COMPONENT CODE C4

PARTS & SERVICE REF NO. AA08024

DATE March 3, 2008
NEWS (C)
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SUBJECT: REDUCED BATTERY SERVICE LIFE

PURPOSE: To inform the field of an installation procedure for a 24 volt to 12 volt converter
to increase battery service life.
APPLICATION: Komatsu Electric Drive Dump Trucks:
830E-AC: A30001 - A30071, A30079 - A30108;
830E-1AC: A30072 - A30078, A30109 & UP;
930E-4: A30462 & Up;
930E-4SE: A30587 & Up
FAILURE CODE: C441KH
DESCRIPTION:

Installation of multiple 12VDC accessories may lead to decreased battery performance or decreased bat-
tery service life. If the 12VDC accessories require a lot of power, two of the 12 volt batteries may not
become fully charged during normal truck operation and may lose performance. Installation of a 60 amp,
24VDC to 12VDC converter will alleviate this problem. Using this converter to power the 12 volt com-
ponents will evenly spread the current load over all four 12 volt batteries. Customers may purchase the 60
amp converter (PC1110) and install it by following the instructions below.
After the installation of the converter, the following components will be powered from the converter:
• Power windows
• Cab auxiliary power outlets
• Entertainment Radio
• Other 12 volt accessories added by the customer

Installation Instructions
1. With the key switch OFF and engine stopped, wait at least 90 seconds. Ensure the steering circuit is
completely bled down by turning the steering wheel back and forth several times. No front wheel
movement will occur when hydraulic pressure is relieved. If the front tires continue to steer after the
engine is stopped, notify maintenance personnel.
2. After the key switch is turned OFF and engine has stopped, wait three minutes, then move both bat-
tery disconnect switches to the OFF position.
3. Disconnect wires (1 and 3, Figure 2) from 12V insulated stud (2). Splice wires (1 and 3) together
with a splice connector (4).

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4. Disconnect the wiring from converter (2, Figure 1) from the auxiliary control box. Remove the con-
verter from the truck.
5. Mount the new converter in the same location as the converter that was just removed.
6. Install a 50 ampere circuit breaker (PB8460) (3, Figure 3) near the converter.
7. Using #8 AWG wire and proper terminal ends, install wire (2, Figure 3) that will connect the
24VDC insulated power stud (1) to circuit breaker (3).
8. Using #8 AWG wire and proper terminal ends, install wire (4) that connects circuit breaker (3) to the
24VDC input on converter (8).

FIGURE 1. AUXILLIARY CONTROL BOX

1. Auxiliary Control Box 2. Converter (PC1615)

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9. Using #8 AWG wire and proper terminal ends, install wire (5, Figure 3) that will connect the
12VDC output from converter (8) to insulated stud (6).
10. Using #8 AWG wire and proper terminal ends, install ground wire (7) from the converter to the
ground block 31 in the auxiliary cabinet.
11. Connect any other 12VDC accessory components to fuses installed in fuse block 3, fuse locations
FS20 through FS24. Power for the fuses to be supplied by terminal FB3-C (10, Figure 3).
12. Place the battery disconnect switches to the ON position.
13. Turn the key switch to the ON position. Check for proper operation of the 12VDC components.

FIGURE 2. CONNECTIONS
1. Wire 3. Wire
2. 24VDC Insulated Power Stud 4. Splice Connector

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1. 24VDC Insulated Power Stud
2. Wire - #8 AWG
3. Circuit Breaker - 50A (PB8460)
4. Wire - #8 AWG
FIGURE 3. CONNECTIONS
5. Wire - #8 AWG 9. Splice Connector
6. 12VDC Insulated Power Stud 10. 12VDC Insulated Power Stud
7. Wire - #8 AWG
8. Converter

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