NOTES

13-2 Toe-In Adjustment Procedure FAM1306

 PRE-SHIFT BRAKE TEST - TEST PROCEDURE
Purpose
This procedure allows the operator to check the
functionality of Service Brake, Parking Brake, Drive
Brake (Hill Start Assist (HSA) - If HSA is enabled)
and retarder prior to each shift.
Pre-Shift Brake Check:
The static brake test allows the operator to check
and verify the service brake, parking brake, drive
Brake and the dynamic retarder at the time they are
tested.
NOTE: Komatsu recommends that operators perform
static brake tests to verify that the braking systems
are adequate at the beginning of each shift before
operating the truck.
After performing each test, it is the operator's
responsibility to determine if the truck passed each
test and if the truck is safe for operation.
The order of performing the brake tests, (service
brake, parking brake, Drive brake or retard system)
does not matter. Each brake test is a separate test,
where one brake system or all can be tested at any
time.
If an operator has questions during brake testing,
refer to the drive system Vehicle Information Display
(VID) panel, located on the back wall of the cab for
guidance.
NOTE: Whether to log the events shall also be an
OEM option. Some mines may not want to fill the TCI
log with these types of events.
Events Requiring PSBT:
534-1 - Hill Start Assist Disabled - Drive Brake Test
needed
NOTE: While 534-1 event is logged the Hill start
assist feature is inhibited. Drive brake portion of
PSBT must be run to un-inhibit the feature.
Operation
The static brake test utilizes a momentary switch and
a check light. The amber light at the top of the switch
acts as the check light.
NOTE: Whether to log the events shall also be an
OEM option. Some mines may not want to fill the TCI
log with these types of events.
Brake Test Switch
The brake test switch (Figure 1-1) is used to initiate a
brake test. Press on the momentary switch to enter
the brake test mode. If certain conditions are met, the
operator can enter a brake test sequence.

If the truck fails any brake test, notify mainte-

nance personnel immediately. DO NOT resume
operation unless the truck passes all brake tests.

Events
The following events have been added to the drive
system software to support the brake test feature.
• 645-1 Service Brake Test Performed FIGURE 1-1.
• 645-2 Parking Brake Test Performed
• 645-3 Retard Test Performed
• 645-4 Retard Test Failed
• 645-5 Brake Test Switch stuck closed
• 645-6 Drive Brake Test Performed

58E-06-09750-01 8/19 Pre-Shift Brake Test - Test Procedure 1

Brake Check Light For example, if the engine is off:
The amber light at the top of the switch is used to ERROR Entering Brake Test
indicate when the truck is in the brake test mode.
Engine not running
When illuminated, a brake test is ready. When
flashing, the brake test is at the validation point, or If the truck is loaded:
the retard system test is finished.
ERROR Entering Brake Test
Truck is NOT empty
If all the conditions are correct, except the brakes are
not set correctly, an error message will be displayed.
For example, if the service brake and parking brake
are both applied together:
ERROR Entering Brake Test
Set Brakes for Test

Brake Test Exit Criteria

FIGURE 1-2.
Description
The operator can choose which brake test to perform
and will set the truck controls based on the settings in
Table 1, “BRAKE TEST SETTINGS,” on page 3. The
drive system will detect the position of the directional
control lever, and will prepare for the appropriate test.
The operator will then press the brake test switch.
Numerous conditions can occur which may interrupt
a brake test, including the following:
• Any of the setup conditions becoming false
• System Fault which restricts the LINK or Propel
mode
• Truck Speed > 2.0 mph in Service Brake test
• One rotation of motor rotor in Park brake or Drive
brake tests
• Truck at torque level for more then 30 seconds

If the brake check light is illuminated solid after • Test requested, (button), but not initiated (pedal)
pressing the brake test switch, the system is in brake for 60 secs.
test mode and is ready to begin the test. The
operator then has 60 seconds to choose and initiate
PERFORMING THE BRAKE TESTS
the test to be performed. After testing, the operator Setup
will then determine if the truck passed the brake
tests, and if it is safe for operation. Before performing any brake test, the following
conditions must be met:
If the brake check light does not illuminate
immediately after pressing the brake test switch, • Dump body empty
there is most likely a problem with the setup. Refer to NOTE: The drive system will not enter any brake test
the setup conditions and take action to prepare the if the truck is loaded.
truck for a brake test.
• Truck located outside on a flat area, where truck
If there is a problem with the truck setup, the VID movement is allowed.
panel will display the problem.

2 Pre-Shift Brake Test - Test Procedure 8/19 58E-06-09750-01

 Before performing any brake test, the truck must be
in the following state:
Engine running (low idle)
Link charged (Ready Mode)
Ensure the area around the truck is free of per-
sonnel and objects. Some truck movement could Dump body down
occur during brake testing. Not in LIMP mode (Both Inverters Cut-in and OK)
The drive system is unable to determine if the
truck is on a hill or in a parking ditch. Testing Zero ground speed
during these conditions will affect test results.
Table 1: BRAKE TEST SETTINGS

BRAKE TEST SETTINGS

Test Type Wheel Brake Service Brake Directional
Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF OFF/RELEASED PARK
Drive Brake ON OFF/RELEASED NEUTRAL
(HSA enabled)
Retard Test OFF OFF/RELEASED PARK

Service Brake Test 6. With the service brake pedal still fully applied,
fully depress the accelerator pedal. The drive
system controller will enter propel mode and
generate torque up to the service brake limit.
Maintain full service brake pressure during the
test.
If the truck fails the service brake test, notify NOTE: The drive system can only detect if the
maintenance personnel immediately. Do not service brakes are applied. It can not detect the
resume operation unless the truck passes all percentage of application. It is up to the operator to
brake tests. press hard enough on the service brake pedal to
1. Firmly depress the service brake pedal. On the achieve a full brake application.
retard/service brake one pedal system, push
the pedal fully to engage service brake
completely.
2. Place the directional control lever in the
NEUTRAL position. Ensure the wheel brake
lock switch is OFF.
3. Press the brake test switch and wait for the
brake check light to be on solid.
4. Fully depress the service brake pedal. Ensure
full brake application is reached. Failure to
reach full brake application will affect the
service brake test results.
5. The VID panel will display:
Service Brake Test READY
Press Accel Pedal to Start

58E-06-09750-01 8/19 Pre-Shift Brake Test - Test Procedure 3

 7. The VID panel will display:
Service Brake Test ACTIVE
Check Truck Movement when Light Flashes
8. Once torque has reached the limit for the
service brake test, the brake check light will
begin to flash. This is the indication for the
operator to make a determination as to the
status of the service brake system.
• If the truck did not move:
The service brake system passed the test.
• If the truck moved during the test:
The service brake system failed the test.
9. Release the accelerator pedal and the torque
will be reduced, the test will stop and the brake
check light will turn off.
10. Place the directional control lever in the PARK
position. Release the service brake pedal.
11. If the truck failed the service brake test, notify
maintenance personnel immediately.
If the test exits abnormally, or if the operator simply
does not press the accelerator pedal far enough to
achieve the torque level for the service brake test,
the VID panel will display:
Brake Test ERROR
Test did NOT Complete
NOTE: If the operator partially or fully releases the
accelerator pedal during the test, torque will be
reduced and the brake check light will go back on
solid when torque falls below the test set point. The
operator can re-apply the accelerator pedal to
increase torque and the brake check light will again
flash when the torque is at the test limit.
4 Pre-Shift Brake Test - Test Procedure
Parking Brake Test
If the truck fails the parking brake test, notify
maintenance personnel immediately. Do not
resume operation unless the truck passes all
brake tests.
1. Place the directional control lever in the PARK
position.
2. Press the brake test switch and wait for the
brake check light to be on solid.
3. The VID panel will display:
Parking Brake or Retard Test READY
Press Accel or Retard Pedal to Start
4. Fully depress the accelerator pedal. The drive
system controller will enter propel mode and
generate torque up to the park brake limit.
5. The VID panel will display:
Park Brake Test ACTIVE
Check Truck Movement when Light Flashes
6. Once the torque has reached the limit for the
parking brake test, the brake check light will
begin to flash. This is the indication for the
operator to make a determination as to the
status of the parking brake system.
• If the truck did not move:
The park brake system passed the test.
• If the truck moved during the test:
7. When the operator releases the accelerator
pedal, torque will be reduced, the test will stop
and the brake check light will turn off.
8/19 58E-06-09750-01
Retard System Test: Drive Brake System Test:

If the truck fails the retard system test, notify If the truck fails the parking brake test, notify
maintenance personnel immediately. Do not maintenance personnel immediately. Do not
resume operation unless the truck passes all resume operation unless the truck passes all
brake tests. brake tests.
1. Place the directional control lever in the PARK 1. Place the directional control lever in the
position. NEUTRAL position.
2. Press the brake test switch and wait for the 2. Press the brake test switch and wait for Hill start
brake check light to be on solid. assist inhibit light to flash
3. The VID panel will display: 3. Remove Brake lock switch (Pre-shift brake test
should illuminate to indicate test has entered)
Parking Brake or Retard Test READY
4. Fully depress the accelerator pedal till the Pre-
Press Accel or Retard Pedal to Start shift Brake test light flashes
4. Fully depress the retard pedal. (On trucks with 5. Once the torque has reached the limit for the
one pedal for service brakes and retard, push test, the brake check light will begin to flash.
pedal to engage retard but not far enough to This is the indication for the operator to make a
engage service brakes.) (Pushing the retard / determination as to the status of the parking
brake pedal far enough to engage service brake system.
brakes will cancel retarder test.) The drive
system controller will ramp up the engine • If the truck did not move:
speed, turn on CM1 through CM4 individually at The Drive Brake system passed the test.
50% and test the retarding system. The system
will verify current flow through each grid leg and • If the truck moved during the test:
the LINK1 and GRID1 sensors. The test has failed. Release the accelerator
5. The VID panel will display the current status of pedal. If the truck starts to roll, apply the service
brakes to hold the truck stationary. Notify
the test.
maintenance personnel immediately.
Retard System Test ACTIVE
CM1, CM2, CM3, CM4
(Elements are added as the test progresses.)
6. Upon successful completion of the test, the light
will flash for 10 seconds indicating a successful
test. The VID panel will display:
Retard System Test PASSED
Or
Retard System Test FAILED or Incomplete
NOTE: If the brake check light never flashes, but
turns off, the test has failed.
7. When the operator releases the retard pedal,
the test will stop and the brake check light will
turn off.
8. If the retard system failed the test, notify
maintenance personnel immediately. Do not
resume operation unless the truck passes all
brake tests.

58E-06-09750-01 8/19 Pre-Shift Brake Test - Test Procedure 5

 NOTES

6 Pre-Shift Brake Test - Test Procedure 8/19 58E-06-09750-01

 PARKING BRAKE BLEEDING/FLUSHING PROCEDURE
1. Securely block the wheels to prevent the truck
from rolling away.
2. Place the directional control lever in PARK and
turn the rest switch ON. Turn the key switch
OFF to shut down the engine and allow 90 sec-
onds for the steering system accumulators to
bleed down. Open bleed down valves to bleed
down the brake accumulators.
3. Open the rear axle housing access door. Close
the brake accumulator bleed down valves.
4. Start the engine and allow the steering system
to fully charge (pump unloads). Then move the
directional control lever to NEUTRAL to disen-
gage the parking brake.
5. Connect a clear plastic hose to bleeder screw
(See Figure 1). Place the other end of hose into
a container 20L or more.
6. Open the bleeder screw and allow hydraulic oil
to run for approximately 20-30L.
7. Repeat Steps 5 and 6 for the other parking
brake assembly.
8. Shut off the engine. Remove the bleed equip-
ment and close the rear axle housing hatch.

84289

FIGURE 1. PARKING BRAKE BLEEDING/FLUSHING PROCEDURE

1. Bleeder Screw

FAM1801 Park Brake Bleeding/Flushing Procedure 18-1

 NOTES

18-2 Park Brake Bleeding/Flushing Procedure FAM1801

 ALTERNATOR TO ENGINE ASSEMBLY CHECKOUT PROCEDURE
Care must be exercised when mounting alternator to probe on the face of the flywheel housing
engine on electric drive vehicles to avoid early adaptor plate.
crankshaft bearing failures. 3. Using the engine barring device, slowly rotate
the engine crank through 2 full revolutions.
Attaching GE Alternator to Cummins QSK50, 60
When complete insure dial indicator returns to
& 78 Engines
0. Record high and low readings for each
NOTE: The following instructions must be followed revolution and average.
for new or repower installations or whenever the 4. The difference between the highest and lowest
engine and/or alternator is serviced. values for each revolution is the TIR (Total
Indicated Runout). If the average of the two
General Instructions: measurements exceeds tolerance limits below,
1. Loosen or remove fan belts prior to measuring contact engineering for next steps.
crankshaft end play to ensure that it moves
Highest Reading – Lowest Reading = TIR
easily back and forth.
2. When taking measurements always clean TIR =_______
mating surfaces and take four equally spaced Limits are shown below:
readings, then average all four.
Max Value mm (in)
3. Clockwise (CW) or counterclockwise (CCW) is
while looking at front or damper end of engine. Cummins “0” Flywheel Housing: 0.25 mm
4. All measurements are set to three decimal (0.010”) used on QSK50/60’s
places. Cummins “00” Flywheel Housing: 0.30 mm
5. Be sure that a surface reference (ie.flat steel (0.012”) used on QSK78
bar) used for dial indicating is calibrated
periodically for flatness and dimensional
accuracy to within +/-.0009”. Also, be sure all
instruments used for measurements are
calibrated on a periodic basis.
6. Do not pry or hammer on engine vibration
damper.
7. Forward is defined as the front of truck and
rearward is defined as the rear of the truck.
8. Refer to Appendix 1 for Summary of Radial and
Axial Runout Limits.
9. Additional Measurements (page 9): It is
assumed that these dimensions are within
specification from the supplier and are therefore
not required for new installations. However,
these measurements must be used for service
rebuilds and/or troubleshooting to confirm these
dimensions are within tolerance specification of
the engine manufacturer.
Engine Flywheel Adaptor Plate Face
Runout (Figure 1-1)
1. Thoroughly clean all mounting surfaces; the
alternator housing, rotor, flywheel, and flywheel
housing.
2. Locate the dial indicator base on the machined
face of the flywheel/flexplate hub and zero the FIGURE 1-1. MEASURING FLYWHEEL HOUSING
ADAPTOR PLATE FACE RUNOUT

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 1

Cummins Crankshaft End Play (Figure 1-2
and Figure 1-3)
5. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the
crankshaft. Measure total crankshaft endplay.
Move crankshaft forward and rearwards as far
as possible. This is accomplished by removing
a hand-hole cover and prying gently on a
crankshaft counter weight or using a rubber
mallet on the crankshaft hub. Confirm the
measurement is equal in both forward and rear
directions. Record values and confirm end play
is within Cummins limits.
NOTE: Do not pry or hammer on engine vibration
damper. FIGURE 1-3. USING PRY BAR ON CRANKSHAFT
COUNTER WEIGHT
Total Crankshaft Endplay: _______
Endplay limits: 0.13 - 0.52 mm (0.005 - 0.020 Engine Flywheel to Flywheel Mating
in.) Surface - Measurement “C” (Figure 1-4)
6. Move the crankshaft rearward to its end travel.
7. Bolt a flat calibrated steel bar across the
flywheel housing as a surface reference to
measure the distance between the flywheel
housing to flywheel Adaptor Plate (CR1).

FIGURE 1-2. RUBBER MALLET USED TO MOVE

CRANKSHAFT REARWARD TO MEASURE
ENGINE END PLAY

FIGURE 1-4. FLAT BAR USED TO MEASURE

DISTANCE BETWEEN ENGINE FLYWHEEL AND
FLYWHEEL MATING SURFACE

2 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

 8. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CR2, CR3, CR4.
1st measurement (12:00 O’clock): CR1
2nd measurement (6:00 O’clock): CR2
3rd measurement (3:00 O’clock): CR3
4th measurement (9:00 O’clock): CR4
Cavg.R = (CR1+CR2+CR3+CR4) / 4 =______
9. Move the crankshaft frontward to its end travel.
10. Repeat the same procedure, 90 degrees apart
from each other in the perimeter, to find the
values CF1, CF2, CF3, CF4.
1st measurement (12:00 O’clock): CF1
2nd measurement (6:00 O’clock): CF2
3rd measurement (3:00 O’clock): CF3
4th measurement (9:00 O’clock): CF4
Cavg.F = (CF1+CF2+CF4+CF4) / 4 = ______
11. The Total Engine Axial Play of the engine is
calculated as:
TEAP = | Cavg.F - Cavg.R | = ______
12. The mean absolute value of the relative location
of the flywheel with respect to flywheel housing
is:
C = TEAP/2 + Cavg.R = ______
Alternator Housing to Rotor Measurement
– Measurement “A” (Figure 1-5 through
Figure 1-8)
13. For GTA41 alternator use 5/8”-11 x 4.5 bolt or
rotor saddle to support the alternator adapter.
For GTA39 alternator place shims between
rotor and stator.
NOTE: Whenever alternator is removed from the
engine for extended storage or transportation of the
alternator, rotor shipping locks must be installed.
Refer to PSN AA12108 for rotor shipping locks.

FIGURE 1-5. BOLT OR ROTOR SADDLE USED AT 6 O’CLOCK POSITION TO SUPPORT ROTOR ON GTA41 

ALTERNATOR

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 3

 FIGURE 1-6. SHIMMING OF GTA39 ALTERNATOR ROTOR

14. Position the Alternator Rotor Rearward by both ends. Alternately tighten each bolt until
placing a push bar across the center of rotor reaches end of travel. (Do not exceed 12
alternator rotor. Position the two 5/8” – 11 bolts ft-lbs). See Figure 1-7.
through the bar ends and fasten to housing on

FIGURE 1-7.FASTEN BAR TO ALTERNATOR

HOUSING TO MOVE THE ALTERNATOR ROTOR
AXIALLY TOWARD SLIP RING (REARWARD).
BOLTS ARE TIGHTENED TO NO MORE
THAN 12 FT-LB.

4 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

 15. Push bar is to remain in position to hold the
rotor in rearward position. Bolt a calibrated flat
steel bar to the rotor as a reference to measure
the distance between the alternator housing
and rotor to determine the reading A1. Make
sure the bars are not contacting each other
affecting the readings. When taking the
measurements, make sure the readings are
taken from the mating surfaces. See Figure 1-8.

FIGURE 1-8.MEASURING DISTANCE BETWEEN ALTERNATOR HOUSING AND ROTOR

16. Repeat the same procedure in three more

locations, ~90 degrees apart from each other in
the perimeter, to find the values A2, A3, A4.

1st measurement (45°): A1

2nd measurement (135°): A2
3rd measurement (225°): A3
4th measurement (315°): A4

Aavg = (A1 +A2 +A3 +A4) / 4 = ______

17. Alternators will have a tag from GE indicating
rotor end play. See Figure 1-9 for example of
tag. Use ½ the End Play in the following
calculation from the tag.
88256
A = Aavg + ½ End Play(GE Tag) = ______

FIGURE 1-9.EXAMPLE OF TAG FROM GE

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 5

 18. Refer to Figure 1-10 below. If measurement C is
greater than A, subtract A from C; the shim
pack is to be added between Rotor and
Flywheel (location B). If measurement A is
greater than C, subtract C from A; the shim
pack is to be added between the Alternator
Housing and Engine Flywheel Housing (location
D). Use a combination to shim within 0.1 mm
(0.004 in). See Table 1 below.
If C > A: shim = C – A; shim at Rotor
If A > C: shim = A – C; shim at Housing

FIGURE 1-10.
Table 1: SHIM COMBINATION DATA

SHIM LOCATION QSK78 (SAE 00) QSK50 & 60 (SAE 0)

P/N - Alt. Hsg. To FW Hsg. Adaptor (Location D) EJ1056 (.004") TM3466 (.004")
EJ1055 (.007") EJ1055 (.007")
TW6616 (.010")
P/N - Alt. Rotor to Flexdrive (Location B) EL3332 (.004") TM3467 (.004")
EL3331 (.007") TM3469 (.007")

19. Remove bolt or saddle bracket supporting rotor
on GTA41 alternator or remove shims placed
between rotor and stator on GTA39 alternator.
20. Carefully move the alternator into place and
engage the engine drive end and the alternator
rotor.
21. Fasten the flywheel housing adapter to the
alternator. Tighten bolts to 175 ft lbs. (240 Nm)
22. Install and torque the flywheel / flexplate
assembly to alternator rotor. Tighten bolts to
175 ft lbs. (240 Nm).

6 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

Measurements after Joining the Alternator 24. Total Crankshaft End Play: ________
and Engine 25. Rotate the crankshaft one full revolution and
23. With the Magnetic base, or similar device, listen for any unusual noise caused by moving
mounted on the front of the engine and the components contacting stationary parts.
indicator on the front of the crankshaft, measure
26. Reset and record Engine Fan Belt Tension.
the total crankshaft endplay.
NOTE: **The total engine crankshaft endplay must
match the original measurement before the alternator
was installed. If the endplay after the alternator and
engine are assembled is less than the original
measurement, re-shimming is required.

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 7