake lock on electric trucks.
This does not clear the Operator Load Counter.
The panel will display: "C1:XX" for 3 seconds,
then indicate:
Mechanical trucks
"C1:oo" Shift selector is in "N".
"C1:- -" Shift selector is not in "N'.
Electric trucks
"C1:oo" Brake lock is on.
"C1:- -" Brake lock is off.
• Condition of the Body Up Switch signal.
The panel will display: "C2:XX" for 3 seconds,
then indicate:
"C2:oo" Body up switch is in up position.
"C2:- -" Body up switch is in down position.
INCLINOMETER
As the truck is tilted fore or aft, the weight distribution FIGURE 20-14. INCLINOMETER SIDE
between the front and rear axles changes. To com- CONNECTOR VIEW
pensate for this, the inclinometer measures the
ground angle at which the truck rests. This data is
Pin Number Wire Color Wire Function
then sent to the payload meter so it can calculate the
correct payload weight. The inclinometer is located 1 Black Ground (GND)
below the operator's center console (passenger seat 2 Red + Power
structure).
3 White Signal
Removal
Adjustment
1. Disconnect inclinometer wire lead from har-
ness. 1. Park the truck on a 0% grade.
2. Remove the three capscrews, nuts and lock- 2. Loosen the three inclinometer mounting cap-
washers (4, Figure 20-13) and inclinometer (3). screws (4, Figure 20-13) and rotate the incli-
nometer until a voltage range of 2.6 ± 0.1 volts
can be measured (using a volt-meter) at pins 1
and 2 of the inclinometer harness connector.
3. Tighten all capscrews (4, Figure 20-13) to stan-
dard torque, after the adjustment.
CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins
No. Description Comments White (RS-232C Port)
3 Lamp Relay 2 2 SG
4 Lamp Relay 3 3 RD
5 Lamp Relay 4 4 TX
CN2 - AMP 040 12 Pins Black Connector CN4 - AMP 040 8 Pins Black
No. Description Comments (Optional Input, Reserved)
COMMON PROBLEMS
Suspension Charging
The Payload Meter II™ is a reliable controller and is rarely the source of failure in calculating payloads. The single
most common cause for an inaccurate payload estimate is improper suspension charging. Often maintenance per-
sonnel will not take the time to properly drain a suspension and carefully recharge it with oil and nitrogen. Most
often technicians will simply 'gas up' the suspensions with more nitrogen and send a truck back into service.
Komatsu engineers have conducted tests at customer sites to monitor suspension charging on trucks and found
many trucks to be improperly charged. Trucks with poorly charged suspensions were sent to service bays for main-
tenance by mine personnel. In some cases these trucks were returned to operation in worse condition than when
they were first checked because service personnel did not take the time to carefully charge the suspensions.
The payload meter uses the pressures from the suspensions to calculate payload. As the truck is loaded, a flat sus-
pension will completely collapse. The top suspension cap will make metal-to-metal contact with the bottom. This
often occurs in the rear suspensions. The pressure in the suspension will not accurately reflect the force applied to
the suspension by the weight of the material in the body and inaccurate payload calculations will result.
In addition to inaccurate payload calculations, improperly charged suspensions increase wear-and-tear on truck
frames and tires, increasing maintenance costs over the life of the truck. Each over-loaded haul cycle with under-
charged suspensions leads to premature failure. Consistently low payload estimates are the first sign that the sus-
pensions are not being properly maintained and the truck is on a path toward increased operating costs and
system failures. Thankfully, the effects of improper suspension charging can be postponed with proper service and
care.
Specific suspension charging procedures for each truck model can be found in the shop manual. In general, the fol-
lowing items are very important for proper charging:
• Completely discharge the suspension. This may take more than an hour for the nitrogen and oil to completely
discharge. However, to ensure that the proper volume of fresh oil is added, it's necessary to remove as much
of the oil/nitrogen mixture as possible.
• Fill the suspension to the proper height with fresh oil, this is critical to keeping the suspensions from bottoming
out.
• Charge the suspension to the proper height with nitrogen.
Refer to Section “H” for the proper charging procedures.
This module contains an example of how to use the Scope program from Komatsu to monitor suspension pressure
data.
410
Voutput = 1 + 4 × = 1.576vdc
2845
Don’t forget to add the 1v since the output of the pressure sensor at 0 psi is 1 volt
The generic version is:
Suspension _ pressure
Voutput = 1 + 4 ×
2845
volts
Voutput = 2.6 volts - 0.103 degree x 5° = 2.085volts
Connector 7821915320
Terminal 7821915010
Connector 7830115260 Connector 7845253670
Terminal 7821912020 Terminal 7827101440
Plate 7821912510 Plate 7821912450
A:A:
PLM RTS
PLM RTS
B:B:
PLM SGND
PLM SGND
C:C:
PLM Rxd
PLM Rxd
D:D:
PLM Txd
PLM Txd
E:E:
PLM CTS
PLM CTS
MATING FACE OF
BRAKE LOCK DOWNLOAD
CONNECTOR CONNECTOR
Originally, this program was designed for engineering testing purposes only. It was not designed for general distri-
bution or use. This program sets the Komatsu Mining Systems Payload Meter II™ into real-time data transfer
mode. This allows the technician to monitor all inputs into the system. Scope also allows for the logging of this
real-time data. These files can be used to analyze the inputs over a period of time.
Scope is used to record suspension pressures during a haul cycle. These pressures can be imported into Microsoft
Excel or other spreadsheet programs to graph each suspension. Visually, a service technician can look for flat or
undercharged suspensions. In addition, all the input to the payload meter can be checked using the PC instead of
the switches on the front panel of the payload meter
System Requirements - Microsoft Windows 95, access to serial communications port 1, EF9159 & EF9160 har-
nesses to connect the Payload Meter II™ to the serial port of the PC. Payload Meter II™ must also be set up to use
MMS Communications Mode. This is indicated on power up of the Payload Meter by OP12. Changing this setting is
described in “Setting the Option Code”.
Downloading Scope – Scope is available on the internet. It can be found at the following address:
http://www.kms-peoria.com/payload
The program, Scopezipped.exe, is a self-extracting executable. Save it into its own directory on your hard drive
and run it. The program will unzip and be ready to run.
NOTE: This program has not been tested on all versions of Windows and may not work on all operating systems.
Using Scope
1. Start Scope Payload Meter II™.
2. Power the Payload Meter II™ System.
3. StartRTM - Start real time communications soon after the payload meter finishes it’s initial display of internal
settings. This display cycle is described in “Displays at Start-Up”.
4. The Scope window should now indicate real-time conditions. The RTM D I/O conditions show the inputs into
the Payload Meter II™. The suspension pressures, inclinometer, speed, and truck status displayed are the
current readings from all sensors. This display will remain live as long as the communications connection is
maintained.
5. To create a record of the data being transmitted by the Payload Meter II™, press StartLog. The program will
prompt for a file name. Once entered, Scope will begin to save data to this file.
6. Use the StopLog command to stop logging data to the file.
7. Use the StopRTM command to stop real time communications. After a period of time, the payload meter
should indicate a communications error.
In the sample data shown, the column marked "Type" refers to the type of data being transmitted; “R” is used for
Real-Time, “F” is used for Final Load and “S” is used for Swing Load.
For the swing load data line the format is Time, S, Swing Load, Predicted Load, FL, FR, RL, RR.
For a final load transmission the format is Time, F, Final Load, FL, FR, RL, RR.
The Payload Meter requires 5 wire RS232 communications. Payload Meter communications connections are :
1 - RTS 2 - Signal Ground 3 - RxD 4 - TxD 5 - CTS
As shown in the previous examples, Scope can be used to create log files of the suspension pressure data.
Graphs of this data can give be used to determine the relative health of the suspensions.
CAB COMPONENTS
INDEX
TRUCK CAB
INDEX
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-17
Removal - Cab
NOTE: The following procedure describes removal of
After the truck is parked in position for the repairs, the cab as a complete module with the hydraulic
the truck must be shut down properly to ensure the brake cabinet attached. All hoses and wire
safety of those working in the areas of the deck, elec- harnesses should be marked prior to removal for
trical cabinet and retarding grids. The following pro- identification to ensure correct reinstallation:
cedures will ensure the electrical system is properly
discharged before repairs are started. 1. Disconnect hydraulic hoses routed to frame
from fittings at rear of cab under brake cabinet
(3, Figure 2-2). (It is not necessary to discon-
nect hoses attached to, and routed under the
cab.) Cap all lines to prevent contamination.
2. Disconnect wire harnesses (4) at connectors
located under hydraulic cabinet.
3. Remove cable and hose clamps as needed for
cab removal
4. Close heater shutoff valves located at the water 7. Evacuate air conditioning system:
pump inlet housing on the right side of the
a. Attach a recycle/recovery station at the air
engine and at the water manifold. Disconnect
conditioning compressor service valves.
heater hoses at each valve and drain coolant
(Refer to Section N, Operator Comfort for
into a container.
detailed instructions.)
5. Remove clamps and heater hoses from fittings
b. Evacuate air conditioning system refrigerant.
underside of deck, below heater. Cap fittings
and plug hoses. c. Remove the air conditioner system hoses
6. Remove air cleaner restriction indicator hoses which are routed to the bottom of the cab
near front, inside corner under cab. from the receiver/drier and compressor. Cap
hoses and fittings to prevent contamination.
8. Attach a lifting device to the lifting eyes pro-
vided on top of the cab.
FIGURE 2-8.
FIGURE 2-7.
FIGURE 2-9.
FIGURE 2-10.
1. Screws 2. Rubber Felt Insert
Installation
1. Install the seal material around the door open-
ing in the cab. Start at the bottom center of the
cab opening and work the seal lip over the
edge of the opening. Go all the way around the
opening. Be sure that the seal fits tight in the
corners. A soft face tool may be used to work
the seal up into the corners.
2. Continue going all the way around the opening.
When the ends of the seal meet at the starting
bottom center of the cab opening, it may be
necessary to trim off some of the seal.
NOTE: The ends of the seal material need to be
square-cut to assure a proper fit.
FIGURE 2-17.
3. Fit both ends so that they meet squarely, then
1. Door Opening Seal 2. Door Hinge Seal
while holding ends together, push them firmly
into the center of the opening.
CAB COMPONENTS
INDEX
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Installation
1. Place the linkage into position in the wiper com-
FIGURE 3-3. PARK POSITION partment.
1. Wiper Motor 2. Linkage Retainer 2. If equipped, place spacer blocks (1, Figure 3-4)
into position under pillow blocks (3). Install cap-
screws (2), the washers, and the nuts that
secure the pillow blocks.
3. Install nut (3, Figure 3-2) on each wiper shaft
and tighten finger-tight. Torque the nuts to 160-
177 in. lbs. (18-20 Nm). Do not overtighten.
Wiper Linkage Replacement The threads on the shafts are easily stripped
when improperly tightened.
Removal
4. Align the linkage and attach to the wiper motor
1. Remove the wiper arms. Refer to Wiper Arm drive arm using retainer (2, Figure 3-3).
Replacement in this section.
NOTE: When the motor is parked, the drive arm will
2. Remove wiper retainer (2, Figure 3-3) and dis- be in the 3 o’clock position as shown in Figure 3-3.
connect the wiper linkage from the wiper motor
5. Install the wiper arms. Refer to Wiper Arm
drive arm.
Installation. Ensure the wipers arms operate
3. Remove nut (3, Figure 3-2) and the washer properly and park in the proper position after
from each wiper shaft. installation is complete.
Service
If windshield washer maintenance is required, check
the strainer opening for obstructions and inspect the
hoses for damage. Check the voltage to the pump
from the control switch. If the pump is inoperable,
replace it with a new pump assembly.
Note: The pump is only available as an assembly
and cannot be repaired.
OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEATER/AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEATER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Heater Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fan Motor And Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Environmental Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATOR CAB AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRINCIPLES OF REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigeration - The Act Of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AIR CONDITIONER SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Compressor (Refrigerant Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Expansion Block Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trinary™ Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYSTEM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handling and Reusing PAG Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing Oil After Servicing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Setting Up a New Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recycled Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reclaimed Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigerant Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
R-134a Refrigerant Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation
Heat for the cab is provided by passing coolant from
the engine cooling system through a heater coil.
Blowers move air across the heating coil which
warms the air for heating or defrosting.
An engine driven freon compressor passes refriger-
ant through an evaporator coil mounted in the same
enclosure. The same blowers used for heating move
air across the evaporator to provide cooled air
through the outlet vents.
All heater and air conditioner controls are mounted
on a pod on the face of the enclosure. Refer to Fig-
ure 4-1 for the following:
• Defroster Switch (1): This is a 2-position toggle
switch; "down " is OFF. "Up" provides air flow
through the defroster vents.
• Heat Vent Control Switch (2): This is a 2-
position toggle switch; "down " is OFF. "Up"
provides heated air flow to the cab floor.
• Fan Control (3): This is a 3-position rotary
switch; rotate knob to select low, medium, or high
fan speed.
• Air Conditioner Temperature Control (4): This
FIGURE 4-1. HEATER/AIR CONDITIONER
is an infinitely variable rotary control; rotate
CONTROLS
counterclockwise to reduce cooling, clockwise to
increase cooling.
1. Defroster Switch 5. Outside/Inside Air
• Outside/Inside Air Selector(5): This is a 2- 2. Heater Control Selector
position toggle switch; "down" recirculates cab Switch 6. Selection Control
air. "Up" allows outside air to flow through heater
3. Fan Speed Switch 7. Outlet Vents
or air conditioner coils.
4. A/C Temperature
• Selection Control (6): This is a variable rotary Control
control. Rotating the knob counterclockwise (blue
arrow) will select increasingly cooler
temperatures. Rotating the knob clockwise (red
arrow) selects increasingly warmer temperatures.
Actuators
Three linear actuators (22, Figure 4-4) are installed
inside the heater housing and are used to actuate the
flappers for the following:
• Defroster outlet FIGURE 4-3. CAB FILTER LOCATION
Test
Visually inspect the flapper and linkage for the func-
tion being diagnosed. Make certain the flapper is not
binding or obstructed, preventing movement from
one mode to the other.
Verify voltage is present at the actuator when the
toggle switch is closed or absent when the toggle
switch is opened.
If voltage is proper, disconnect actuator from flapper
and verify actuator force is comparable to a known
(new) actuator. If not, replace with a new actuator.
Reclaimed Refrigerant
Reclaimed refrigerant has been filtered through a
R-134a Refrigerant Containers
more thorough filtering process and has been pro-
cessed to the same standards of purity as virgin Two basic, readily available containers are used to
refrigerant. Because of this, reclaimed refrigerant is store R-134a: the 30 or 60 pound bulk canisters (Fig-
acceptable for use in all systems, not just mobile. ure 4-6).
The reclaiming equipment used for this process is
Always read the container label to verify the contents
expensive, and therefore, not common among nor-
are correct for the system being serviced. Note the
mal maintenance shops. Equipment such as this is
containers for R-134a are painted light blue.
more commonly found in air conditioning specialty
shops.
Refrigerant Quantity
If not enough refrigerant is charged into the system,
cooling ability will be diminished. If too much refriger- FIGURE 4-6. R-134a CONTAINERS
ant is charged into the system, the system will oper-
ate at higher pressures, and in some cases, may 1. 30 lb. Cylinder 2. 60 lb. Cylinder
damage system components. Exceeding the speci-
fied refrigerant charge will not provide better cooling.
If an incorrect charge is suspected, recover the
refrigerant from the system, and charge the system
with the correct operating weight (6.9 lb, 3.13 kg).
This is not only the recommended procedure, but it is
also the best way to ensure that the system is operat-
ing with the proper charge and providing optimum
cooling. Using the sight glass to determine the
charge is not an accurate method.
8 24 - 29 ft.lbs. 33 - 39 Nm
10 26 - 31 ft.lbs. 36 - 42 Nm
12 30 - 35 ft.lbs. 41 - 47 Nm
Only SAE and/or Mobile Air Conditioning Society
(MACS) approved flushing methods with the Installation torque for the single M10 or 3/8 in. cap-
appropriate refrigerants are to be performed screws securing the inlet and outlet fittings onto the
when removing debris from the system. Other compressor ports is 11 - 25 ft.lbs. (15 - 34 Nm).
methods may be harmful to the environment, as
well as air conditioning components.
Expansion Valve
When removing the expansion valve from the sys-
tem, remove the insulation, clean the area and dis-
connect the line from the receiver-drier. Detach the
capillary (bulb) and external equalizer tube (if
present) from their mounting locations. Remove the
expansion valve from the evaporator inlet. Expansion
valve service is limited to cleaning or replacing the fil-
ter screen. If this is not the problem, replace the
valve. Secure the capillary and equalizer, if used, to
clean surfaces and replace or attach any insulating
material.
Compressor
NOTE: Some compressors may be discarded
The compressor can fail due to shaft seal leaks (no because it is suspected that internal components
refrigerant in the system), defective valve plates, within the compressor have seized. Ensure that
bearings, or other internal parts or problems associ- the compressor clutch is working properly before
ated with high or low pressure, heat, or lack of lubri- discarding a compressor for internal seizure. The
cation. Be sure the compressor is securely mounted normal compressor life span should be about
and the clutch pulley is properly aligned with the twice as long as the normal life span of the com-
drive pulley. pressor clutch.
Use a mechanic's stethoscope to listen for noises It is important to note that often times a weak clutch
inside the compressor. coil may be mistaken for a seized compressor. When
a coil’s resistance has increased over time and the
magnetic field weakens, the coil may not be able to
pull the load of the compressor. Failure of the coil to
allow the compressor shaft to be turned, may appear
as though the compressor is locked up.
FIGURE 4-14.
Servicing the Compressor Clutch 1. Belt Pulley 3. Shaft
2. Clutch Hub/Drive 4. Locknut
* RECOMMENDED TOOLS FOR COMPRESSOR Plate
CLUTCH REMOVAL AND INSTALLATION
**J-9403 Spanner Wrench 2. Remove the drive belt from compressor belt
pulley (1, Figure 4-14).
**J-25030 Clutch Hub Holding Tool
FIGURE 4-15.
Use the proper tools to remove and replace 1. Thin Wall Socket 3. Clutch Hub
clutch components. Using the recommended 2. Clutch Hub Holding
tooling helps prevent damage to compressor Tool
components during maintenance.
Do not drive or pound on the clutch plate, hub
assembly, or shaft. Internal damage to the com-
pressor may result.
FIGURE 4-18.
FIGURE 4-17.
FIGURE 4-19. If the resistance of the coil is not within the specifica-
tions, the clutch will not operate properly. Remove
1. Pulley Assembly 3. Retaining Ring Pliers the retaining ring and replace the coil.
2. Pulley Retainer Ring
FIGURE 4-21.
1. Bearing Installer 2. Universal Handle
Indications:
Low side pressure - VERY LOW
High side pressure - VERY LOW
Discharge air is warm.
No bubbles observed in sight glass, may show oil
streaks.
- Pressure sensing switch may have compressor Add refrigerant (make sure system has at least
clutch disengaged. 50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
-
enable the compressor to operate, if the com-
- Refrigerant excessively low; leak in system. pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is warm.
The low pressure switch may have
shut off the compressor clutch.
Leaks Found:
Add refrigerant (make sure system has at least
50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable the compressor to operate, if the com-
pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
Indications:
Low side pressure - Normal
High side pressure - Normal
Discharge air is only slightly cool.
(In a cycling type system with a
thermostatic switch, the switch may not cycle
the clutch on and off, so the low pressure
gauge will not fluctuate.)
Indications:
Low side pressure - HIGH
High side pressure - HIGH
Discharge air is only slightly cool.
Indications:
Low side pressure - VERY LOW or in a Vacuum
High side pressure - HIGH
Discharge air only slightly cool.
Expansion valve body is frosted or sweaty.
Indications:
Low side pressure - HIGH
High side pressure - Normal
Air from vents in the cab seems warm
or only slightly cool.
Indications:
Low side pressure - LOW
High side pressure - Normal to HIGH
Discharge air is only slightly cool.
Look for sweat or frost on high side hoses
and tubing. The line will be cool to the touch
near the restriction.
Indications:
Low side pressure - HIGH
High side pressure - LOW
Compressor operates noisily.
Indications:
Low side pressure - Normal
High side pressure - Normal
Low side pressure may cycle within a smaller
range as the compressor clutch cycles
more frequently than normal. This may indicate
the thermostat is set too high.
Indications:
Low Side High
High Side High
Discharge air may be warm.
High pressure hoses and lines are very hot.
Date:____________Hour Meter:________________
NOTE: Compressor should be run at least 5 minutes
(40°F minimum ambient temperature) every month,
Maintenance Interval in order to circulate oil and lubricate components.
COMPONENT (months)
Maintenance Interval
3 6 12 Done
COMPONENT (months)
1. Compressor
3 6 12 Done
Check noise level
4. Expansion Valve X
Check clutch pulley
Inspect capillary tube (if
Check oil level used) for leakage, damage,
Run system 5 minutes looseness
Check belt tension 5. Evaporator
(80-100) lbs; V-belt
Clean dirt, bugs, leaves, etc.
Inspect shaft seal for leakage from fins (w/ compressed air)
Check mounting bracket Check solder joints on inlet/
(tighten bolts) outlet tubes (leakage)
Check clutch alignment w/ Inspect condensation drain
crankshaft pulley (within
6. Other Components
0.06 in.)
Check discharge lines
Perform manifold gauge
(hot to touch)
check
Check suction lines
Verify clutch is engaging
(cold to touch)
2. Condenser
Inspect fittings/clamps/hoses
Clean dirt, bugs, leaves, etc.
Check thermostatic switch for
from coils (w/compressed air)
proper operation
Verify engine fan clutch is
Outlets in cab: 40°F to 50° F
engaging (if installed)
Inspect all wiring connections
Check inlet/outlet for
obstructions or damage Operate all manual controls
through full functions
3. Receiver-Drier
Check inlet line from
condenser (should be hot to
touch)
Replace, if system is opened
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DYNAMIC RETARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PASSENGER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONTROL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation
1. Install stub shaft (11, Figure 5-1) on steering
column splines. Leave a 0.125 in. (3.2 mm) gap
between end of stub shaft and end of steering
column housing. Tighten clamp capscrew (6) to
standard torque.
2. Apply molybdenum disulphide or multi-purpose
NLGI grease to external splines of stub shaft.
3. With the steering column tilted at approximately
30°, insert the lower end of the column into the
opening in the instrument panel. Attach saddle
bracket (5) with capscrews and washers (4).
Tighten to standard torque.
4. Position saddle bracket over tapped mounting
holes and install capscrews and washers (3).
Tighten capscrews just enough to secure col-
umn in position.
FIGURE 5-1. STEERING COLUMN INSTALLATION 5. With capscrews (3) loosened, allow steering
column to slide downward until stub shaft (11)
1. Steering Column 7. Capscrews, Washers splines bottom in steering control unit (9). When
2. Trim Cover 8. Front Access Cover
the stub shaft is at rest at the bottom of the input
3. Capscrews, Washers 9. Steering Control Unit
collar, slide column out to obtain 0.08 to 0.120
4. Capscrews, Washers 10. Capscrews, Washers
in. (2 to 3 mm) clearance between end of stub
5. Saddle Bracket 11. Stub Shaft
shaft and steering control unit. Tighten cap-
6. Capscrew & Nut
screws (3) to standard torque.
Removal NOTE: The gap in Step 5 can be measured by
etching a line across saddle bracket (5) and the
1. Shut down the engine by turning the key switch
bracket mounting face while the stub shaft is at rest
"Off" and allow the steering accumulators to
in the control unit. Pull the column away from the
bleed down. Allow at least 90 seconds for bleed
control unit until the correct gap exists between the
down. Turn the steering wheel to ensure no
mark on the bracket and the mark on mounting face.
pressure remains.
6. Carefully tighten capscrews (7 & 10). It is impor-
2. Open the battery disconnect switches.
tant to use care when tightening to be certain no
3. Remove access cover (8, Figure 5-1) from the binding occurs between stub shaft and steering
front of the cab. unit splines.
4. Loosen capscrews (7 & 10) on control unit (9).
5. Disconnect wire harness from the steering col-
umn at the connector.
HORN BUTTON
The horn (2, Figure 5-3) is actuated by pushing the
button in the center of the steering wheel. Operation
of the horn should be verified before moving the
truck. Observe all local safety rules regarding the use
of the horn as a warning signal device before starting
engine and moving the vehicle.
WINDSHIELD WIPERS
The windshield wipers (13, Figure 5-2) are powered
by an electric motor. Refer to INSTRUMENT PANEL
AND INDICATOR LIGHTS, for a location and
description of the windshield wiper and washer con-
trols.
1. Center Console
2. F-N-R Selector Switch
3. Hoist Control Lever
4. Ash Tray
5. Cigar/Cigarette Lighter
6. L.H. Window Control Switch
7. R.H. Window Control Switch
8. Engine Shutdown Switch
9. Override/Fault Reset Switch
10. BLANK - NOT USED on this truck
11. RSC "Off/On" Switch
12. Retarder Speed Control Dial
13. Propulsion System Controller (PSC)
Diagnostic Port
14. Engine Diagnostic Port (3 Pin)
15. Truck Control Interface (TCI)
Diagnostic Port
16. Passenger Seat
(mounted on top of the right hand
portion of the Console structure)
LIGHTER
The LIGHTER (5, Figure 5-5) may be used for light-
ing cigars/cigarettes.
Always use CAUTION with smoking materials!.
This socket may also be used for a 12 VDC power
supply.
To lower body:
Move hoist lever forward to "down" position and
release. Releasing the lever places hoist control
valve in the "float" position allowing the body to
return to frame.
WIRE NUMBERS
1. 712/21PB/11S 11. 71/79M/SPR55/79H/72F/SPR54 21. 712D/31TS/710/49
2. 11S/11TD/11R 12. 712BL/52B/39H/710/SPR59 22. 712D/38G/710/49
3. 712/47S/47L/710 13. 71/52C/21PB/21 23. 15V/72MT/49/710
4. 11L/48A/48B 14. 41TS/74X/74Z/710 24. 11L/36
5. 11L/48F 15. 45R/710 25. 15V/34BT/710/49
6. 49/710 16. 41H/710 26. 710/72RQ
7. N/A 17. 45L/710 27. 11D/41L/41TS
8. 712/28E 18. 41TS/77/77A/710 28. High 66S/Low 66L/710
9. 11L/11RB 19. 712D/710/49 Park/712W / Washer 66
10. 712/69M/SPR56/SPR57/SPR58 20. 712D/31PS/710/49 29. 49/41TS
(8, Figure 5-6) NOT USED ON 930E Use at shovel and dump only to hold truck in
position.
RED color indicator lights alert the operator that the • If the indicator light illuminates at higher truck
indicated truck function requires immediate action speed and high engine RPM, DO NOT
OPERATE TRUCK.
by the operator. Safely stop the truck and shut down
the engine.
DO NOT OPERATE THE TRUCK WITH A RED If the low steering
WARNING LIGHT ILLUMINATED. warning light con-
tinues to illumi-
Refer to Figure 5-7 and the descriptions below for
nate and the alarm
explanations of the symbols.
continues to sound, low steering pressure is
Location of the symbols is described by rows (A-E) indicated. The remaining pressure in the accu-
and columns (1 - 6). mulators allows the operator to control the truck
to a stop. Do not attempt further operation until
the malfunction is located and corrected.
A1 Not Used
C1. Low Accumulator Precharge Pressure
The low accumulator precharge warning light, if illu-
B1 Low Steering Pressure RED
minated, indicates low nitrogen precharge for the
steering accumulator(s). To check for proper accu-
mulator nitrogen precharge, engine must be stopped
C1 Low Accumulator RED and hydraulic system completely bled down; then
Precharge Pressure turn keyswitch to "Run" position. Warning light will
NOT illuminate if system is properly charged. The
D1 Not Used warning light will flash if the nitrogen precharge
within the accumulator(s) is below 1100 ± 45 psi
(7585 ± 310 kPa).
E1 Low Brake Pressure RED
If low accumula-
tor precharge
warning light
flashes, notify
A1. NOT USED maintenance personnel. Do not attempt further
Not currently used. Reserved for future use or operation until the accumulators have been
options. recharged with nitrogen to 1400 psi (9653 kPa).
Sufficient energy for emergency steering may not
B1. Low Steering Pressure be available, if system is not properly charged.
When the keyswitch is turned "ON", the low steering D1. NOT USED
pressure warning light will illuminate until the steering
system hydraulic pressure reaches 2100 psi (14.7 Not currently used. Reserved for future use or
MPa). The warning horn will also turn on, and both options.
will remain on, until the accumulator has been
E1. Low Brake Pressure
charged.
This red indicator light indicates a malfunction within
During truck operation, the low steering pressure
the hydraulic brake circuit. If this light comes on and
warning light and warning horn will turn sound if
buzzer sounds, shut down truck operation and
steering system hydraulic pressure drops below
notify maintenance personnel.
2100 psi (14.7 MPa).
NOTE: Adequate hydraulic fluid is stored to allow the
• If the light illuminates momentarily ("flickers")
operator to safely stop the truck.
while turning the steering wheel at low truck
B2. NOT USED This amber service brake indicator light will illuminate
when the service brake pedal is applied or when
Not currently used. Reserved for future use or brake lock or emergency brake is applied. Do not
options. attempt to drive truck from stopped position with ser-
vice brakes applied, except as noted in "Operating
C2. Circuit Breaker Tripped Instructions, Starting On a Grade With a Loaded
This light will illuminate if any of the circuit breakers Truck", Section 3, Operation & Maintenance Manual.
in the relay circuit control boards are tripped. The
relay circuit boards are located in the Electrical Inter- C3. Body Up
face Cabinet. NOTE: Additional circuit breakers are This amber Body Up indicator, when illuminated,
in the operator cab behind the center console, how- indicates the body is not resting on the frame. The
ever tripping of these circuit breakers should not acti- truck should not be driven until body is down and
vate this light. light is off.
E2. Low Fuel This RED engine monitor warning light will illuminate
if a serious engine malfunction is detected in the
This amber low fuel indicator will illuminate when the electronic engine control system.
usable fuel remaining in the tank is approximately 25
gallons (95 liters). A warning buzzer will also sound. • Electric propulsion to the wheel motors will be
discontinued.
INDEX
INDEX
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. ENGINE -
a. Check the oil level on the dipstick. Refer to
the engine manual for oil recommendations.
(Lube Key “A”).
b. Inspect exhaust piping for security.
c. Check for abnormal noises and fluid leaks.
*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation).
*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:
*This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:
FIGURE 2-7.
1. Magnetic Plug 2. Cover
FIGURE 2-8.
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N.C.) . . . . . . . . . . . . . . . . . . . . . P3-10
System Components
The system is comprised of these basic elements
plus the necessary hoses and lube lines:
1. Hydraulically Powered Reciprocating Cylinder
and Pump (1 & 5, Figure 3-1).
Pump Specifications:
• 16:1 Pressure Ratio.
NOTE: The theoretical ratio of this pump is 16:1
MAXIMUM, depending on the application and
variable internal friction. The actual ratio may be less,
but should be at least 10:1.
• Input Pressure: 300-3000 psi (2068 - 20685 kPa)
• Input Flow: 1.0 gpm (3.8 l/min.)
• Max. Hydraulic Temperature: 210°F (98.8°C) FIGURE 3-1. TYPICAL AUTO LUBE SYSTEM
• Output Pressure: 3500 psi (24132 kPa) max. 1. Pump Cylinder 7. Pump Cycle Timer
• Output Flow: 11 cu. in./min. (180 cc/min.) 2. Cylinder Pressure 8. Solenoid Valve, SV2
• Operating Ambient Temperature: -40°F to +135°F Gauge 9. Solenoid Valve, SV1
(-40°C to +57.7°C) 3. Valve Body Assembly 10. Pressure Reducing
• Seals: Buna-N 4. Orifice Assembly Valve
5. Pump Assembly 11. Vent Valve Assembly
• Filtration Required: 10 Micron
6. Canister/Reservoir
• 24VDC power source.
b. Pressure Reducing Valve: The Pressure
Reducing Valve (10) lowers hydraulic fluid
2. Combination Valve Body (3, Figure 3-1)
pressure to the operating range of the
includes:
hydraulic pump cylinder. It is factory set at its
a. 24VDC Solenoid Valves (SV1 & SV2) are maximum pressure of 300 psi (2069 kPa),
used as directional valves that are integrated but may be adjusted lower.
with the hydraulically operated pump. The
c. The Cylinder Pressure Gauge (2): indicates
controls are designed to insure maximum
hydraulic fluid pressure going to the hydrau-
flow rates within the specified operating tem-
lic pump cylinder after passing through the
perature range.
pressure reducing valve.
Solenoid Valve SVI (9) controls hydraulic
d. Orifice Assembly (4): delivers metered
fluid pressure flow through the pressure
hydraulic pressure from the pressure reduc-
reducing valve and on to the vent valve.
ing valve to the top of the vent valve assem-
Solenoid Valve SV2 (8) directs the hydraulic bly. This fitting should be connected to the
fluid to the hydraulic cylinder which operates top of the Vent Valve assembly (11) with a
the grease pump. high pressure 1/4 in. hose.
Injector Adjustment
FIGURE 3-4. TYPE SL-1 INJECTOR (SINGLE)
1. Adjusting Screw 11. Spring Seat The injectors may be adjusted to supply from 0.008
2. Locknut 12. Plunger in3 to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per
3. Piston Stop Plug 13. Viton Packing injection cycle. The injector piston travel distance
4. Gasket 14. Inlet Disc determines the amount of lubricant supplied. This
5. Washer 15. Viton Packing travel is in turn controlled by an adjusting screw in
6. Viton O-Ring 16. Washer the top of the injector housing.
7. Injector Body Assy 17. Gasket
Turn the adjusting screw (1, Figure 3-4) counter-
8. Piston Assembly 18. Adapter Bolt
clockwise to increase lubricant amount delivered and
9. Fitting Assembly 19. Adapter
clockwise to decrease the lubricant amount.
10. Plunger Spring 20. Viton Packing
When the injector is not pressurized, maximum injec-
NOTE: The Piston Assembly (8) has a visible tor delivery volume is attained by turning the adjust-
indicator pin at the top of the assembly to verify the ing screw (1) fully counterclockwise until the
injector operation. indicating pin (8) just touches the adjusting screw. At
the maximum delivery point, about 0.38 inch (9.7
mm) adjusting screw threads should be showing.
Decrease the delivered lubricant amount by turning
the adjusting screw clockwise to limit injector piston
travel. If only half the lubricant is needed, turn the
adjusting screw to the point where about 0.19 inch
(4.8 mm) threads are showing. The injector will be
set at minimum delivery point with about 0.009 inch
(0.22 mm) thread showing.
NOTE: The above information concerns adjustment
of injector delivery volume. The timer adjustment
should also be changed, if overall lubricant delivery is
too little or too much. Injector output should NOT be
adjusted to less than one-fourth capacity.
STAGE 1.
The injector piston (2) is in its normal or
“rest” position. The discharge chamber (3) is
filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant (6),
the slide valve (5) is about to open the pas-
sage (4) leading to the measuring chamber
(1) above the injector piston (2).
STAGE 2.
When the slide valve (5) uncovers the pas-
sage (4), lubricant (6) is admitted to the mea-
suring chamber (1) above the injector piston
(2) which forces lubricant from the discharge
chamber (3) through the outlet port (7) to the
bearing.
STAGE 3.
As the injector piston (2) completes its
stroke, it pushes the slide valve (5) past the
passage (4), cutting off further admission of
lubricant (6) to the passage (4) and measur-
ing chamber (1). The injector piston (2) and
slide valve (5) remain in this position until
lubricant pressure in the supply line (6) is
vented.
STAGE 4.
After venting, the injector spring expands,
causing the slide valve (5) to move, so that
the passage (4) and discharge chamber (3)
are connected by a valve port (8). Further
expansion of the spring causes the piston to
move upward, forcing the lubricant in the
measuring chamber (1) through the passage
(4) and valve port (8) to refill the discharge
chamber (3).
NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first
timing cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be
as specified.
NOTE: Normally, during operation, the injector indicator stem (1, Figure 3-4) will move into the body of the
injector when pressure builds properly. When the system vents (pressure release) the indicator stem will again
move out into the adjusting yoke.
TROUBLE: Timer Turns On At Intervals Two To Ten Times More Often Than Set Time Interval
Electrical noise is being introduced into the power IMPORTANT: In some instances, electrical noise
supply to the timer overcoming suppressor capaci- may be generated into vehicle electrical system
tor causing uncontrolled turn-on of its output relay. which may cause timer to turn on at random
intervals, independent of timer setting.
If this occurs, a 250 to 1,000 MFD capacitor rated
150 to 350 VDC should be added across BAT (+)
and BAT (-) terminals to suppress this noise and
improve timer performance.
Daily Lubrication System Inspection It is good practice to manually lube each bear-
ing point at the grease fitting (Zerk, Figure 3-4)
1. Check grease reservoir level. provided on each Injector. This will indicate if
Inspect grease level height after each shift of there are any frozen or plugged bearings, and
operation. Grease usage should be consistent will help flush the bearings of contaminants.
from day-to-day operations. 5. System Checkout
• Lack of lubricant usage would indicate an Remove all SL-1 injector cover caps to allow
inoperative system. visual inspection of the injector cycle indicator
• Excessive usage would indicate a broken supply pins during system operation.
line. Start truck engine.
2. Check all grease supply lines from the SL-1
Lift the passenger seat and connect a jumper
Injectors to lubrication points (11, Figure 3-2).
wire between "SOL" (Wire 68A) and "LUBE
Repair or replace all worn / broken feed line SW" on the 24VDC solid state timer (Figure 3-
hoses. 7).The hydraulic grease pump should operate.
Make sure that all air is purged and all new feed Keep the jumper wire connected until the pump
line hoses are filled with grease before sending stalls out at 2000 PSI. (Refer to NOTE: follow-
the truck back into service. ing step 7, page 3-3, regarding pressure
3. Inspect key lubrication points for a bead of lubri- switch.)
cant around seal. With the pump in the stalled-out mode, check
Make note of all lubrication points that look dry. each SL-1 injector assembly. The cycle indica-
Notify maintenance staff for repair service. tor pin should be retracted inside the injector
body.
250 Hour Inspection
Once all of the SL-1 injectors have been
1. Check all grease supply hoses from the SL-1 inspected under pressure remove the jumper
Injectors to lubrication points (11, Figure 3-2). wire between the "SOL" terminal and "LUBE
SW" terminal on the timer assembly. The pump
Repair or replace all worn / broken feed line
should shut off and the pressure in the system
hoses.
should drop to zero venting back to the grease
Make sure that all air is purged and all new feed reservoir.
line hoses are filled with grease before sending
With the system vented, check all of the SL-1
the truck back into service.
injector indicator pins. All of the pins should be
2. Check all grease supply line hoses from the visible.
pump to the SL-1 injectors (11, Figure 3-2, typi-
cal). NOTE: Refer to the system troubleshooting chart, if
the injectors are not working properly. Replace or
Repair or replace all worn / broken supply lines. repair injectors, if defective.
Make sure that all air is purged and all new sup- Reinstall all injector cover caps.
ply line hoses are filled with grease before
sending the truck back into service. Check timer operation. With engine running,
lube system should activate within 5 minutes.
3. Check grease reservoir level.
The system should build 2000PSI within 25-40
Fill reservoir if low. seconds.
Check reservoir for contaminants. Clean, if If the system is working properly, the machine is
required. ready for operation.
Check that all filler plugs, covers and breather If the system is malfunctioning, refer to the trou-
vents on the reservoir are intact and free of con- bleshooting chart in the service manual.
taminants.
L
G
Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-32
Lubrication and Service . . . . . . . . . . . . . . . . . . . . P2-3
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Lubrication System, Automatic . . . . . . . . . . . . . . . P3-3
O S
Oiling and Charging Procedure, Suspension . . . . H4-3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Operator Cab Controls . . . . . . . . . . . . . . . . . . . . . N5-3 Software Functions, PSC. . . . . . . . . . . . . . . . . . . E2-32
Optional Equipment Starter, 24VDC (Refer to Engine Manual)
Fire Control System . . . . . . . . . . . . . . . . . . . . . .M2-3
Seal Assemblies, Gap Adjustment
Payload Meter II . . . . . . . . . . . . . . . . . . . . . . . .M20-1
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-11
Overhead Display Panel . . . . . . . . . . . . . . . . . . . N5-23 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-12
Seat, Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
P Solenoid
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3 Bleeddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-5
Pedal Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M8-1
Accelerator, Electronic . . . . . . . . . . . . . . . . . . . E2-54 Specifications
Retarder, Electronic . . . . . . . . . . . . . . . . . . . . . E2-54 HYDRAIR® II Oil . . . . . . . . . . . . . . . . . . . . . . . H4-10
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5 HYDRAIR® II Nitrogen . . . . . . . . . . . . . . . . . . . H4-10
Plates, Warning and Caution . . . . . . . . . . . . . . . . . A4-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
Portable Test Unit (PTU) . . . . . . . . . . . . . . . . . . . . E3-6 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3 Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3 Spindle, Front Wheel Hub . . . . . . . . . . . . . . . . . . .G3-3
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8 Starter Isolation Diode . . . . . . . . . . . . . . . . . . . . . . D2-5
Engine/Alternator Mating . . . . . . . . . . . . . . . . . . C4-5 Status/Warning Indicator Lights . . . . . . . . . . . . . . N5-24
Pressure Control Adjustment, Pump . . . . . . . . . . L10-4 Steering
Propulsion System Controller (PSC) . . . . . . . . . . . E2-5 Accumulator Charging Procedure . . . . . . . . . . . . L6-7
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . E3-22 Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
Pump, Hoist System . . . . . . . . . . . . . . . . . . . . . . . L3-3 Hydraulic Check-Out Procedure . . . . . . . . . . . . L10-3
Pump, Steering/Brake System. . . . . . . . . . . . . . . L6-14 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-3
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . L6-25
Strainer, Hydraulic Tank. . . . . . . . . . . . . . . . . . . . L3-17
Suspension, HYDRAIR® II
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
U
Unloader Valve, adjustment . . . . . . . . . . . . . . . . .L10-4