Page 3 This material is proprietary to Komatsu Mining Systems, Inc. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Systems, Inc.
Page 4 NOTES:...
Page 5: A00017 03/01 Introduction A
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”...
Page 6 This “ALERT” symbol is used with the signal words, “ CAUTION” , “ DANGER” , and “WARNING” in this man- ual to alert the reader to hazards arising from improper operating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken.
Page 7 TABLE OF CONTENTS SUBJECT ........SECTION GENERAL INFORMATION .
Page 8 KOMATSU MODEL 930E Dump Truck Introduction A00017 03/01...
Page 9: Table Of Contents
SECTION A GENERAL INFORMATION INDEX TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS ....A2-1 GENERAL SAFETY AND TRUCK OPERATION ......A3-1 WARNINGS AND CAUTIONS .
Page 10 NOTES A1-2 Index A01001 2/94...
Page 11: Grade
MAJOR COMPONENT DESCRIPTION Truck And Engine Operator’s Cab The 930E Dump Truck is an off-highway, rear dump The Operator’s Cab has been engineered for operator truck with AC Electric Drive. The gross vehicle weight comfort and to allow for efficient and safe operation of is 1,100,000 lbs.
Page 12 930E MAJOR COMPONENTS A2-2 Major Component Description A02055...
Page 13 Suction ..Single, Full Flow, 100 Mesh Komatsu & G.E. must analyze each job condition to assure Hoist & Steering Filters . . Beta 12 rating = 200 proper application ..Dual, In-Line, High Pressure...
Page 14 STANDARD DUMP BODY* WEIGHT DISTRIBUTION Capacity: EMPTY ..Pounds . . Kilograms Struck ..224 yds ..171 m Front Axle (49.3%) . . . 219,913 ..99 751 Heaped @ 2:1 (SAE) 276 yds .
Page 15 Check also that there is no one near the machine. UNAUTHORIZED MODIFICATION • Any modification made to this vehichle without authorization from Komatsu Mining Systems, Inc. can possibly create hazards. • Before making any modification, consult the authorized regional Komatsu Mining Systems, Inc. distributor.
Page 16 LEAVING THE OPERATOR’S SEAT • When preparing to leave the operator’s seat, do not touch any control lever that is not locked. To prevent accidental operations from occurring , always carry out the following: • Move the shift control lever to the Neutral position (N) and set the parking lever/switch to the PARKING position. •...
Page 17 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES • Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature and are under pressure. If the cap is removed, or the oil or water is drained, or the filters are replaced, there is danger of serious burns.
Page 18 • The ROPS installed on equipment manufactured and designed by Komatsu Mining Systems, Inc. fulfills all of the regulations and standards for all countries, but if it is modified or repaired without authorization from Komatsu Mining Systems, Inc., or is damaged when the machine rolls over, the strength will drop and it will not be able to...
Page 19 In addition, know the proper use and care of all the safety equipment on the truck. Only qualified operators or technicians should attempt to operate or maintain the Komatsu Truck. Safe practices start before the operator gets to the equipment! SAFETY AT WORKSITE •...
Page 20 IN OPERATOR’S CAB - BEFORE STARTING ENGINE • Do not leave tools or spare parts lying around in the operator’s compartment or allow trash to accumulate in cab of truck. Keep all unauthorized reading material out of truck cab. • Keep the cab floor, controls, steps, and handrails free of oil, grease, snow, and excess dirt.
Page 21 • Check for flat tires periodically during shift. If truck has been run on a “flat”, it must not be parked in a building until the tire cools. If tire must be changed, do not stand in front of rim and locking ring when inflating tire mounted on the machine. Observers should not be permitted in the area and should be kept away from the side of such tires.
Page 22 TRAVELING ON SLOPES • Traveling on slopes could result in the machine tipping over or slipping. • Do not change direction on slopes. To ensure safety, go down to level ground before turning. • Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine slip on even the slightest slope.
Page 23 WHEN DUMPING • Before starting the dumping operation, check that there is no person or object behind the machine. • Stop the machine in the correct position, and check again that there is no person or object behind the machine. Give the determined signal, then slowly operate the dump body.
Page 24 BATTERY BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. • Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.
Page 25 ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. • These tags are available from your Komatsu distributor. (Part No. 09963-03000) PROPER TOOLS •...
Page 26 DURING MAINTENANCE PERSONNEL • Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS • Place attachments that have been removed from the machine in a safe place so that they do not fall.
Page 27 RADIATOR WATER LEVEL • If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator to cool down before adding the water. • Slowly loosen the cap to relieve pressure before removing the cap. USE OF LIGHTING When checking fuel, oil, coolant, or battery electrolyte, always use lighting with anti-explosion specifications.
Page 28 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE • Immediately after stopping operations, the engine cooling water and oil at all parts are at high temperature and under high pressure. In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced, it may result in burns or other injury.
Page 29 If the proper procedure for carrying out maintenance or replacement of the wheel or tire is not used, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult the authorized regional Komatsu Mining Systems, Inc. distributor, or the tire manufacturer. STORING TIRES AFTER REMOVAL •...
Page 30 ADDITIONAL JOB SITE RULES • Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...
Page 31 WHEN REPAIRS ARE NECESSARY 1. Only qualified maintenance personnel who under- 9. If truck is to be towed for any reason, use a rigid stand the systems being repaired should accom- tow bar. Check truck cab for decal recommending plish repairs. special towing precautions.
Page 32 “REST” indicator light in the overhead Prior to welding and/or repairing the Truck, mainte- panel is illuminated. nance personnel should attempt to notify the Komatsu factory representative. Only qualified personnel, spe- 3. With engine cooled down, turn keyswitch counter- cifically trained for servicing the AC Drive System, clockwise to “Off”...
Page 33 Engine Control System power cables, or use them as hand or foot holds. (ECS) inside the electrical cabinet behind the Notify the Komatsu factory representative im- operator’s cab (disconnect left one first). Also, mediately. Only qualified personnel, specifi- disconnect the ground strap from the ECS.
Page 34 NET DOORS ON THIS TRUCK WHEN THE ENGINE truck. Only qualified operators or technicians should IS RUNNING! NEVER CLIMB ON ANY POWER CA- attempt to operate or maintain the Komatsu Truck. BLES OR USE POWER CABLES FOR HAND- HOLDS OR FOOTHOLDS, UNLESS THE ENGINE...
Page 35 START HERE Walk Around Inspection A03017 General Safety and Operating Instructions A3-21...
Page 36 7. Move behind the rear of the front wheel, inspect 16. Move on around the right dual tires, inspect be- for leaks at hub or brakes or any unusual condi- tween the tires for rocks, and for condition of the tions.
Page 37 26. Before climbing ladder to first level, be sure 33. Adjust seat and steering wheel so that it is com- ground level engine shutdown switch is “ON”. fortable for use. Inspect fire control actuator to be sure safety pin 34. Read and understand the description of all Opera- is in place and plastic tie that prevents accidental tor Controls in Section “N”, Cab, “Instrument actuation is in place and in good condition.
Page 38 AFTER ENGINE HAS STARTED 1. Become thoroughly familiar with steering and emergency controls. After engine has started and low pressure and warning systems are normal, test the truck steering in extreme right and left directions. If the steering system is not operating properly, shut engine down immediately.
Page 39 MACHINE OPERATION SAFETY 7. Check parking brake periodically during shift. Use parking brake ONLY for parking. Do not use park PRECAUTIONS brake for loading / dumping. After the truck engine is started and all systems are Do not attempt to apply parking brake while truck functioning properly, the operator must follow all local is moving! safety rules to insure safe machine operation.
Page 40 6. Maintain a safe distance when following another Dynamic Retarding is available in “Neutral” only when vehicle. Never approach another vehicle from the truck speed is above 3 mph (4.8 kph). rear, in the same lane, closer than 50 ft. (15 m). When dynamic retarding is in operation, the engine When driving on a down grade, this distance RPM will automatically go to an advance RPM retard...
Page 41 the service brakes. Releasing the pedal returns the PASSING brake and retarder to the “off” position. 1. Do not pass another truck on a hill or blind curve! When the pedal is partially depressed, the dynamic 2. Before passing, make sure the road ahead is retarding is actuated.
Page 42 2. Carefully maneuver truck into dump position. 6. Reduce engine RPM as last stage of hoist cylinder When backing truck into dump position, use only begins to extend and let engine go to low idle as the foot-operated brake pedal to stop and hold last stage reaches half-extension.
Page 43 Do not tow the truck any faster than 5 MPH (8 kph). Attachments for towing the 930E are available from the a. Shift Selector Switch to “Forward”, release Komatsu Distributor Parts Department as follows: Brake Lock, depress Override button and drive Front Bumper Modification Kit - MK3941: This kit...
Page 44 SAFE PARKING PROCEDURES 3. With engine cooled down, turn keyswitch counter- clockwise to “Off” position for normal shutdown The operator must continue the use of safety precau- of engine. tions when preparing for parking and engine shut- If engine does not shutdown with keyswitch, use down.
Page 45 a. Press top of switch to the “On” (center posi- tion), then press firmly to the “Momentary” (up- per position) and hold briefly to activate the 5 M i n u t e I d l e Ti me r (switch is spring-loaded to return to “On”...
Page 46 NOTES: A3-32 General Safety and Operating Instructions A03017...
Page 47 Rollover Protective Structure and Falling attached to the truck. The plates and decals listed here Object Protective Structure meets various SAE per- are typical of this Komatsu model, but because of formance requirements. customer options, individual trucks may have plates and decals that are different from those shown here.
Page 48 The Wheel Brake Lock switch is for holding These decals are placed above the battery disconnect the truck while parked at the shovel during switches on the right side of the front bumper to loading, or while dumping. It applies the rear indicate “Off”...
Page 49 Warning plates are attached to both the hydraulic tank These WARNING decals are mounted on the side of and fuel tank to alert technicians not to work on the each of the accumulators (both steering and brake) to truck with the body in the raised position unless alert technicians to discharge all gas and hydraulic body-up retention device (pins or cable) is in position.
Page 50 A CAUTION decal is attached below the hydraulic tank A wheel motor oil level decal is attached to the gear oil level sight gauge. Check level with body down, cover on both electric wheel motors. This decal engine stopped, and key switch “Off”. Add oil per filling stresses the fact that the truck must be on a level instructions, if oil level is below top of sight glass.
Page 51 This CAUTION decal is placed near the battery discon- A CAUTION decal is also attached to the door of the nect switches on the right side of the front bumper to rear hatch cover to alert personnel that HOT EX- alert servicing technicians that before doing any weld- HAUST AIR is present and may cause injury.
Page 52 This CAUTION decal is placed on the back of the This decal is placed near three different indicator control cabinet to alert service technicians that this lights: area contains capacitors and must not be disturbed in any manner. • In the operator cab, on the D.I.D. panel on the rear wall.
Page 53 This page illustrates a variety of decals which are mounted on deck mounted cabinets, housings, and structures which must be lifted in a specific manner, and from specific points, in order to safely move or lift any of these structures. If any of these decals are damaged or defaced, so that it is no longer legible, it should be replaced immedi- ately.
Page 54 A product identification plate is located on the main frame in front of the right side front wheel and shows the Truck Model Number, Maximum G.V.W. and Product Identification Number (Truck Serial Number). The Product Identification Number (Truck Se- rial Number) contains information which will identify the original manufacturing bill of mate- rial for this unit.
Page 55 STANDARD CHARTS AND TABLES This manual provides dual dimensioning for most EFFECT OF SPECIAL LUBRICANTS specifications. U.S. standard units are specified first, On Fasteners And Standard Torque Values with metric (SI) units in parentheses. References Haulpak Division does NOT recommend the use of throughout the manual to standard torques or other special “friction-reducing”...
Page 56 Standard Assembly Torques For Standard Metric Assembly Torque For 12-Point, Grade 9, Capscrews (SAE) Class 10.9 Capscrews & Class 10 Nuts The following specifications appy to required assembly The following specifications appy to required assembly torques for all 12-Point, Grade 9 (170,000 psi minimum torques for all meteric Class 10.9 finished hexagon tensile), Capscrews.
Page 57 TABLE IV TABLE VI TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR WITH OR WITHOUT O-RING SEAL O-RING BOSS FITTINGS SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE CODE (O.D.) UNF – 2B FT. LBS. CODE (O.D.) UNF –...
Page 58 TABLE VIII TORQUE CONVERSIONS Foot Pounds – ft. lbs. To Newton.meters (N.m) FT. LBS. (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96...
Page 59 NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example: Example: Convert 975 psi to kilopascals (kPa). 1. Select Table X. 2. Go to PSI row 90, column 7; read 668.8 97 psi = 668.8 kPa. 3.
Page 60 TABLE XIII – COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS ENGLISH to METRIC METRIC to ENGLISH TO CONVERT MULTIPLY TO CONVERT MULTIPLY FROM FROM inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394 inch – in. centimeter (cm) 2.54 centimeter (cm)
Page 61 STORAGE AND IDLE MACHINE PREPARATION There may be periods when it is necessary for a ma- Much of this material is of a general nature since the chine to be idle for an extended period of time. Properly environment, where the machine has been standing prepared, a stored machine may promptly and safely idle, will play a big part in its overall condition.
Page 62 Type C-4 oil as tion of the vehicle is scheduled. specified in Section "P", Lubrication and Service, ® of the Komatsu service manual. 1. Engine should be prepared for storage according to instructions found in the engine manufacturer’s manual.
Page 63 Refer to Fluid Specifi- cations in Section "P", Lubrication and Service, of ® the Komatsu service manual for the proper anti- freeze and conditioner concentrations. After refill- ing the system, always operate the engine until the thermostats open to circulate the solution through the cooling system.
Page 64 Air pressure must be released from tires with bad cuts or wear that extends into the plies, before removal from the vehicle. Also, do not allow per- sonnel to stand in removal path of tires. 12. Check all tires carefully for serviceability and inflate to proper pressure.
Page 65 RECONDITIONING AN IDLE VEHICLE 3. Inspect tires thoroughly for tread and side wall condition, weathering, cuts and cracks. a. Any tire suspected of being unserviceable should be dismounted and thoroughly in- NEVER attempt operation of a vehicle which has spected inside and out before being inflated. been standing idle for a long period until all sys- tems which affect steering, brakes, engine, trans- mission and running gear have been completely...
Page 66 Do not attempt to use contaminated hydraulic oil, precleaner according to instructions in Section especially if water entry into the system is sus- ® "C", of the Komatsu service manual. pected. e. Drain and flush engine cooling system. Fill with NOTE: If filling is required, use clean hydraulic oil only.
Page 67 d. Check exposed portions of all hydraulic cylin- der rams for rust, pitting and corrosion. If plat- ing is deteriorated, the cylinder should be removed and overhauled or replaced; pitted or scored plating will cause leakage at the cylinder seals. 8.
Page 68 ENGINE OPERATION Insure that all tools and loose equipment have 2. Turn key switch "On". Warning lights for low brake been removed prior to engine start-up. Sound horn and steering pressure should illuminate and the prior to engine start. Make sure emergency shut horn should sound.
Page 69 AFTER ENGINE HAS STARTED Any machine which is unsafe and/or not in top operat- 5. When satisfied that all discrepancies have been ing condition should not be assigned to an operator for corrected, the vehicle is ready for a road test. This production use.
Page 70 ENGINE STORAGE Preparing Engine For Storage When an engine is to be stored or removed from Therefore, it is recommended that the engine be proc- operation for a period of time, special precautions essed for storage as soon as possible after removal should be taken to protect the interior and exterior of from operation.
Page 71 4. Circulate the coolant by operating the engine until 14. Drain the engine cooling system. normal operating temperature is reached 160° - 15. Drain the preservative oil from the engine crank- 185° F ( 71° - 85° C). case. Reinstall and tighten the drain plug. 5.
Page 72 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 1. Remove the covers and tape from all of the open- 8. Install and connect the fully charged batteries. ings of the engine, fuel tank and electrical equip- 9.
Page 73 ELECTRIC DRIVE TRUCKS Storage Instructions and Procedures Placing Equipment Into Storage This instruction provides the recommended proce- Perform the following instructions when preparing dures for protecting equipment from damage during General Electric equipment for storage. There are three both short-term and long-term storage periods and for main equipment categories to consider: maintaining adequate protection while in storage.
Page 74 When Storing A Truck That Is Not Operational Do not operate trucks without oil in the Motorized Wheel gear cases. When a truck which is not fully operational is being stored for a period of any length, perform the following: 3.
Page 75 4. Fill with recommended oil. Refer to the Motorized Periodic Inspections Wheel Service Manual for the type and amount oil It is important that periodic inspections (every three to be used. This oil should be drained and new oil months) of stored equipment be performed to insure should be added after 500 hours of operation.
Page 76 For The First Hour After all storage protection has been removed, the truck has been cleaned and inspected and repairs made as necessary, the Motorized Wheel gear case has been filled with new oil, the dirt seals have been completely purged with new grease and the system completely checked, the truck can be placed into service.
Page 77: Table Of Contents
SECTION B STRUCTURES INDEX STRUCTURAL COMPONENTS ........B2-1 Preparation .
Page 78: Index
NOTES B1-2 Index B01016...
Page 79: Structural Components
STRUCTURAL COMPONENTS The 930E deck components are removable in sections as shown in Figure 2-1. The following removal and installation instructions detail the steps to be taken before the decks and hood can be removed. Additional steps may be required before the deck or other major structure is removed, depending on optional equip- ment installed on the truck at the factory or after deliv- ery.
Page 80: Grille, Hood And Ladder
The anti-slip material on the decks should be in- spected and maintained for the safety of all person- nel. • • • • If weld repairs are necessary, disconnect all elec- trical harnesses and remove the ground strap from the Engine Control System (governor) located in the Auxillary Control Cabinet behind the cab.
Page 81: Decks
FIGURE 2-3. TYPICAL DECK STRUCTURE MOUNTING (NOTE: Bottom, RH deck shown. LH deck mounting is similar to RH deck) 1. Deck Structure 5. Headlights 2. Deck Mounting Location 6. Retard Grid Mounting Location 3. Payload Indicator Lights 7. Electrical Connector 4.
Page 82: Left Deck
Installation 4. Install lifting device to lift eyes at each corner of the deck and take up slack. Do not attach lifting Repeat above procedures in reverse order for installa- device to the hand rail structure. tion of the deck and components. Tighten all attaching hardware to standard torque specifications as listed in 5.
Page 83: Dump Body
2X the weight being lifted. When in doubt as to the weight of components or any assembly procedure, contact the Komatsu area representative for further information. Lifting eyes and hooks should be fabricated from the proper materials and rated to lift the load being placed on them.
Page 84: Installation
3. If not already installed, install retainer (1) and When in doubt as to the weight of components or capscrews (2) to hold bushing (12) in place. any assembly procedure, contact the Komatsu Tighten capscrews to 40 ft.lbs. (55 N.m) torque. area representative for further information.
Page 85: Body Pads
BODY PADS 5. Install the mounting hardware and torque to 65 It is not necessary to remove the dump body to replace ft.lbs. (88.1 N-m) body pads. Pads should be inspected during sched- uled maintenance inspections and replaced if worn 6.
Page 86: Body Guide
BODY GUIDE BODY-UP RETENTION CABLE 1. Body guide wear points should be inspected each time a body pad inspection is performed. (Refer to Figure 3-5) The body guide should be centered between the wear plates (3), with a maximum gap Any time personnel are required to perform main- of 0.19 in.
Page 87: Rock Ejectors
ROCK EJECTORS Rock Ejectors are placed between the rear dual wheels to keep rocks or other material from lodging between the tires. Failure to maintain the Rock Ejectors could allow debris to build up between the dual wheels and cause damage to the tires. Inspection 1.
Page 88 NOTES B3-6 Dump Body B03013 03/01...
Page 89: Fuel Tank
FUEL TANK FIGURE 4-1. FUEL TANK INSTALLATION 1. Fuel Tank 7. Fuel Return Hose 13. Low Fuel Switch 19. Ground Wire 2. Capscrews & L/W’s 8. Fuel Supply Hose 14. Wire Harness 20. Wire Harness 3. Mounting Cap 9. Fuel Gauge Sender 15.
Page 90: Removal
Removal Repair 1. Raise truck body and install body-up cable. If a tank has been damaged and requires structural repair, carry out such repairs before final cleaning. 2. Drain fuel from tank into clean containers. 3. Disconnect fuel tank wire harness and remove clamps attached to tank.
Page 91: Vent
VENT FUEL GAUGE SENDER If truck is not equipped with a fast fueling system, the A fuel gauge sending unit (9, Figure 4-1) mounted on fuel tank is vented through a small mesh type filter the side of the tank provides an electrical signal to installed in a port on the top of the tank (5, Figure 4-1).
Page 92 NOTES B4-4 Fuel Tank B04015...
Page 93 SECTION C ENGINE INDEX POWER MODULE ......... . C2 Preparation .
Page 94 NOTES C1-2 Index C01021 03/01...
Page 95 POWER MODULE The radiator, engine and alternator assemblies are After the truck is parked in position for the repairs, the mounted on a roller equipped subframe which is con- truck must be shut down properly to ensure the safety tained within the truck’s main frame and is referred to of those working in the areas of the deck, electrical as a “Power Module”.
Page 96 FIGURE 2-1. HYDRAULIC PUMP DRIVE SHAFT 1. Hydraulic Pump 4. Pump Drive Shaft 2. Shaft Guard 5. Alternator 3. Blower Duct Preparation for Removal The complete power module, including the hood and grille weighs approximately 34,750 lbs. (15,760 kg). Make sure lifting device to be used has ade- FIGURE 2-2.
Page 97 FIGURE 2-3. ENGINE AIR INLET PIPING 1. Air Cleaner Assemblies 7. Reducer Elbow 2. Left Rear Intake Duct 8. T-Bolt Clamp 3. Left Front Intake Duct 9. Duct Support Rod 4. Hump Hose 10. Right Front Intake Duct 5. T-Bolt Clamp 11.
Page 98 11. Close cab heater shutoff water valves, disconnect water lines and drain water from the heater core. Secure water lines away from engine compart- ment to prevent interference with power module removal. 12. Drain engine coolant into clean containers for re-use after engine installation.
Page 99 FIGURE 2-5. POWER MODULE REMOVAL & INSTALLATION 1. Alternator 5. Power Module Sub-frame 8. Front Frame/Sub-frame Mount 2. Rear Power Module Lift Eye 6. Heat Exchanger Piping 9. Front Power Module Lift Eye 3. Rear Frame/Sub-frame Mount 7. Heat Exchanger 10.
Page 100 FIGURE 2-7. POWER MODULE LIFT POINTS 1. Module Lifting Tool 4. Engine 2. Alternator 5. Power Module Subframe 3. Lifting Points FIGURE 2-6. SUBFRAME ROLLERS 6. Roll the power module forward sufficiently so that 1. Roller Assembly 3. Capscrews adequate clearance is provided in front of electri- 2.
Page 101 Power Module Installation 6. Lower the power module to the subframe guide rails, relax the hoist slightly and roll the power 1. Inspect the main frame guide rails. Remove any module into truck frame as far as possible before debris which would interfere with power module the lifting chains contact the electrical cabinet.
Page 102 3. Attach hoist to the front center deck and lift into 8. Connect the hydraulic pump drive shaft compan- position. Install capscrews, flatwashers, lock- ion flange (4, Figure 2-1) to the alternator (5). washers and nuts at each mounting bracket. Tighten capscrews to standard torque.
Page 103: Cooling System
COOLING SYSTEM RADIATOR Removal 1. Drain coolant from radiator and engine. Be pre- pared to catch approximately 200 gallons (757 Federal regulations prohibit venting air condition- liters) of coolant. If the coolant is to be reused, it ing system refrigerants into the atmosphere. An must be stored in clean containers.
Page 104 FIGURE 3-4. FAN GUARD 1. Fan Guard (LH) 3. Fan Guard (RH) FIGURE 3-3. RADIATOR PIPING 2. Fan Shroud 4. Engine Subframe (Bottom View) 1. Drain Cock 4. Outlet Elbow (Rear) 2. Outlet Elbow (Front) 5. Heat Exchanger 3. Radiator Mounting 6.
Page 105 4. Install upper support rods (4) and mounting hard- ware at radiator brackets and front upright brack- ets. Do not tighten at this time. 5. Adjust the lower stabilizer support rods to position the radiator perpendicular to the subframe within ±0.12 in.
Page 106 RADIATOR FILLING PROCEDURE COOLANT SYSTEM TROUBLESHOOTING If abnormal coolant temperatures are experienced, perform the following visual inspections and tests: 1. Check coolant level and thoroughly inspect sys- tem for leaks. The cooling System is pressurized due to thermal a. Check for proper coolant/antifreeze mixture. expansion of coolant.
Page 107 POWER TRAIN ALTERNATOR REMOVAL PROCEDURE Removal The following instructions cover the removal of the main alternator from the engine after the power module has been removed from the truck. (Refer to Figure 4-1.) When lifting alternator, attach hoist to lift eyes only.
Page 108 3. Remove access cover at front, right side of the engine flywheel housing. Reach through the ac- cess openings and remove twelve [12] capscrews (6, Figure 4-3) joining the engine drive ring (7) to the alternator rotor (8). (Rotate crankshaft to align each capscrew with access hole.) Be certain all capscrews have been removed! 4.
Page 109 ENGINE/ALTERNATOR MATING MEASURING PROCEDURE 1. Thoroughly clean the alternator housing mounting surface, rotor drive adapter mounting surface and flywheel housing adapter mounting surfaces. 2. With magnetic base mounted on the front of the engine and the dial indicator on the front of the crankshaft, measure total crankshaft end-play: The following instructions must be followed to Verify end play is within 0.13 - 0.38 mm...
Page 110 4. Refer to Figure 4-5. Alternator End-play: a. Using a flat steel bar (3, Figure 4-5) bolted rigidly to the alternator rotor (2), install a 5/8" - 11 capscrew (4) at each end into the alternator housing (1). Leave capscrews finger-tight. b.
Page 111 Joining Alternator and Engine When lifting alternator, attach hoist to lift eyes only. The alternator weighs approximately 7,400 lbs. (3357 kg). Use a lifting device that can handle the load safely. 1. Use the two top lift brackets provided on the alternator for lifting.
Page 112 ENGINE Service Complete instructions covering the disassembly, as- Removal sembly and maintenance of the engine and its compo- Refer to instructions in previous sections for removal nents can be found in the engine manufacturer’s instructions for the Power Module, alternator, and ra- service manual.
Page 113 AIR FILTRATION SYSTEM AIR CLEANERS Operation The truck engine must be shut down before serv- Air required by the diesel engine passes through the icing the air cleaner assemblies or opening the air cleaner assemblies mounted on each side of the engine air intake system.
Page 114 FIGURE 5-2. AIR CLEANER ASSEMBLY 1. Dust Cap 5. Wing Nut 9. Safety Filter Element 12. Clean Air Outlet 2. Dust Cap Gasket 6. Wing Nut Gasket 10. Main Filter Element 13. Pre-Cleaner Gasket 3. Tube 7. Safety Element Indicator 11.
Page 115 6. Reset the indicator nut from red to green by gently MAIN FILTER ELEMENT CLEANING blowing air into threaded hole from gasket side of NOTE: Remember that only the main filter elements nut. may be cleaned and then only if they are structurally 7.
Page 116 FIGURE 5-4. CLEANING FILTER ELEMENT WITH COMPRESSED AIR 2. Clean dust loaded elements with dry filtered com- pressed air: a. Maximum nozzle pressure must not exceed 30 FIGURE 5-5. REMOVING DUST FROM PRECLEANER TUBES psi (207 kPa). Nozzle distance from filter ele- ment surface must be at least one inch (25 mm) to prevent damage to the filter material.
Page 117 5. Submerge precleaner section (see Figure 5-6.) in AIR INTAKE TROUBLESHOOTING a solution of Donaldson D-1400 and warm water To insure maximum engine protection, be sure that all (mix solution according to package directions). connections between air cleaners and engine intake Tube section must be down.
Page 118 NOTES C5-6 Air Filtration System C05013 5/98...
Page 119 SECTION D ELECTRICAL SYSTEM (24 VDC NON–PROPULSION) INDEX 24 VDC ELECTRIC SUPPLY SYSTEM ....... D2 ELECTRICAL SYSTEM DESCRIPTION .
Page 120 • 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 possible to the area to be welded. NEVER weld on the rear of the Electrical Control Cabinet or the retard grid ex- haust air louvers.
Page 121 24VDC ELECTRIC SUPPLY SYSTEM ELECTRICAL SYSTEM DESCRIPTION The Komatsu truck utilizes a 24VDC electrical system which supplies power for engine starting circuits and most non-propulsion electrical components. The DO NOT SMOKE or allow flame around a dead 24VDC engine starting circuit is supplied by four, heavy battery or during the recharging operation.
Page 122 To remove corrosion, clean the battery with a solution The rate of self-discharge of a battery kept at 100°F of ordinary baking soda and a stiff, non-wire brush and (38°C) is about six times that of a battery kept at 50°F flush with clean water.
Page 123 BATTERY CONTROL BOX BATTERY SUPPLY SYSTEM The battery control box (4) is located near the right 24VDC BATTERY CHARGING ALTERNATOR corner of the front bumper. This box contains the battery disconnect switches and other components Refer to Optional Equipment, Section “M” for informa- listed below.
Page 124 Battery Disconnect Switches The three battery switches provide a convenient method of disconnecting the truck batteries from the truck electrical circuits. The rear disconnect switch (2) opens the starter battery circuit only, preventing engine startup while still allow- ing battery power to the 24VDC control system circuits if desired.
Page 125 Battery Equalizer 4. If alternator voltage is outside above limits, refer to Section “M” for battery charging alternator The majority of the accessory and control circuits service information. operate at 24VDC. Several components however, re- quire 12VDC (cab window regulator motors, cas- 5.
Page 126 NOTES D2-6 24VDC Electric Supply System D02018...
Page 127 24 VDC ELECTRICAL SYSTEM COMPONENTS PASSENGER SEAT BASE COMPONENTS COMPARTMENT TAIL LIGHT RESISTOR DIODE ASSEMBLIES The 24 VDC electrical system components shown in The tail light resistor diode assembly RD1, RD2 (2, Figure 3-1 are accessed by unlatching the passenger Figure 3-1) is a circuit designed to vary the intensity of seat base lid and tilting the passenger seat forward.
Page 128 FIGURE 3-1. PASSENGER SEAT BASE COMPARTMENT 1. Seat Base 7. 5 Minute Idle Contactor 12. 5 Minute Idle Relay 2. Tail Light Resistor/Diodes (RD1/RD2) 8. Inclinometer 13. Connector (RP226) 3. Terminal Board (TB13) 9. Hoist Control 14. Connector (RP231) 4. Terminal Board (TB12) 10.
Page 129 5 Minute Idle Timer BRAKE WARNING BUZZER (BWB) The 5 minute idle timer (6) circuit is activated when the The brake warning buzzer (11) provides an audible operator presses the 5 minute idle timer engine shut- alarm for the operator if a malfunction occurs in the down switch mounted on the instrument panel.
Page 130 Temperature and Latch The Temperature and Latch Card has two circuits to operate two different indicating lights. The temperature circuit is controlled by a coolant temperature sensor which decreases electrical resistance as its tempera- ture increases. It will have a resistance of approxi- mately 1000 ohms at 185 F (85 C) and 500 ohms at...
Page 131 Hot Switch Inverter Card (Slot 4) (Not Used) Diode Matrix (With Sound) The Diode Matrix With Sound Card works very much Oil Level like the other Diode Matrix Card, except that it contains The Oil Level Card is used to turn on the Low Oil Level extra diodes to activate the alarm horn in addition to Indicator Light to warn the operator engine oil/hydrau- the flasher.
Page 132 TRUCK CONTROL INTERFACE PANEL ELECTRICAL INTERFACE CABINET The Truck Control Interface Panel (TCI) (6, Figure 3-3) The Electrical Interface Cabinet (1, Figure 3-3) is is the main interface between truck systems and de- mounted near the rear of the cab and on the left side vices and service personnel.
Page 133 FIGURE 3-3. ELECTRICAL INTERFACE CABINET 1. Cabinet Assembly 8. Cabinet Service Light 15. Cable Entrance Panel 2. Special Interface Module (SIM) 9. Barometric Pressure Transducer 16. Diode Board (DB1) 3. Relay Board (RB1) 10. Circuit Breaker Panel 17. 24 VDC Terminal 4.
Page 134 FIGURE 3-4. CIRCUIT BREAKER PANEL 1. Cabinet Service Light Switch 2. Circuit Breakers DIODE BOARD - DB1 The diode board (16, Figure 3-3) contains replaceable diodes. Some of the diodes are used in the coil circuit of various relays to suppress the resultant coil voltage spike when power is removed from the circuit, prevent- ing damage to other circuit components (lamp fila- ments etc.).
Page 135 Service RELAY BOARDS The Electrical Interface Cabinet contains six relay To replace a relay: boards to provide control for many of the 24VDC NOTE: The relays are labelled to identify the applicable circuits. Two types of boards are used; those contain- circuits and components Also, refer to the Circuit ing circuit breakers in addition to 24VDC relays and a Breaker Chart at the end of this Section.
Page 136 To replace a circuit panel card RELAY BOARD IDENTIFICATION DO NOT remove the small screws that hold the cover The six relay boards are identified as follows: plate to the circuit panel. Replace circuit panel as a (Refer to Figure 3-3 for location.) complete assembly.
Page 137 RELAY BOARD FUNCTIONS Relay Board 3 (RB3) The following describes the components and functions 1 - Light Module Display card of each relay board. 1 - Rev Light (Green): This light is “ON” whenever the selector switch is in the “reverse” position, and the Relay Board 1 (RB1) key switch is in the “ON”...
Page 138 Relay Board 6 (RB6) Installing Additional Circuits Relay board 6 (Figure 3-7) does not contain circuit To add an additional circuit with a relay, connect the breakers or modular cards. Additional circuits may be wires as described below: added by utilizing the empty relay sockets provided. The control circuit for the relays are the “+ ”...
Page 139 Adjustment BODY-UP SWITCH Prior to adjusting the body-up switch, inspect body The body-up switch (3, Figure 3-8) is located inside the pads for wear or damage and replace pads if required. right frame rail near the front of the body and must be The body must be resting on the frame in the normal adjusted to specifications to ensure the proper electri- body down position when adjustments are made.
Page 140 HOIST LIMIT SWITCH The hoist limit switch (5, Figure 3-9) is located inside the right frame rail above the rear suspension (near the body pivot pin). The hoist limit switch is designed to stop the hoist cylinders before reaching full extension, preventing possible damage to the dump body or hoist cylinders.
Page 141 CIRCUIT BREAKERS AMPS DEVICE(S) PROTECTED CIRCUIT LOCATION CB00 12 Volt Power Source 11B1 Battery Control Box Fan Clutch Power Electrical Interface Cabinet ECM Main Power 240M Electrical Interface Cabinet ECM Main Power 241M Electrical Interface Cabinet ECM Rec. Power 240R1 Electrical Interface Cabinet ECM Rec.
Page 142 NOTES D3-16 24VDC System Components D03019 04/01...
Page 143 SECTION E ELECTRICAL PROPULSION SYSTEM INDEX ELECTRIC PROPULSION SYSTEM COMPONENTS ..... E2 GENERAL SYSTEM DESCRIPTION ......E2-1 System Components .
Page 144 • 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 possible to the area to be welded.
Page 145 ELECTRICAL PROPULSION SYSTEM COMPONENTS The following information provides a brief description The alternator field is supplied from a tertiary winding of system operation and major components of the AC on the alternator and is controlled by a silicon control- propulsion system. Refer to the appropriate GE publi- led rectifier (SCR) bridge.
Page 146 FIGURE 2-1. PROPULSION SYSTEM DIAGRAM E2-2 Electrical Propulsion System Components E02014 3/01...
Page 147 SYSTEM COMPONENTS The PSC contains the following internal, removable printed circuit boards and an external fiber optic board. Brief descriptions of board functions are as follows: AUXILIARY BLOWER SYSTEM » 17FB127 Power Supply: Supplies regulated The Auxiliary Blower System, mounted behind the +15VDC, -15VDC, and +5VDC for internal main electrical cabinet, consists of the blower assem- panel use and ±15VDC external circuits.
Page 148 TRUCK CONTROL INTERFACE PANEL (TCI) The 17FL349 TCI Panel contains the following inter- nal, removable printed circuit boards: The Truck Control Interface Panel (TCI) (17FL349 or 17FL373) is the main interface between truck systems and devices and service personnel. This panel is used »...
Page 149 Diagnostic Information Display DID PANEL FAULT CODES The 17FM558 Diagnostic Information Display (DID) The Tables on the following pages list the possible (Figure 2-2) is located in the cab, behind the passenger event codes which may be displayed on the DID panel seat.
Page 150 TABLE II: DID PANEL FAULT CODES (Codes Received from PSC) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER Displayed when all faults have been NO FAULT None reset. A ground fault is detected if leakage current to ground (truck chassis) HIGH GROUND FAULT No power exceeds 145 ma for more than .05...
Page 151 TABLE II: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER INVERTER COMMUNICATION No power Lost Communication with an inverter. FAILED inv 1 No power Lost Communication with an inverter. inv 2 No power Lost Communication with an inverter.
Page 152 TABLE II: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER Problem has occurred in the system PSC CPU CARD No power CPU card. Flash CRC computation did not match flash CRC No power expected value.
Page 153 TABLE II: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER A panel connector B, C, or D is not PSC PANEL CONNECTOR No power properly connected. CN1 connector not properly CN1 CONNECTOR No power connected.
Page 154 TABLE II: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER CHOPPER 2 FAILED No propel A failure has occurred in Chopper 2. MOTOR STALL No propel Motors stalled with torque above limit. TACH LEFT REAR None Input from M1 sensor out of tolerance.
Page 155 TABLE II: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER chopper GTO temp None Temp out of range. chopper diode temp None Temp out of range. left GTO module temp None Temp out of range.
Page 156 TABLE II: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER Indicates message errors between TCI COMMUNICATION FAULT None PSC and TCI. A limp mode request is received while ILLEGAL LIMP REQUEST None truck is moving.
Page 157 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 100/200 INVERTER CPU CARD pat fail out 100 No power Pattern had bad A, B, C output 100% no extvi TIC No power Extrapolation interrupt not running...
Page 158 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 102/202 INV I/O CARD gnd not ok No power Logic ground not ok no IO card No power Could not access I/O card eoc not working...
Page 159 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 103/203 (cont.) link V too hi No power Link voltage too positive infilV too hi No power Input filter voltage too positive High freq.
Page 160 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 113/213 INVERTER, GENERAL Aup cur hi No power Phase A current out too high Adn cur hi No power Phase A current in too high Bup cur hi...
Page 161 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 113/213 (cont.) Phase C volt too high while phase A C volt hi Adn No power down on Phase C volt too low while phase A up C volt lo Aup...
Page 162 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 113/213 (cont.) Phase C negative current low Cph neg I low No power (unbalance) Phase A negative current high Aph neg I hi No power (unbalance)
Page 163 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 115/215 INVERTER SYSTEM no direction No power No direction called for for dir mismatch No power Calling forward, running backward rev dir mismatch No power...
Page 164 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 119/219 INVERTER, PHASE A- alarm AN No power Phase A negative GTO did not turn off Adn fb not off No power Phase A down feedback not off...
Page 165 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 127/227 INVERTER, PHASE B+ Bup temp short No Propel Phase B up thermistor short Bup temp open No Propel Phase B up thermistor open Bup temp warm...
Page 166 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 135/235 INVERTER, PHASE C+/C- alarm CP No power Phase C positive GTO did not turn off Cup fb not off No power Phase C up feedback not off...
Page 167 TABLE III: DID PANEL FAULT CODES (Codes Received From Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 143/243 INVERTER, TACH 1 tach1 rate hi No power Tach 1 high rate of change tach1 no input No power Tach 1 no frequency input TACH_INTERMIT...
Page 168 TABLE IV: DID PANEL FAULT CODES (Codes Received from Inverter 1, 2) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER 155/255 INVERTER, 2ND LOAD second load open No power Second load connection open INV 1 GENERIC EVENT None Inverter shutdown with no event code.
Page 169 TABLE IV: DID PANEL FAULT CODES (Codes Received from TCI) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER TCI CPU CARD No propel TCI CPU card problem. 10ms task failed to init No propel TCI CPU card problem. 20ms task failed to init No propel TCI CPU card problem.
Page 170 TABLE IV: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER FREQUENCY INPUT None Front wheel speed input out of range left front wheel speed None Left front wheel sensor out of range. right front wheel speed None Right front wheel sensor out of range.
Page 171 TABLE IV: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER Simultaneous FORWARD and DIRECTION MISMATCH No propel REVERSE commands received. Engine start request denied due to the ENGINE START REQUEST DENIED None following: Engine warning occurs after engine...
Page 172 TABLE IV: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER One of the connected batteries’ volts CONNECT BATTERY VOLTS None incorrect with engine speed above low idle. Control battery voltage below control battery low None minimum limit...
Page 173 TABLE IV: DID PANEL FAULT CODES (Cont.) EVENT EVENT DETECTION RESTRICTION EVENT DESCRIPTION INFORMATION Limp Lockout Possible Limit NUMBER High dc bus voltage detected during high dc buss when running None operation. High dc bus voltage detected after high dc buss after pc powerup None phase controller powerup.
Page 174 PSC SOFTWARE FUNCTIONS Test State: The purpose of this state is to provide an environment The operation of the AC Drive System is regulated by for the verification of system functionality. Test state a software program which resides in the Propulsion will support a variety of activities, including: System Control Panel’s memory.
Page 175 Retard State: Transition from Test State to Ready State: This state provides the power system configuration This transition will occur upon completion of any re- and overall environment for retard, where energy from quired testing if all of the following conditions are true: vehicle movement is dissipated in the retard grid resis- 1.
Page 176 Transition from Ready State to Retard State: Transition from Propel State to Retard State: The system will transition from Ready state to Retard The system will transition directly from Propel state to state if truck speed is such that retard is allowed and Retard state if at least one of the following conditions at least one of the following conditions exists: exists:...
Page 177 DC LINK STATE De-Powering the Link Power is provided to the inverters and motors via the The PSC software will attempt to de-power the DC link DC link. The DC link has two associated states: (i.e., command the system configuration defined be- powered and unpowered.
Page 178 1. If the truck is in neutral, the commanded engine Desired DC Link Voltage speed at full scale accel pedal will be the engine’s The desired link voltage is controlled by the alternator high idle. If the truck is not in neutral, the maxi- during all powered states except retard.
Page 179 Propel Torque Control Retard Torque Control This software function commands the appropriate mo- The retard system converts braking torque from the tor torque to the inverters during propel. The torque wheel motors to energy dissipated in the resistor grid. command is primarily a function of the accel pedal The requested retard torque is based on the following position and is limited by the physical constraints of the three sources:...
Page 180 Resistor Grid Control EVENT PROCESSING The first resistor grid (RG1) will always be engaged The PSC contains very powerful troubleshooting soft- when retard is active since the grid blower motors are ware. The PSC software constantly monitors the AC wired across it. drive System for any abnormalities (events).
Page 181 3. Inverter Powerup Tests - The purpose of these Initiated Tests tests is to verify that each inverter sub-system is These tests are performed when requested by main- functional: tenance personnel; the truck must be in test mode for a. Enabling Inverter Powerup Tests - The pow- these tests to run: erup tests for a given inverter will be enabled if 1.
Page 182 Event Logging And Storage Data Packs A data pack is defined as an extended collection of This software function is responsible for the recording information relevant to a given event. of event information. There are two basic levels of event storage: event history buffer and data packs. NOTE: The concepts of lockout, soft reset, and accept The event history buffer provides a minimum set of limit do not apply to data packs.
Page 183 Event Reset PSC - PTU Communications Processing There are two basic types of event resets: soft and This software function performs the processing neces- hard. The difference between the soft and hard reset sary for the PSC (System CPU Card) to communicate is a soft reset only affects events that have not been through an RS-232 serial link to the Portable Test Unit locked out and a hard reset affects events regardless...
Page 184 ABNORMAL CONDITIONS/OVERRIDING Entering/Exiting Limp Home Mode FUNCTIONS The PSC will enter limp home mode if all of the following conditions are true: Software functions given up to this point assumed for the most part that the truck is operating under more or 1.
Page 185 PROPULSION SYSTEM COMPONENT ABBREVIATIONS 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 component’s tion. Refer to Figures 2-3 through 2-8 for the location primary function is also listed.
Page 186 TABLE V: PROPULSION SYSTEM COMPONENTS DESCRIPTION (Cont.) REF. COMPONENT FUNCTION Provides overload protection for control equipment and BATFU System Fuse the System Batteries. Battery Disconnect Switch Connects and disconnects the 12 VDC and 24 VDC BATTSW circuit batteries (located at right front corner of truck). (System Batteries) Works in conjunction with BFC and BLFP to maintain Battery Blocking Diode...
Page 187 TABLE V: PROPULSION SYSTEM COMPONENTS DESCRIPTION (Cont.) REF. COMPONENT FUNCTION Detects amount of current flow through the Alternator Battery Boost Current tertiary winding. Signal turns off the AFSE battery circuit when the tertiary winding voltage level is able to excite Transformer the Alternator field.
Page 188 TABLE V: PROPULSION SYSTEM COMPONENTS DESCRIPTION (Cont.) REF. COMPONENT FUNCTION Picks up with GF contactor and applies B+ to the AFSE Alternator Field Relay (17LV66) (battery boost) during initial acceleration phase. Alternator Field Relay Coil GFRS Suppresses voltage spikes when GF coil is de-energized. Suppression Module Ground Resistor Panel Detects power circuit grounds.
Page 189 TABLE V: PROPULSION SYSTEM COMPONENTS DESCRIPTION (Cont.) REF. COMPONENT FUNCTION The PSC is the main controller for the AC drive system. Propulsion System Controller All propulsion and retarding functions are controlled by (17FL320) the PSC based on internally stored software instructions. Provide positive driving voltages (PWM or square wave, PM1A+, 1B+, 1C+ GTO Phase Modules (17FM628)
Page 190 TABLE V: PROPULSION SYSTEM COMPONENTS DESCRIPTION (Cont.) REF. COMPONENT FUNCTION Provides the main interface between the various truck Truck Control Interface systems, controls, and equipment and is used in (17FL373) conjunction with the DID by maintenance personnel. Discharges the Alternator field when the AFSE is first Alternator Field Thyrite (Varistor) turned off.
Page 191 FIGURE 2-3. ELECTRICAL CABINET, FRONT VIEW E02014 3/01 Electrical Propulsion System Components E2-47...
Page 192 FIGURE 2-4. ELECTRICAL CABINET, TOP VIEW E2-48 Electrical Propulsion System Components E02014 3/01...
Page 193 FIGURE 2-5. ELECTRICAL CABINET, REAR & FLOOR VIEW E02014 3/01 Electrical Propulsion System Components E2-49...
Page 194 FIGURE 2-6. CONTACTOR BOX (Right Side, Electrical Cabinet) FIGURE 2-7. INFORMATION DISPLAY PANEL (Left Front Corner of Electrical Cabinet) FIGURE 2-8. RETARDING GRIDS E2-50 Electrical Propulsion System Components E02014 3/01...
Page 195 ELECTRONIC ACCELERATOR AND RETARD PEDALS The accelerator pedal provides a signal to the Truck Control Interface (TCI) when the operator requests power. The retard pedal provides a signal to the Pro- pulsion System Controller (PSC) when the operator requests retarding. The pedal signals are processed by the analog card in the respective panel for use by the system controllers to provide the desired mode of operation.
Page 196 NOTES E2-52 Electrical Propulsion System Components E02014 3/01...
Page 197 System (ECS) harnesses and ground wire (MTU engine). If equippped with • • • • NEVER open any electrical cabinet covers DDEC or Komatsu engine, disconnect or touch the Retarding Grid elements until ECM harnesses. GE cards should be...
Page 198 NORMAL TRUCK SHUTDOWN PROCEDURE 1. Reduce the engine speed to idle. Place the selec- tor switch in NEUTRAL and apply the parking brake. Be certain the “Parking Brake Applied” indicator lamp in the overhead display panel is illuminated. 2. Place the drive system in the REST mode by turning the Rest switch on the instrument panel ON.
Page 199 DOWN THE ENGINE. blower power cables. 3. If all red drive system warning lights are off, apply • • • • Notify the Komatsu factory representative the parking brake, shut down the engine and or Distributor immediately. chock the wheels.
Page 200 SYSTEM CHECKOUT Note: The following test procedures are applicable to Release 17 software. Procedures required for later software versions may vary. Contact the Komatsu Test equipment needed to fully test A/C system distributor or factory representative for current soft- • • • • One PTU (Portable Test Unit; lap top computer) ware version available.
Page 201 TABLE I. CIRCUIT RESISTANCE CHECKS (All readings taken from circuit to ground) 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. ∞ All devices listed for 11A circuit reading must be OFF.
Page 202 Resistance Checks, Propulsion System Circuits: 8. VOM positive lead on the DC negative bus and the VOM negative lead on the DC positive bus. 4. Additional preparation On the Rx1 scale the resistance should be NOTE: Be certain preparations described in step 1. approximately 5.5 ohms.
Page 203 If equipped with Make sure the ground block wires are connected. Komatsu or MTU/DDC 16V4000 engine, dis- Resistance should be 10K ohms. connect circuit 21B wires at the starter sole- noids and insulate.
Page 204 Approximately 11 volts at the 10V wire on 11 (Front wall, Electrical Interface Cabinet) TB28. 11S (TB30) If truck is equipped with Komatsu or MTU/DDC 11L (CB30) 16V4000 engine, measure the following: 11A (TB30) +15 volts at the 15VL wire on TB32.
Page 205 Voltage should be 5.0 volts. Verify approximately 3.5 volts. 6. If truck is equipped with Komatsu engine, install a jumper from 22F0 @ TB32 to ground. Note: If battery voltage is low in step 12 or 13, refer to “Memory Backup Battery Replacement”...
Page 206 (See Figure 3-3.) is installed, disconnect and insulate 21B circuits at starter solenoids. Apply park brake and brake 2. Have a replacement battery (Komatsu Part Num- lock. ber GE0455) available for immediate installation. a. Connect the serial communication cable from...
Page 207 MTU 396 cable from the PTU to one of the two ports located engine. If MTU/DDC 16V4000 or Komatsu engine to the right of the PSC Panel. (RS11 is used for is installed, disconnect and insulate circuit 21B at the inverter card in slot No.
Page 208 1. Disconnect Circuits 21SS and 21SR, and insulate from engine starter if equipped with MTU 396 ¤ Cursor to “minute” - type minute {enter} engine. If MTU/DDC 16V4000 or Komatsu engine ¤ Move cursor to “(reset clock)” {enter} is installed, disconnect and insulate 21B circuits ¤...
Page 209 TCI Analog Input Checks: On the TCI PTU: ¤ Move cursor to “Normal Operation” {enter} ¤ Cursor to “TCI Real Time Data” {enter} 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:...
Page 210 1. Apply the park brake switch and place the Rest from the starters or 21 B (MTU/DDC 16V4000 or switch in the OFF position. Komatsu engine) are removed from starter sole- noids and the parking brake is applied. 2. On the TCI COMMUNICATION MENU, place cursor on “Engine Stopped Tasks”...
Page 211 Note: Value will be (-01) if the TCI is not communicat- Propulsion Sys. Temp. Caution Amber ing with the aux inverter. High Brake/Hydraulic Oil Temp. STOP ENGINE (Komatsu engine only) No Propel Propulsion System at Rest Amber Propulsion System Not Ready...
Page 212 TCI Digital Input Tests: 4. Turn OFF and ON all circuit breakers on relay boards RB1, RB2, RB3, RB4, and RB5 in the 1. Verify park brake switch is on. Turn REST switch Electrical Interface Cabinet. OFF (down). Verify the Circuit Breaker Tripped lamp on 2.
Page 213 (Note: If equipped with Komatsu engine, ENGCAUTION will not be highlighted on PTU.) Stop Engine Warning Lamp (Jumper circuit 509 @ TB30 to ground to illuminate overhead lamp) ENGWARN If equipped with Komatsu engine, jumper 528A @ TB32 to ground to illuminate 2nd indicator lamp.) RESET Clear/delete pushbutton switch on Console...
Page 214 PSC Checkout Procedure 7. Highlight the devices listed in steps 1 through 11 in the Table below on the digital output section on PSC Digital Output Tests: this screen and then press {enter}. Press {enter} again to turn off 1. Turn OFF the Control Power Switch. 8.
Page 215 13. Turn ON the Control Power Switch 21. Turn ON the Control Power Switch ¤ Cursor to “Engine Stopped Tasks” {enter} ¤ Cursor to “Engine Stopped Tasks” {enter} ¤ Cursor to “Manual Test Mode” {enter} ¤ Cursor to “Manual Test Mode” {enter} ¤...
Page 216 PSC Digital Input Checks: 3. Turn OFF the key switch in the cab. KEYSW and CPSFB will no longer be high- The following tests are made on the “Manual Test lighted Screen” as selected during PSC Digital Output Test procedure. 4.
Page 217 17FM458 Panel Checks: 6. With the PTU connected to the PSC, enter the following: A3PV Panel ¤ c:\>ACNMENU {enter} 1. Remove the wires from panel terminals A and C. ¤ Highlight “PTU TCI & PSC” {enter} 2. With the Control Power Switch ON, measure ¤...
Page 218 Pedal Percentages and Meter Calibration Meter Calibration Procedure 1. Connect the serial communication cable from the The following procedures are used to calibrate the PTU to the TCI port, behind the center console, retarder and accelerator pedals, retarder lever, and the on the passenger side.
Page 219 E: Truck Speed: 12. Record the following information from the screen: ¤ Arrow to mph box {enter} F: Accelerator pedal: ¤ Type in: 25 {enter} Record the accel pedal voltage with pedal released (typical value; 1.61) 9. Adjust speedometer internal adjustment pot to obtain 25 mph (or 40 km/h).
Page 220 Reprogram With Serial Numbers and Pedal Per- ¤ Cursor to: 5) Change/View Truck Specifics {enter} centages: ¤ Type accelerator pedal, retard pedal and retard ¤ On the Main Menu, highlight “AC TRUCK lever percentages (see instructions and example SETUP (CFG)” {enter} in Figure 3-5), for the OFF and fully applied posi- tions.
Page 221 I: Program TCI K: Check Pedal Percentages ¤ On the PSC PTU - cursor to “Normal Operation” (PTU connected to TCI port) {enter} 1. Place the REST switch in the OFF position and ¤ Cursor to “PSC Real Time Data” {enter} turn keyswitch ON.
Page 222 Connect the positive lead to BAT engine) to the starter or 21B (MTU/DDC 16V4000 b. Connect the negative lead to F101. or Komatsu engine) to the starter solenoids. 2. Close the cabinet door. 2. Place both Inverter Cutout Switches on the side of the control cabinet to the CUTOUT position 3.
Page 223 FIGURE 3-6. PSC REAL TIME DATA SCREEN FIGURE 3-7. TCI REAL TIME DATA SCREEN E03015 3/01 AC Drive System Electrical Checkout Procedure E3-27 (Release 17 Software)
Page 224 ADDITIONAL TRUCK CHECKS 3. Start the engine. • • • • Be certain Rest Switch is ON. 4. Move the GF Cutout Switch to the NORMAL • • • • Place Inverter Cutout switches in the CUTOUT position. (down) position. 5.
Page 225 5. Connect the PTU to the PSC communication port. Inverter Link Voltage Check: ¤ c:\>ACNMENU {enter} 1. On the PSC PTU: ¤ Highlight PTU TCI & PSC {enter} ¤ Cursor to “Normal Operations” {enter} ¤ Enter your name {enter} ¤ Cursor to “View/Set PSC Analog Outputs” {enter} ¤...
Page 226 If truck is equipped with DDEC engine, jumper circuit 541M @ TB24 to ground. ¤ Cursor to “TCI Real Time data” {enter} b. If truck is equipped with Komatsu engine, 9. With the engine running, place the Rest Switch in jumper circuit 22FO @ TB32 to ground.
Page 227 FIGURE 3-9. TCI REAL TIME DATA SCREEN SAMPLE Initiate Loadbox Test: 2. “CCU” should momentarily display at the bottom of the screen. (This is a self-test indication). 1. To initiate the loadbox test, on the PSC PTU: 3. Put the Selector Switch in NEUTRAL and depress ¤...
Page 228 NOTE: If the “HP ADJ” value is (-)400 it is an indication 7. Compare values displayed on the Loadbox Test that the zero to ten volt engine command is not getting Screen with the sample screen in Figure 3-11. to the PSC (Circuit 72E and 72R). Refer to “PVM 8.
Page 229 ¤ Cursor to LDBX INIT on the Loadbox Screen and HP plus value from graph = corrected HP) press {enter}. 16. Note engine temperature and pressure gauges for Trucks with Komatsu SSDA16V160 engine: normal values. a. The output horsepower should be 2700 HP ±5% @ 1900 +10, -15 rpm.
Page 230 FIGURE 3-13. TOTAL PARASITIC LOSS AT FULL POWER Komatsu SSDA16V160 - 2700 GHP, ECS 8 Blade, 78" dia. 5.3" PW @ 798 RPM FIGURE 3-14. TOTAL PARASITIC LOSS AT FULL POWER DDEC 4000 - 2700 GHP, ECS 8 Blade, 78" dia. 5.3" PW @ 836 RPM...
Page 231 PVM OPTIMUM LOAD CURVE HANDSHAKING Trucks equipped with Komatsu engine: TROUBLESHOOTING 1. With the engine shut down, keyswitch ON and Note: a value of below 0.5VDC or above 9.5VDC (on control power ON, measure voltage between 72E circuit 72E to 72R) indicates a failure.
Page 232 MISCELLANEOUS COMPONENT REPAIR 9. If there IS voltage, reconnect the harness and disconnect the GTO Gate lead on the “G” termi- nal. 10. If there IS red light visible with the gate lead • • • • BE CERTAIN TO ALLOW ADEQUATE TIME disconnected, the GTO is shorted and the entire FOR LINK VOLTAGE TO DRAIN DOWN be- phase module or chopper module must be re-...
Page 233 To Remove the Snubber Resistors: 7. Install the four mounting bolts for each snubber resistor assembly. Tighten to 65 ft. lbs. (88 N.m) 1. Disconnect the upper and lower “L” brackets to torque. the DC link with a 3/4" inch socket. Remove only the outer four “L”...
Page 234 AUXILIARY BLOWER CONTROL Subcode 03: SYSTEM TROUBLESHOOTING Description: An overcurrent condition was detected during operation. 1. Check Capacitor Bank and Controller connec- tions. 2. Verify the inductor connections match-up (+ and The Auxiliary Capacitor Panel remains charged for -) from the Auxiliary Inverter and to the Auxiliary at least 15 minutes after engine shutdown.
Page 235 Subcode 07: Subcode 08: Description: A low DC bus voltage was detected after Description: A low DC bus voltage was detected the phase controller power up sequence. during operation. 1. Check the 3-phase input connections and fuses 1. Check Capacitor Bank and Controller connec- F1 and F2.
Page 236 Subcode 09: Subcode 12: 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.
Page 237 Auxiliary Inverter (Controller) 7. Whenever it is determined that an Aux Inverter input SCR has failed, both AC Input fuses must Troubleshooting be replaced and the old ones discarded. 8. Check pin and wire continuity between Aux con- troller CNX connector (7, Figure 3-12) and ap- propriate PSC &...
Page 238 Auxiliary Snubber Panel Troubleshooting The Auxiliary Capacitor Panel remains charged for at least 15 minutes after engine shutdown. Be certain LED’s D1 and D2 (6, Figure 3-12) are OFF before working on Auxiliary Blower Control cir- cuits. 1. After verifying capacitor charge warning LED’s (6, Figure 3-12) are not lit, disconnect external wiring from snubber panel terminals (3, Figure 3-10) to isolate the panel from other system components...
Page 239 IGBT Troubleshooting 7. After all circuits have been tested, reconnect all cables to their proper terminals. Reconnect J1, J2, J3, J4, J7 and J8. The Auxiliary Capacitor Panel remains charged for 8. Reinstall cover (2) and attach harness connector at least 15 minutes after engine shutdown. Be at CNX receptacle.
Page 240 NOTES E3-44 AC Drive System Electrical Checkout Procedure 3/01 E03015 (Release 17 Software)
Page 241 SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX TIRES AND RIMS ......... . G2 FRONT TIRES AND RIMS .
Page 242 NOTES G1-2 Index G01017...
Page 243 TIRES AND RIMS The truck tires should be inspected and tire pressure checked with an accurate pressure gauge before each working shift. Tire pressure will vary according to manufacturer and local working conditions. Consult the tire manufacturer for recommended tire pressure. When inflating tires always use a safety cage.
Page 244 FIGURE 2-2. FRONT WHEEL HUB AND RIM ASSEMBLY 1. Wheel Hub 5. Rim 9. O-Ring 2. Stud 6. Bead Seat Band 10. Clamp Bracket 3. Tire Inflation Hose 7. Side Flange 11. Flanged Nut 4. Swivel Connector 8. Lock Ring FRONT TIRES AND RIMS Removal 6.
Page 245 Installation REAR TIRES AND RIMS NOTE: Remove all dirt and rust from mating parts Removal before installing wheel assembly. 1. Park truck on level ground and block front wheels. 1. Grip wheel assembly with the tire handler and Position a jack under rear suspension mounting align tire inflation hose and wheel hub (1, Figure plates as shown in Figure 2-3.
Page 246 FIGURE 2-5. REAR WHEEL ASSEMBLY 1. Wheel Motor Mounting 4. Extension 8. Clamps 12. Wheel Motor Transmission Flange 5. Wheel Hub 9. Adaptor Ring 13. Extension 2. Inner Wheel Rim 6. Flanged Nut 10. Flanged Nut 14. Bracket 3. Disc Brake Assembly 7.
Page 247 4. If the adaptor ring (9) requires installation, install 8. Secure inner and outer dual tire inflation lines to adaptor onto wheel hub/wheel motor. Lubricate bracket (14) on outer rim. the studs and nut flanges with lithium base 9. Remove blocks from under truck and lower truck grease.
Page 248 3. Following tool manufacturers instructions, move tire bead in far enough to permit placing a wedge between tire and flange at side of tool. Tire Removal 4. Repeat this procedure at locations approximately 90° from the first application. Continue this pro- cedure until tire bead is free from rim.
Page 249 Tire Installation 4. Position tire over rim and work tire on as far as possible without prying against the beads. Any 1. Before mounting tire to rim, remove all dirt and damage to tire bead will destroy air seal and rust from rim parts, particularly the O-ring groove cause air leaks at these points.
Page 250 NOTES G2-8 Tires and Rims G02015...
Page 251 FRONT WHEEL HUB AND SPINDLE PREPARATION WHEEL HUB AND SPINDLE ASSEMBLY 1. Reduce the engine speed to idle. Place the selec- The following instructions will cover the complete re- tor switch in NEUTRAL and apply the parking moval, installation, disassembly, assembly and bear- brake.
Page 252 10. Using several 1.25" UNF x 8.00" long , grade 8 capscrews and hardened flatwashers (see Figure 7. Remove capscrews and washers (1, Figure 3-3) 3-4 for Komatsu part numbers), install the pusher securing retainer plate (2) to spindle structure and tool on the bottom of the steering arm.
Page 253 FIGURE 3-4. SPINDLE REMOVAL TOOL FIGURE 3-5. SPINDLE REMOVAL TOOL INSTALLATION 1. Capscrew Insertion 2. Tool Structure Holes (“X”) 1. Capscrew 3. Removal Tool (Part No. KC7095) 4. Spindle Arm 2. Hardened Washer 5. Spindle (Part No. WA0366) 6. Suspension Piston 11.
Page 254 Installation 1. Clean spindle bore and suspension rod taper to 8. Install tie rod on steering arm using EH4638 be certain they are free of rust, dirt, etc. alignment tool. Tighten pin retaining nut to 750 ft. lbs. (1017 N.m) torque. 2.
Page 255 Disassembly 1. Remove wheel hub and spindle as covered in 11. Remove capscrews (23) and hardened washers “Removal” before proceeding to Step 2. Clean (24) securing brake assembly inner gear to wheel assembly to remove dirt accumulation. hub. 2. To aid in complete disassembly of wheel hub and 12.
Page 256 FIGURE 3-6. FRONT WHEEL SPINDLE, HUB & BRAKE ASSEMBLY 1. Wheel Hub 15. Washer 29. Inner Bearing Cup 2. Stud 16. Speed Sensor 30. Seal Assembly 3. Capscrew 17. Sensor Bracket 31. Capscrew 4. Washer 18. Disc Brake Assembly 32. Hardened Washer 5.
Page 257 Assembly 8. Install a new O-ring (9) onto spindle cap (10). Lubricate the O-ring with clean hydraulic oil. In- stall the cap into the end of spindle (26). The tapped holes on the spindle cap must face the outside for disassembly purposes. NOTE: All mating surfaces of wheel and brake components must be clean and dry during assem- Wheel Bearing Adjustment:...
Page 258 NOTE: Measure the shims individually for accuracy. The above procedure results in a shim pack which will provide a nominal 0.020 in. (0.508 mm) preload for the bearings after assembly. Example: Socket head capscrews (34) are installed to posi- Step 19 (average depth) 1.416 in.
Page 259 23. After the brake assembly is properly positioned on the adaptor, remove the alignment studs and in- stall the remaining brake adaptor/brake assembly mounting capscrews (20) and hardened flatwash- ers (21). Tighten capscrews to 1995 ft. lbs. (2705 N.m) torque. 24.
Page 260 Removal 3. Remove locknuts (9, Figure 3-8) capscrews, (3) and retainers (10) from both ends of assembly. 1. With engine shut down and key switch “Off”, allow at least 90 seconds for the accumulator to bleed 4. Remove pins (16) from each end of assembly and down.
Page 261 Installation Bearing Replacement NOTE: Sleeve alignment tool, part number EH4638 1. Remove capscrews (2, Figure 3-9) and lockwash- included in tool group, should be used to hold bearing ers (3). Remove bearing retainer (4). spacers (4, Figure 3-8) and spherical bearings (11) in 2.
Page 262 TOE-IN ADJUSTMENT 1. The steering system must first be centered in the straight ahead position. Shut down engine and turn key switch OFF. Allow at least 90 seconds for the accumulators to bleed down. DO NOT turn the steering wheel. Block front and back of rear wheels.
Page 263 REAR AXLE HOUSING ATTACHMENT PIVOT PIN Removal 1. Park truck on firm level surface and block front and rear of all tires. Truck body must be empty and down against frame before attempting this procedure. 2. Release all brakes. 3. Charge rear suspensions with nitrogen until pis- tons are fully extended.
Page 264 6. Install clamps (17) on cover rings (9). Tighten Assembly clamps just enough to hold covers in place. 1. Setup an appropriate tool to press spherical bear- 7. Charge front suspension as described in “Oiling ing (4, Figure 4-2) into bearing carrier (3). Be and Charging Procedure”, Section “H”.
Page 265 PIVOT EYE REPAIR Assembly If damage occurs to the pivot eye (4, Figure 4-3), it may 1. Setup an appropriate tool to press bearing carrier be necessary to remove it from the rear axle structure (3, Figure 4-2) into the bore of the pivot eye (1) to facilitate repair and bearing replacement.
Page 266 ANTI-SWAY BAR NOTE: The anti-sway bar mounting arrangement is identical at each end. Removal 1. Position frame and rear axle housing to allow use of a puller arrangement to remove anti-sway bar pins (4, Figure 4-4) on the rear axle housing and the frame.
Page 267 REAR AXLE HOUSING 4. Verify the LINK VOLTAGE lights are OFF. If they REAR AXLE HOUSING remain on longer than 5 minutes after shutdown, Read and observe the following instructions be- notify the electrical department. fore attempting any repairs on propulsion system 5.
Page 268 FIGURE 5-1. REAR AXLE HOUSING AND WHEEL MOTORS 1. Disc Brake Assembly 6. Relay Valve 12. LH Wheel Motor 2. Brake Cooling Oil Return 7. Wheel Motor Power Cables 13. Park Brake Line 3. Clamp 8. Air Sensor/Rear Light Harness 14.
Page 269 22. Attach overhead hoist or crane to lift eyes on rear 4. Install rear suspensions, as described in Section axle housing and move from rear of frame. “H”. 5. Connect auto lube system hoses and clamps. 6. Route wheel motor cables (7, Figure 5-1) into Cleaning and Inspection housing and clamp in place.
Page 270 WHEEL MOTOR Front wheels must be securely blocked to prevent Read and observe the following instructions be- movement as brakes will be released. fore attempting removal of the wheel motors or any repairs on the propulsion system components! All electrical cables and hydraulic hoses should be marked prior to removal.
Page 271 11. Disconnect wheel motor power cables (7) at wheel Installation motor terminals. Disconnect speed sensor cable 1. Install two guide pins 180° apart in the rear hous- at connector in center of housing. ing. 12. Tie up cables and hoses as necessary to prevent damage during wheel motor removal.
Page 272 8. Connect air sensor hose, if removed. Install park brake apply hose (13). 9. Install inspection covers on access holes (17). All propulsion system power cables must be prop- 10. Install air duct (5). Close duct inspection covers erly secured in their wood or other non-ferrous and install duct tube in rear opening of axle hous- cable cleats.
Page 273 SECTION H ® HYDRAIR II SUSPENSIONS INDEX FRONT SUSPENSION ........H2 Removal .
Page 274 NOTES H1-2 Index H01013 04/01...
Page 275: Front Suspension
FRONT SUSPENSION ® The HYDRAIR II suspensions are hydro-pneumatic Removal components containing oil and nitrogen gas. The oil 1. Park unloaded truck on hard level surface. Block and gas in the four suspensions carry the gross truck wheels and set parking brake. Remove front weight less wheels, spindles and rear axle assembly.
Page 276 5. Place a suitable container under suspension cyl- inder. Remove bottom drain plug (19, Figure 2-8) and allow cylinder to drain completely. ® NOTE: Front HYDRAIR II suspensions are equipped with lower bearing retainer puller holes. If only rod wiper, rod seals, bearing, O-ring and backup ring replacement is required, it will not be necessary to remove suspension from truck.
Page 277 Replace only with bolts of correct hardness. Refer to lesser grade/size. the Komatsu Parts Catalog for correct part number. Before installation, inspect each capscrew for any defects and number of punch marks. Replace cap- screw and related hardware if two punch marks are evident;...
Page 278 “TURN-OF-THE-NUT” Tightening Procedure 1.) Mark a reference line on a corner of the hexagonal capscrew head or nut and the a. Tighten all fourteen capscrews (1, 6, 8, Figure 2-3) to 400 ± ± ± ± 40 ft .lbs. (542 ± ± ± ± 5 N.m) torque. mounting surface opposite this corner as shown.
Page 279 MINOR REPAIR ONLY (LOWER BEARING & SEALS) Bearing Retainer Removal If only rod wiper, rod seals, bearing, O-ring and backup rings are to be replaced, refer to steps below for lower bearing retainer removal. 1. Remove lower bearing retainer capscrews and hardened washers (20 &...
Page 280 14. Nut 29. Rod Wiper 15. Roll Pin MAJOR SUSPENSION REBUILD Disassembly NOTE: Refer to your Komatsu Distributor for HY- ® DRAIR II repair information and instructions not cov- ered in this manual. 1. With suspension held in a vertical position (end cap up), remove capscrews (1, Figure 2-7) and hardened washers (2).
Page 281 Assembly 4. Install new backup rings and O-rings (15, Figure 2-7) in end cap grooves. Backup rings must be NOTE: All parts must be completely dry and free of positioned toward the flange on the end cap. foreign material. Lubricate all interior parts with clean ®...
Page 282 NOTES H2-8 Front Suspensions H02013 2/01...
Page 283 REAR SUSPENSIONS ® The HYDRAIR II suspensions are hydro-pneumatic Removal components containing oil and nitrogen gas. The oil an 1. Remove capscrews, washers, and metal shield gas in the four suspensions carry the gross truck (2, Figure 3-1) from the suspension. weight less wheels, spindles and final drive assembly.
Page 284 5. Open valve on suspension charging kit to release nitrogen from the suspension. Disconnect charg- ing kit. 6. Disconnect lubrication lines. Disconnect pressure sensor cable. 7. Position a fork lift under the suspension housing, above the lower mounting pin. Secure suspen- sion to fork lift.
Page 285 Installation 1. Inspect mounting bore sleeves (9, Figure 3-3) and 6. Install capscrew (2, Figure 3-3) and locknut (3). bearing spacers for damage or wear. Check fit of Tighten to 343 ft. lbs. (465 N.m) torque. pins in bores prior to installing suspension. 7.
Page 286 Disassembly NOTE: If other repairs are necessary, refer to your local Komatsu Distributor for repair information and NOTE: The suspension should be placed in a fixture instructions not covered in this manual. which will allow it to be rotated 180° vertically.
Page 287 FIGURE 3-4. REAR SUSPENSION ASSEMBLY 1. Housing 2. Capscrews 3. Hardened Flatwashers 4. Piston Bearing 5. Piston Rod 6. Bleeder Screw 7. Vent Plug 8. Shield 9. Capscrew 10. Washers 11. Vent Plug 12. Charging Valve 13. Plug (Sensor) 14. Vent Plug 15.
Page 288 NOTES H3-6 Rear Suspensions H03013...
Page 289 These procedures cove the Oiling and Charging of ® HYDRAIR Charging Kit ® HYDRAIR II suspensions on Komatsu Trucks. Jacks and/or Overhead Crane Suspensions which have been properly charged will Support Blocks (Front and Rear) for: • provide improved handling and ride characteristics...
Page 290 3. Be certain outlet valves (3) and inlet valve (4) are FRONT SUSPENSION closed (turned completely clockwise). 1. Park unloaded truck on a hard level surface. Block 4. Turn swivel nut (small hex) on charging valve 3 wheels, apply parking brake. full turns counterclockwise to unseat valve.
Page 291 830E** 1.0 (25.4) 9.0 (229) 410 (2827) 930E* 1.0 (25.4) 9.0 (229) 440 (3034) FIGURE 4-3. CHARGING VALVE 930E-2* 1.0 (25.4) 9.0 (229) 425 (2930) 1. Valve Cap 6. Valve Body * with Standard Rock Body 2. Seal 7. O-Ring ** with Combination Body /Tailgate 3.
Page 292 3. If removed, install charging valve with new O- REAR SUSPENSION ring(9, Figure 4-3). Lubricate O-ring with clean ® HYDRAIR oil. 1. Park unloaded truck on a hard, level surface. 4. Tighten valve body (large hex, 6) to 16.5 ft. lbs. Apply parking brake.
Page 293 3. Depress the charging valve core to release nitro- Rear Suspension Nitrogen Charging gen pressure from the suspension. When nitro- gen pressure has been vented to atmosphere, loosen and remove the charging valve. The sus- pension should have collapsed slowly as gas pressure was released.
Page 294 5. Turn charging valve swivel nut clockwise to 6. Raise truck frame with crane or jacks to release tighten. the nitrogen charging dimension blocks and re- move blocks. Lower frame and remove lifting a. If the charging valve is being reused, tighten equipment.
Page 295 SECTION J BRAKE SYSTEM INDEX BRAKE CIRCUIT ......... . . J2 Service Brake Circuit .
Page 296 BRAKE CIRCUIT CHECKOUT PROCEDURE ......J4 Equipment Required ........J4-3 Initial System Setup .
Page 297 BRAKE CIRCUIT The Komatsu truck is equipped with an all-hydraulic cabinet (Figure 2-1) behind the cab. The hydraulic actuated wet disc service brake system. The brake components cabinet is easily accessible for brake sys- system utilizes Type C-4 hydraulic oil provided by the tem diagnostic and service work.
Page 298 FIGURE 2-1. HYDRAULIC COMPONENTS CABINET 1. Rear Brake Accumulator 11. Brake Lock Shuttle Valve 20. Low Brake Pressure Switch 2. Charging Valve 12. Brake Manifold 21. Park Brake Pressure Switch 3. Front Brake Accumulator 13. Pressure Reducing Valve (PR) 22. Stop Light Pressure Switch 4.
Page 299 SECONDARY BRAKING AND AUTOMATIC APPLY Normal Operation (key switch on, engine running) A fundamental function of the secondary brake system Parking brake switch “ON” is to provide reserve braking in the event of any single The parking brake solenoid (15, Figure 2-1) is failure.
Page 300 BRAKE LOCK CIRCUIT By turning on the dash mounted toggle switch, a sole- The primary function of the brake lock is to provide a noid valve (14, Figure 2-1) and pressure reducing valve means for the operator to hold the vehicle while at the (13) will apply unmodulated pressure oil at 2000 psi shovel or dump.
Page 301 FIGURE 2-2. BRAKE VALVE (FULL CUT-AWAY) 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.
Page 302 Rear Axle Brake Lines For reference to the brake lines that connect to the rear axle housing, refere to Figure 2-3. NOTE: If hoses (4, Figure 2-3) and (10) are switched, the rear brakes will be slow to apply and slow to release.
Page 303 BRAKE CIRCUIT COMPONENT SERVICE BRAKE VALVE The brake pedal assembly combines the dynamic retarding control with service brake control functions. As the pedal is depressed, the first portion of pedal travel actuates an internal potentiometer which pro- vides an electrical signal to the propulsion system, signalling a request by the operator for retarding.
Page 304 Removal Installation 1. Place the brake valve assembly into position and If the Brake Valve is to be removed from the vehicle secure in place with capscrews and lockwashers. for repair or adjustment, additional equipment will be Tighten capscrews to standard torque. required as outlined in disassembly, assembly.
Page 305 Disassembly 1. Match mark each section of the brake valve prior NOTE: If not already removed, remove electronic re- to disassembly. tard pedal (16, Figure 3-2) from brake pedal by remov- 2. Drain all oil from all ports of the valve by rotating ing pivot shaft (8).
Page 306 NOTE: The spools (12), reaction plungers (21, 22) and spool return springs (20) may fall out at this time. Keep parts separate so they may be installed in the same bores from which they were removed. 17. Remove and discard the O-ring (30) from the counterbore in the base of the valve body.
Page 307 FIGURE 3-4. BRAKE VALVE 1. Adjustment Collar 11. Spring Seat 21. Reaction Plunger (B1) 30. O-Ring 2. Nut 12. Regulator Spool 22. Reaction Plunger (B2) 31. Retaining Plug 3. Actuator Plunger 13. Back-up Ring 23. Wiper Seal 32. Base Plate 4.
Page 308 ® Cleaning and Inspection 3. Apply a thin bead of Loctite Prism 410 onto the upper sides of the cap. Apply the bead to the two 1. Clean all metal parts with solvent and air dry. long sides only. Do not apply it to the rounded 2.
Page 309 3. Install the orange back-up ring (4) on top of the poly-pak seal. Start by hand and then continue to work into the groove either by hand or by using an O-ring installation tool. 4. Install the wiper seal (5) in the top counterbore. Position the seal in the groove so that the register lip is facing up toward the actuator.
Page 310 5. Repeat Steps 1 through 4 for the “B2” actuation 19. Using new seals (27 & 28, Figure 3-4), install plunger. pressure differential pressure switch assembly (35) on valve body. Install socket head capscrews 6. Install the plunger return spring (10, Figure 3-4), (36).
Page 311 DIFFERENTIAL PRESSURE SWITCH NOTE : In the following assembly, make a note of the color (red or green) of spring (8). The spring color will The differential pressure switch (1, Figure 3-8) on the determine final adjustment of the switch. Refer to brake valve detects an imbalance in the brake apply Table I, "Differential Pressure Switch Adjustment".
Page 312 VALVE BENCH TEST AND ADJUSTMENT • Hose fittings for valve ports: The following parts and test equipment will be required Port PX:........7/16 in., # 4 SAE to completely bench test and adjust the brake valve. Ports P1, P2, B1 and B2: ..3/4 in. , #8 SAE The differential pressure switch can also be calibrated Port T: .........
Page 313 Test Set Up Procedure Brake Valve Output Pressure Adjustment 1. Position the valve in the fixture to allow plungers 1. Install the pedal pivot shaft pin in the actuator base to be activated by hand using a lever (refer to by itself without installing the pedal assembly.
Page 314 13. Slowly depress plunger to obtain pressure shown Final Test and Adjustment in Table I on the “B1” pressure gauge: The brake pedal actuator must be installed on the Adjust screw plug in bottom port of differential brake valve body prior to final test and adjustment. pressure switch counterclockwise until Refer to “Installation of Brake Pedal Actuator to Brake switch contacts just close.
Page 315 27. Continue turning the set screw until pressure Installation Of Brake Pedal Actuator Assembly begins to rise on one of the brake apply pressure to Brake Valve gauges. 1. Install jam nut (22, Figure 3-10) and set screw (21) 28. Back-off the set screw 1/8 turn. to brake pedal actuator (17).
Page 316 FIGURE 3-10. BRAKE VALVE AND PEDAL ASSEMBLY 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.
Page 317 DUAL RELAY VALVE Removal 1. Securely block the wheels to prevent possible The dual relay valves (one for front and one for rear roll-away. brake circuits) supply the apply pressure for each disc 2. Place selector switch in NEUTRAL, turn the rest brake assembly.
Page 318 FIGURE 3-11. DUAL RELAY VALVE & DIFFERENTIAL PRESSURE SW. 1. Manifold Body 9. Sleeve 17. Sleeve 25. O-Ring 2. Valve Body 10. Seal 18. O-Ring 26. Switch 3. Differential Pressure 11. Spool Spring 19. Plug 27. Body Switch Assembly 12. Regulator Spool 20.
Page 319 Disassembly Cleaning and Inspection 1. Clean all metal parts with solvent and air dry. The parts installed in the valve body for the “B1” and 2. Apply a light film of type C-4 hydraulic oil to “B2” bores are identical, however the parts must not plungers (14, Figure 3-11) and insert in sleeves be interchanged between the two bores.
Page 320 10. Install regulator spool assemblies into their re- Cleaning and Inspection spective sleeve bores. The spherical end must be 1. Clean all metal parts with solvent and air dry. inserted toward the spring seat. Push into bore 2. Inspect spool assembly (32, Figure 3-11) and bore until contact is made with lower spring seat.
Page 321 VALVE TEST AND ADJUSTMENT • Hose fittings for valve ports: The following parts and test equipment will be required Port “PX”: ..... 7/16 in.,#4 SAE O-ring. to completely bench test the dual relay valve. The Ports “B1” and “B2”: ..3/4 in., #8 SAE O-ring. differential pressure switch can be calibrated and its Port “T”: ....
Page 322 Test Set Up Procedure Brake Valve Output Pressure Adjustment 1. Setup valve on test stand as shown in Figure 3-12. 1. With pump operating and supply and pilot pres- sure adjusted as described in setup instructions, 2. Attach the pilot input supply line to the port labeled inspect valve for leakage.
Page 323 Differential Pressure Switch Adjustment 16. Reduce pilot pressure. Close “B1” needle valve (11) and open “B2” circuit needle valve (12). 10. Attach an ohmmeter or continuity tester lead to connector on differential pressure switch wire. 17. Slowly increase pilot pressure and verify switch contacts close at 300 ±30 psi (2,068 ±207 kPa) Attach other lead to valve body.
Page 324 HYDRAULIC BRAKE ACCUMULATORS ACCUMULATORS - HYDRAULIC COMPONENTS CABINET Four hydraulic brake accumulators are installed on the truck. Two identical accumulators are located on the Removal brake manifold in the brake control cabinet behind the 1. Shut down engine to bleed steering accumulators. operator’s cab.
Page 325 FIGURE 3-17. PLUG AND POPPET REMOVAL 8. Remove plug and poppet assembly from shell. (Refer to Figure 3-17.) 9. With wrench on valve stem flats, remove the nut FIGURE 3-14. LOCKNUT REMOVAL from the valve stem. 10. Insert hand into shell fluid opening. Depress bag and eliminate as much gas pressure as possible.
Page 326 5. Bladder may be checked by inflating to normal 7. Position name plate over valve stem and install size and checking with a soapy solution. After valve stem nut by hand (Figure 3-20). Remove testing, deflate immediately. bladder pull rod. 6.
Page 327 13. Install washer onto plug and poppet assembly and Charging Procedure push until seated against anti-extrusion ring. (Re- 1. Mount hose assembly gland nut on pressure fer to Figure 3-22). regulator. 14. Install O-ring over plug and poppet assembly and push until seated.
Page 328 ACCUMULATORS - FRAME MOUNTED Figure 3-26 illustrates the (RH) frame mounted brake circuit accumulators which provide additional oil stor- age for the front and rear brake circuits. Removal 1. Place the selector switch in NEUTRAL, turn the rest switch ON. Turn key switch OFF to shut down engine and allow at least 90 seconds to allow steering accumulator oil to drain back to tank.
Page 329 Disassembly 1. Remove charging valve (3, Figure 3-27). 2. Remove gland (4). Note: Figure 3-28 illustrates a tool that can be fabri- cated locally to aid in removing the gland. 3. Remove plugs and/or adaptor (10 & 11). Using a round rod, push piston (6) out of accumulator.
Page 330 b. Verify housing I.D. does not exceed 8.002 in. TESTING (203.25 mm). To carry out the testing required, it will be necessary c. Check dimensions frequently during honing to check for internal and external leaks at high pres- operation to prevent removal of too much ma- sure.
Page 331 ACCUMULATOR CHARGING 1. Valve Cap 2. Seal PROCEDURE 3. Valve Core (Frame Mounted Brake Accumulators) 4. Swivel Nut 5. Rubber Washer 6. Valve Body 7. O-ring 8. Valve Stem Do not loosen or disconnect any hydraulic line or 9. O-ring component until engine is stopped and key switch has been “Off”...
Page 332 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) Due to wear, the Retarder Control Lever assembly (4, Figure 3-30) may occaionally require adjustment or repair. Lever Assembly Removal Lever Assembly Installation 1. Connect harness connecter (5, Figure 3-30) to Adjustment of the lever assembly or replacement of lever assembly (4).
Page 333 Disassembly and Adjustment Assembly 1. Remove the capscrews (6, Figure 3-30) and lock- 1. If handle (16, Figure 3-30) or lever (15) has been washers (7) from lever assembly. removed from shaft (14), assemble as follows: 2. Remove potentiometer (8). a.
Page 334 NOTES J3-32 Brake Circuit Component Service J03019 1/99...
Page 335 BRAKE CIRCUIT CHECK-OUT PROCEDURE The brake circuit hydraulic pressure is supplied from NOTE: If internal leakage within the steering circuit is the steering circuit at the bleed down manifold. Some excessive, this also may contribute to problems within brake system problems, such as spongy brakes, slow the brake circuit.
Page 336 The steering circuit can be isolated from the brake The steering accumulator can be bled down with en- circuit by removing the brake supply line from the gine shut down, turning key switch “Off”, and waiting bleeddown manifold. 90 seconds. Confirm the steering pressure is released Plug the brake supply line and cap the port in the by turning the steering wheel - No front wheel move- bleeddown manifold.
Page 337 EQUIPMENT REQUIRED BRAKE CIRCUIT ABBREVIATIONS Included on the last page of this module is a data sheet Automatic Apply Pressure to record the information observed during the hydraulic Accumulator, Front Brake brake system check-out procedure. The data sheet Supply Pressure to Brake Valve for can be removed, copied, and used during the check- Front Brakes out procedure.
Page 338 INITIAL SYSTEM SET-UP Prior to checking the brake system, the hydraulic steering system must be operating properly, have correct accumulator precharge and be up to normal operating temperatures. Refer to Section L, “Hydraulic System”, for steering system operation troubleshoot- ing procedures and specifications. Be certain brakes have been properly bled to remove trapped air.
Page 339 BRAKE SYSTEM CHECKOUT 18. Quickly and completely depress pedal. Verify that within 1 second after brake is applied: NOTE: Unless otherwise specified, perform the follow- Left front brake pressure reads 2400 ± 75 psi ing checks with engine running, Rest switch in the ON (16,545 ±517 kPa) position, park brake ON and brake lock released.
Page 340 Failure Modes Check-Out 36. Turn key switch ON. Very slowly, open the rear brake accumulator bleeddown valve a small 29. Start engine and allow low brake accumulator amount ([NVR] 19, Figure 4-1) while observing pressure (LAP1 gauge) to stabilize at or above LAP1 decreasing pressure.
Page 341 45. Depress the brake pedal very slowly until the brake ! WARNING ! DO NOT attempt to adjust a "red" spring to 600 ±50 psi (4 137 ±345 kPa). This will differential pressure switch activates the low brake pressure lamp and buzzer. cause the spring to "bottom out"...
Page 342 49. Disconnect the hose (5, Figure 4-4) that supplies oil to the brake valve (“P1” port), rear brake circuit, by removing at the tee attached to the bottom of the hydraulic cabinet (brake manifold port “AR1”). Cap the tee fitting, but hose must be vented to atmosphere.
Page 343 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: The Brakes are Locked, Service and/or Parking Parking brake solenoid is de-energized. Check power to solenoid Connections to tank and pressure ports reversed. Correct the plumbing. Parking brake solenoid coil defective. Replace coil.
Page 344 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released Brake valve out of balance (not tracking). Check the switch and replace if defective. Check differential pressure switch adjustment. Refer Differential pressure switch is defective or improperly to Table I - Differential Pressure Switch Adjustment.
Page 345 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: The Low Pressure Warning Circuit Not Operating Properly The Low Brake Pressure lamp is burned out. Replace the bulb. The electrical circuit is open. Check switch circuit wiring. Pressure switch defective. Replace the pressure switch. TROUBLE: Low Pressure Warning is On Even Though System Pressure is Proper Short in electrical system.
Page 346 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Oil is Leaking Around the Pedal Base Defective seal on top of brake valve. Replace the seal. 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.
Page 347 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET MACHINE MODEL UNIT NUMBER SERIAL NUMBER INITIAL SYSTEM SET-UP Operate Hydraulic Steering System to obtain proper operating temperature. Refer to Check-out Procedures. STEP 2 All brake Accumulators charged to 1400 psi (9.65 MPa). STEP 7 Maximum rear brake pressure (brake lock).
Page 348 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET STEP 24 Brake lock degradation switch actuation pressure. STEP 27 Rear brake pressure with brake lock applied. Failure Modes Check-out STEP 32 Low accumulator pressure after 2 minutes. STEP 33 Pressure when warning systems actuate (front brakes). Pressure at which auto apply actuates.
Page 349 WET DISC BRAKE ASSEMBLY The oil cooled, wet disc brake assemblies mounted on the front and rear wheels are similar in design. The rear wheel brakes differ from the front in their mounting arrangement only. The rear brake assembly requires an adapter hub (1, Figure 5-1) for installation on the wheel motor wheel hub.
Page 350 MAINTENANCE Brake disc wear should be checked every 1000 hrs. using the wear indicator tool (Part Number EF9302), included in the tool group shipped with the truck. Refer to Figure 5-2. BRAKE DISC WEAR INDICATOR The brake disc wear indicator tool is inserted in a port which is open to cooling oil.
Page 351 6. While fully applying the service brake pedal, check brake wear as follows: a. Remove wear indicator cover (1, Figure 5-2). b. Push pin (8) in until it stops against brake piston. c. Measure the distance from indicator pin end face (2) to housing face (3).
Page 352 BRAKE REBUILD • The brake assembly should be disassembled and reassembled on a clean, dry work surface. The surface should be wooden or if metal, cov- ered with padding to prevent damaged to ma- chined surfaces. • Match mark individual parts for correct orienta- tion prior to disassembly.
Page 353 FIGURE 5-5. INITIAL DISASSEMBLY 1. Seal Carrier 5. Hardened Washer 9. Separator Plate 2. Capscrew 6. O-Ring 10. Damper 3. Back Plate 7. Ring Gear 11. Friction Disc 4. Capscrew 8. Piston Housing 12. Inner Gear FIGURE 5-6. PISTON/HOUSING ASSEMBLY REMOVAL 1.
Page 354 12. Attach a lift strap through bars and lift inner gear 15. Position piston assembly with retract springs on (5) out of brake assembly. Remove shipping bars top as shown in Figure 5-7. and spacers. 16. Remove capscrews (1, Figure 5-7), spring guides 13.
Page 355 Cleaning and Inspection 5. Inspect piston retract springs (3, Figure 5-7). Check springs for free height and test for height under load. Replace if not within approximately 10% of specification. Free Height: ... 4.00 in.
Page 356 Assembly 8. After completion of piston leakage test, release pressure, remove hydraulic source and drain oil from piston apply cavity. Plug ports to prevent contamination. 9. Install O-ring (4, Figure 5-6) in groove of ring gear The work area must be clean! Handle all parts (5).
Page 357 17. Follow procedures in “Floating Ring Seal Assem- 18. Install seal carrier on back plate. Secure in place bly/Installation” to install seal assembly in cavities with six 1/2 UNC x .75 in. socket head capscrews in the back plate and seal carrier. to retain seal carrier in position until brake assem- bly is installed on the truck.
Page 358 NOTE: After a front wheel brake assembly is installed, Seal Gap Adjustment: the seal must be setup for proper seal compression. 24. Refer to Figure 5-12 and adjust seal gap: Refer to “Seal Assembly Gap Check” in Section G, a. Measure seal gap “A” at three equally spaced “Front Wheel Hub and Spindle”.
Page 359 Floating Ring Seal Assembly/Installation Failures are usually caused by combinations of factors rather than one single cause, but many failures have one common denominator: – ASSEMBLY ERROR! When using tri-chloroethane or any solvent, avoid Floating ring seals should ALWAYS be installed in prolonged skin contact.
Page 360 3. Place installation tool onto seal ring with toric. Refer to Special Tools, Section “M” for installation tool. Lower the rings into a container of tri-chlo- roethane until all surfaces of toric ring are wet. 6. If small adjustments are necessary, DO NOT PUSH DIRECTLY ON THE SEAL RING.
Page 361 10. Be certain both housings are in correct alignment and are square and concentric. Move the parts slowly and carefully toward each other. 8. Wipe the polished metal seal surfaces with clean tri-chloroethane to remove any foreign material or fingerprints. No foreign particles of any kind should be on the seal ring faces.
Page 362 WET DISC BRAKE BLEEDING Rear Wheel Brakes: PROCEDURE 7. Crack open the O-ring plug located next to the cooling oil port and brake apply port on the brake NOTE: Rear wheel brakes must be bled prior to backplate. Close plug after oil runs clear and free rear tire installation.
Page 363: Parking Brake
PARKING BRAKE The Model 930E truck is equipped with a dry disc type When the parking brake switch is placed in the ON parking brake assembly mounted on each wheel motor position, the parking brake solenoid valve (SV2) lo- rotor shaft. The parking brake assemblies are inboard cated on the brake manifold in the hydraulic compo- mounted and can be accessed through the rear axle nents cabinet is de-energized, removing hydraulic...
Page 364 Removal MAINTENANCE Parking brake repairs should be performed when the The parking brake system requires periodic inspection wheel motor is removed from the truck whenever pos- to determine the amount of wear incurred to insure sible. If repairs are necessary when the wheel motor is adequate brake torque is available.
Page 365 Gear Removal: Park Brake Installation: If the rotor shaft gear (4, Figure 7-1) is worn, damaged NOTE: Two oil supply ports are provided on the lower or otherwise requires removal, follow the procedures half of the parking brake assembly. Install the O-ring below: fitting for attaching the supply hose (7, Figure 7-1) to the lowest port, depending on whether the brake is to...
Page 366 Disassembly Assembly 1.Match mark housing (3, Figure 7-2), piston housing 1. If dowel pins (2, Figure 7-2) have been removed, (4), and cap structure (5). press new dowel pins into holes in housing until fully seated against shoulder. 2. Install a separator disc (12) over dowel pins. Insert a spring (1) over each dowel pin.
Page 367 FIGURE 7-2. PARKING BRAKE ASSEMBLY 1. Compression Spring 7. Belleville Springs 13. Friction Disc 2. Dowel Pin 8. Piston Seal Assembly 14. Gear (Armature) 3. Housing 9. Piston Seal Assembly 15. Plug 4. Piston Housing 10. Capscrew 16. Oil Supply Port 5.
Page 368 PARKING BRAKE BLEEDING PROCEDURE 1. Apply the parking brake, put selector switch in 6. Connect a clear plastic hose to the parking brake NEUTRAL, place the Rest switch in the ON posi- bleeder screw. Place the other end of hose in a tion, turn the key switch OFF to shut down the container.
Page 369 SECTION L HYDRAULIC SYSTEM INDEX HYDRAULIC SYSTEM ........L2 HOIST CIRCUIT OPERATION .
Page 370 STEERING AND BRAKE PUMP ....... L6-12 Removal ........L6-12 Installation .
Page 371 HYDRAULIC SYSTEM The following is a general description of the Model tion can be found under the different system circuits 930E hydraulic system. Additional information con- such as the hoist circuit, steering circuit, and hydraulic cerning individual component description and opera- brake circuit.
Page 372 Note: Figure 2-1 illustrates the general location of the Hoist Circuit Operation hydraulic components on early production models. Hydraulic oil from the tank (8, Figure 2-2) is supplied Refer to Figure 2-2 through 2-5 for components in- to a gear type hoist circuit pump, rated at 246 GPM stalled on current production trucks.
Page 373 FIGURE 2-2. HOIST PUMP PIPING (Top View) 1. Hoist Cylinders 6. Pump Drive Shaft 2. Brake/Hoist Return Oil Manifold 7. Hoist Circuit Filters 3. Overcenter Manifold 8. Hydraulic Tank 4. Hoist Valve 9. Hoist Valve Pilot Circuit Hoses 5. Bleeddown Manifold L02028 Hydraulic System L2-3...
Page 374 Steering Circuit Operation Steering system oil is directed to the accumulators (5), used to store pressurized oil in the event of loss of Hydraulic oil from the tank is supplied to a piston type, pump pressure. Oil is also directed to the flow amplifier pressure compensated steering and brake circuit valve (3) for use by the cab mounted steering control pump (16, Figure 2-3), rated at 66 GPM (257 l/min.) @...
Page 375 FIGURE 2-4. STEERING SYSTEM COMPONENTS (Bottom View) 1. Steering Cylinders 6. Hoist Circuit Pump 2. Manifold 7. Steering/Brake Pump 3. Flow Amplifier Valve 8. Hydraulic Tank 4. Bleeddown Manifold 9. Shut-off Valve 5. Steering Circuit Accumulators 10. Steering/Brake Circuit Filter L02028 Hydraulic System L2-5...
Page 376 Disc Brake Cooling System When the hoist control valve is in the float or hold position, oil is supplied by the hoist valve to the disc brake assemblies located at each wheel to remove heat generated during service brake application. Oil supplied to the rear wheel brakes flows from the hoist valve (10, Figure 2-6) to the Brake/Hoist Return Oil Manifold (8), to the brake assemblies and is then...
Page 377 FIGURE 2-6. DISC BRAKE COOLING SYSTEM 1. Heat Exchanger 6. Left Front Brake Cooling Inlet Hose 2. Front Brake Cooling Oil Supply From Hoist Valve 7. Hydraulic Tank 3. Left Front Brake Cooling Outlet Hose 8. Brake/Hoist Return Oil Manifold 4.
Page 378 NOTES: L2-8 Hydraulic System L02028...
Page 379 HYDRAULIC SYSTEM COMPONENT REPAIR 3. Remove the rear axle blower duct to allow the hoist HOIST PUMP pump to be lowered from the pump module mounting bracket for removal. Remove duct sup- Removal port bracket. NOTE: The hoist pump can be removed without re- 4.
Page 380 5. Loosen the capscrews securing the inlet and outlet hoses (1, Figure 3-2) on the hoist pump and allow oil to drain. Remove inlet and outlet hoses. Cap or cover all lines and pump inlets and outlets to prevent contamination. 6.
Page 381 7. Attach a suitable lifting or support device to the Installation hoist pump capable of handling approximately NOTE: The following assumes the steering pump is 250 lbs (113 kg). Attach a support to the front end already in position on the truck. of the steering pump to hold it in place during removal of the hoist pump.
Page 382 Disassembly 3. The pump may be supported by placing on wood blocks with the input drive shaft pointing down. NOTE: As parts are removed they should be laid out in Mark each section nearest the input drive gear to a group in the same order in which they are removed. facilitate reassembly 4.
Page 383 5. Remove connector plate (9, Figure 3-5). Remove 7. Remove gear plate (5) and pressure plate (19). O-ring (8) and steel rings (10) and (14). Remove Remove steel rings, backup ring, O-ring and re- dowels (6) if damaged, or if connector plate re- tainer and isolation plate.
Page 384 10. Remove bearing plate (10, Figure 3-6). If the bear- hammer to loosen. Remove O-ring (8). Remove ing plate is stuck, tap lightly with a plastic hammer dowels (6) if damaged or if replacement of the to loosen it. Remove O-rings (9) and (11). flange (5) or gear plate (7) is necessary.
Page 385 FIGURE 3-7. PREPARATION FOR SEAL REMOVAL 1. Flange 3. Wooden Blocks 2. Bearings FIGURE 3-8. SHAFT SEAL REMOVAL 14. Remove outboard shaft seal (2), snap ring (21) and 1. Flange 3. Bearings inboard shaft seal (20). 2. Punch NOTE: To aid in shaft seal removal place the flange on two small wooden blocks as shown in Figure 3-7.
Page 386 NOTE: Replacing new bearing in the flange, connector INSPECTION OF PARTS plates or bearing plate is not recommended due to 1. Examine the gear bores in both gear plates, refer- close tolerances and special tooling required for ence Figure 3-9. During the initial break-in, the crimping the bearing in place to prevent bearing spin.
Page 387 6. Position the press ring over the seal. Make sure milled on one side; turn that side up or toward the the seal stays centered and true with the bore, and pressure plate. start applying pressure with the vise. Continue 12.
Page 388 15. Install the opposite pressure plate with the bronze side down and the milled slot facing toward the discharge side. 16. Install steel rings (11, Figure 3-14), backup ring (12), O-ring and retainer (13). Install isolation plate with its relief toward the pressure plate. 17.
Page 389 18. Lubricate O-ring (3, Figure 3-15) and install in 20. Lubricate I.D. of bearings (26). Install O-rings (8 & bearing plate (7). Lubricate O-rings (4) and install 9) and dowel (25) if removed. Install gear plate (10). over studs (12). Replace dowel (2) if removed. Make sure relief in gear plate is toward bearing Install bearing plate (7).
Page 390 21. Install rear drive gear (1) and idler gear (13). The 26. Lubricate the thru stud threads and install two rear drive gear must be timed with the front drive opposite stud nuts and hardened washers. Tighten gear. This is accomplished by lining up a tooth on nuts to 240 to 250 ft lbs (325 to 339 N.m) torque.
Page 391 TROUBLESHOOTING GUIDE (HOIST PUMP) TROUBLE POSSIBLE CAUSE SUGGESTED CORRECTIVE ACTION 1. Sandblasted band around pressure 1. Abrasive wear caused by fine 1. Was clean oil used? plate bores particles. 2. Was filter element change period 2. Angle groove on face of pressure a.
Page 392 5. Continue to repeat steps 1 thru 4 until oil level is HYDRAULIC TANK maintained in the top sight gauge with the engine stopped, key switch “Off”, and body down. Filling Instructions NOTE: With engine running and oil at operating tem- NOTE: If filling is required, use only type C-4 hydraulic perature, the oil should be visible in the lower sight oil as specified on the truck Lubrication Chart.
Page 393 Installation NOTE: If the oil is to be reused, clean containers must be used with a filtering (3-micron) system available for 1. Install hydraulic tank and secure with capscrews refill. and lockwashers. Tighten to 459 ft. lbs. (622 N.m) torque. 2.
Page 394 possible and check for proper oil level. Once the HYDRAULIC TANK BREATHERS breather filters become oil soaked, they will plug very There are two breather filters located on top of the quickly. hydraulic tank to allow air in and out of the tank. The NOTE: Plugged breather filters can cause pressure filters should be replaced at the interval specified on build up inside the hydraulic tank and can cause the...
Page 395 STEERING CIRCUIT restricted, a warning indicator is activated at 40 psi (276 STEERING CIRCUIT OPERATION kPa) and oil will bypass the element at 50 psi (345 kPa). The steering/brake pump (7, Figure 4-1) supplies oil to System pressure is regulated to between 2750 psi (19.0 the bleeddown manifold (4) after passing through a MPa) and 3025 psi (20.9 MPa) by an unloader valve high pressure filter (10).
Page 396 Oil pressure from the bleeddown manifold is routed COMPONENT DESCRIPTION back to the pump and sensed by the “ACC” port on the unloader valve. A steering pressure switch, mounted on the bleeddown manifold is connected electrically to a “Low Steering Pressure” warning lamp mounted in the cab and warns the operator if system pressure drops below 2300 psi (15.9 MPa).
Page 397 BLEEDDOWN MANIFOLD VALVE The bleeddown manifold valve (4, Figure 4-1) is located on the inside of the left hand frame rail just behind the flow amplifier. The bleeddown manifold is equipped with the following major circuit components as shown in Figure 4-3: •...
Page 398 FIGURE 4-4. BLEEDDOWN MANIFOLD SCHEMATIC 1. Steering/Brake Pump Inlet 16. Spare Return Port 2. Steering Pump Pressure Test Port 17. Autolube Pump Supply 3. Steering Accumulator 18. Hoist Pilot Return 4. APU Port 19. Hoist Pilot Power Down 5. Pressure Feedback (to Steering Pump) 20.
Page 399 Relief Valves The switches monitor nitrogen pressure when the key switch is turned ON and before the engine is started. The 4000 psi (28. MPa) relief valve limits maximum If nitrogen pressure is too low, the warning lamp turns steering circuit pressure by returning oil to the hydrau- on - a latching circuit prevents the warning lamp from lic tank through internal passages in the bleeddown turning off when the engine is started and steering...
Page 400 FLOW AMPLIFIER The flow amplifier (3, Figure 4-1, & Figure 4-5) is located The flow amplifier uses the amount of flow from the on the left frame rail forward of the bleed down manifold steering control unit to determine a proportional valve and is used in the steering circuit to provide the amount of flow to send from the bleed down manifold high volume of oil required for the steering cylinders.
Page 401 FIGURE 4-5. FLOW AMPLIFIER VALVE L04031 Steering Circuit L4-7...
Page 402 No Steer FLOW AMPLIFIER SYSTEM OPERATION (Refer to Figure 4-6): Refer to figures 4-6 through 4-9 for oil flow paths during the following conditions: High pressure oil from the steering pump and steering accumulators is available through the steering bleed- Neutral down manifold to the “HP”...
Page 403 FIGURE 4-6. FLOW AMPLIFIER - NO STEER L04031 Steering Circuit L4-9...
Page 404 Steering Left This oil now inside sleeve “E” pushes valve “F” against its spring to give the oil access to a series of holes “K”, (Refer to Figure 4-7): that are in the same plane as hole “G”. The passage of When the operator turns the steering wheel “left”, the oil through holes “K”...
Page 405 FIGURE 4-7. FLOW AMPLIFIER - LEFT STEER L04031 Steering Circuit L4-11...
Page 406 Steering Right The oil enters the flow amplifier assembly at port “R” and shifts the directional valve the opposite direction. (Refer to Figure 4-8): The oils flow through the amplifier valve exactly the Only a few differences occur between steer left and same.
Page 407 FIGURE 4-8. FLOW AMPLIFIER - RIGHT STEER L04031 Steering Circuit L4-13...
Page 408 No Steer, External Shock Load As the cylinders are allowed to move, the other ends will have less than atmospheric pressure on port “CL”. (Refer to Figure 4-9): This low pressure permits oil that is escaping through When the operator is not turning the steering wheel, the “CR”...
Page 409 FIGURE 4-9. FLOW AMPLIFIER NO STEER - EXTERNAL SHOCK LOAD L04031 Steering Circuit L4-15...
Page 410 STEERING PUMP Operation The steering/brake pump is mounted on the rear of the The driveshaft (35, Figure 4-10) runs through the cen- hoist system pump. The drive shaft mates with an terline of pump housing (37) and valve plate (48). The internally splined coupling inside the hoist pump when cylinder barrel (45) is splined to the drive shaft.
Page 411 FIGURE 4-10. STEERING PUMP 1. Plug 2. O-Ring 3. Spring 4. Back-Up Ring 5. O-Ring 6. Back-Up Ring 7. O-Ring 8. O-Ring 9. O-Ring 10. Back-Up Ring 11. Spring 12. Control Piston Sleeve 13. Spring 14. Piston 15. Pin 16. Control Piston Stop Pin 17.
Page 412 PRINCIPLE OF OPERATION Full Pump Volume: Control piston (1, Figure 4-11) controls the angle of the swashblock (4). When control piston moves to the full right position, the pump is at maximum pumping ca- pacity. The driveshaft turns the splined housing (2) which contains the pumping pistons (3).
Page 413 If the truck is oper- ating at high altitude and problems are experienced, consult the Komatsu Factory Representative for adjust- ment procedures. Figure 4-15 shows the schematic of the pump and the pressure control valves.
Page 414 NOTES L4-20 Steering Circuit L04031...
Page 415 STEERING CONTROL UNIT Removal NOTE: Clean steering control unit and surrounding area carefully to help avoid contamination of hydraulic oil when lines are opened. 1. Shut down engine and bleed down steering circuit. NOTE: To insure the hydraulic oil has completely drained from the accumulators, turn the steering wheel.
Page 416 STEERING CONTROL UNIT REBUILD Disassembly The steering control unit is a precision unit manufac- tured to close tolerances, therefore complete cleanli- ness is a must when handling the valve assembly. Work in a clean area and use lint free wiping materials or dry compressed air.
Page 417 4. Remove end cover (4) and O-ring (2, Figure 5-5). 13. Remove the dust seal (2, Figure 5-6) using a screwdriver. Take care not to scratch or damage the dust seal bore. FIGURE 5-5. END COVER REMOVAL 1. Gear Wheel Set 2.
Page 418 FIGURE 5-7. STEERING CONTROL VALVE 1. Dust Seal 7. Bearing Assembly 13. Tube 19. End Cover 2. Housing & Spools 8. Ring 14. O- ring 20. Washers 3. Ball 9. Pin 15. Distribution Plate 21. Rolled Pin 4. Threaded Bushing 10.
Page 419 Assembly NOTE: When assembling the spool and sleeve, only one of the two possible matching positions of the spring slots can be used. The reason is that in the other end of the sleeve and spool (opposite end of the spring slots) there are three slots in the spool and three holes in the sleeve.
Page 420 6. With neutral position springs (7, Figure 5-10) centered in spool and sleeve, install ring (3), rear bearing race (4), thrust bearing (5) and front bearing race (6) in that order. The chamfer on the rear bearing must be facing away from the bear- FIGURE 5-11.
Page 421 10. Install the check ball in the hole shown in Figure 11. Grease the housing O-ring (3) with Vaseline and 5-12. Install threaded bushing and lightly tighten. install in the housing groove. 12. Install the distribution plate (15, Figure 5-7) with plate holes matching the corresponding holes in the housing.
Page 422 NOTES L5-8 Steering Control Unit L05021...
Page 423 STEERING CIRCUIT COMPONENT REPAIR BLEEDDOWN MANIFOLD VALVE Do not loosen or disconnect any hydraulic line or component connection until engine is stopped and keyswitch has been “off” for at least 90 seconds. Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by pene- trating the skin and cause serious injury and pos- sibly death if proper medical treatment by a physician familiar with this injury is not received...
Page 424 ACCUMULATORS Removal 1. Insure key switch has been “Off” for at least 90 seconds to allow accumulator oil to drain back to tank. Move steering wheel to be certain all pres- surized oil is released. 2. Remove charging valve guard (3, Figure 6-2) and loosen small hex on charging valve (4) three complete turns.
Page 425 Disassembly 1. Remove charging valve (3, Figure 6-4). 2. Remove gland (4). Note: Figure 6-5 illustrates a tool that can be fabricated locally to aid in removing the gland. 3. Remove plugs and/or adaptor (10 & 11). Using a round rod, push piston (6) out of accumulator. 4.
Page 426 b. Verify housing I.D. does not exceed 8.002 in. TESTING (203.25 mm). To carry out the testing required, it will be necessary c. Check dimensions frequently during honing to check for internal and external leaks at high pres- operation to prevent removal of too much ma- sure.
Page 427 STEERING ACCUMULATOR CHARGING PROCEDURE Do not loosen or disconnect any hydraulic line or component until engine is stopped and key switch has been “Off” for at least 90 seconds. Pure dry nitrogen is the only gas approved for use in the steering accumulators. The accidental charging of oxygen or any other gas in this com- partment may cause an explosion.
Page 428 FLOW AMPLIFIER FIGURE 6-7. FLOW AMPLIFIER VALVE 1. Capscrew 2. Lockwasher Removal 3. Capscrews 4. Lockwasher 5. Cover 6. O-ring 7. O-ring 8. O-ring Relieve pressure before disconnecting hydraulic 9. (Not Used) and other lines. Tighten all connections before 10. O-ring applying pressure.
Page 429 L06021 Steering Circuit Component Repair L6-7...
Page 430 Disassembly 1. Remove counterpressure valve plug (17, Figure 6-7), and O-ring (16). Remove counterpressure valve assembly (15). 2. Remove plug (18) and seal (19). Using an 8 mm hex allen head wrench, remove the relief valve assembly (54). Remove steel seal (55). 3.
Page 431 Assembly 9. Install amplifier spool assembly (53). Install priority valve spool (44) and spring (43). Install spring 1. Thoroughly lubricate each part prior to installation (52). using clean, type C-3 hydraulic oil. 10. Install spring control (29), springs (30 & 31) and 2.
Page 432 STEERING CYLINDERS Figure 6-10 illustrates details of the steering cylinder mounting. Refer to Section “G” for removal and instal- Relieve pressure before disconnecting hydraulic lation instructions. and other lines. Tighten all connections before applying pressure. Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by pene- trating the skin and cause serious injury and pos- sibly death if proper medical treatment by a...
Page 433 FIGURE 6-11. STEERING CYLINDER ASSEMBLY 1. Housing 4. Piston Bearing 7. Backup Ring 10. Rod Structure 2. Locknut 5. Piston Seal Assembly 8. Gland 11. Rod Wiper 3. Piston 6. O-Ring 9. Capscrew 12. Rod Seal 13. Bearing Disassembly Cylinder Assembly 1.
Page 434 STEERING AND BRAKE PUMP steering pump can be closed, eliminating the need to completely drain the tank. Removal 2. Drain the hydraulic tank by use of the drain located on the bottom side of the tank. NOTE: Be prepared to contain approximately 250 gal. (947 L) of hydraulic oil.
Page 435 Oil level in the hydraulic tank may be below the level of the pump(s) causing extreme pump wear NOTE: Use only Komatsu filter elements, or ele- during this initial pump start-up. ments that meet the Komatsu hydraulic filtration specification of Beta 12 = 200.
Page 436 DISASSEMBLY Stroke adjuster assembly (items 12, 13, 14, 15 and 16, Figure 6-13) MUST be removed BEFORE further When disassembling or assembling pump, choose disassembly of control piston. a work area where no traces of dust, sand or other 8. Without disturbing jam nut (16), unscrew gland abrasive particles which could damage the unit are (15) and remove stroke adjuster as a complete in the air.
Page 437 FIGURE 6-13. PUMP, FRONT HOUSING 1. Shaft 8. Name Plate 15. Gland 21. Housing 2. Bearing 9. Plug 16. Jam Nut 22. Seal Retainer 3. Snap Ring 10. O-Ring 17. Pin 23. Elbow Fitting 4. Retainer Ring 11. Plate 18. O-Ring 24.
Page 438 FIGURE 6-14. PUMP, ROTATING GROUP 1. Springs 10. Cylinder Barrel 19. Dowel Pin 2. Seal 11. Control Piston 20. Saddle 3. Piston Ring 12. Ball 21. O-Ring 4. Sleeve 13. Piston Shoe Assembly 22. Roll Pin 5. Back-Up Ring 14. Retainer Ring 23.
Page 439 Rotating Group Driveshaft Group 28. Remove bearing retaining ring (3, Figure 6-13). Use a mallet on the tail shaft and tap driveshaft (1) out from the front of the pump housing. 29. Remove seal retainer (22) from pump housing. The rotating group weighs approximately 30 lbs. Use a mallet and tap saddle (20, Figure 6-14) out Extreme care must be taken not to damage cylin- from the inside of the pump housing.
Page 440 a. Place square end of piston on bench and hold b. Measure shoe thickness (the part held between down firmly. Pull on end of shoe with other retainer (27, Figure 6-14) and cradle. All shoes hand and note end play. A good piston/shoe fit must be equal within 0.0001 in.
Page 441 Swashblock Group 12. Compare saddle bearing (24) thickness in wear area to thickness in a non-wear area. Replace 11. Inspect swashblock (25, Figure 6-14) for saddle bearings if difference is greater than 0.004 scratches, grooves, cracks or uneven surface. in (0.102 mm). Replace if defective.
Page 442 Driveshaft Group ASSEMBLY 15. Remove shaft seal (26, Figure 6-13). The procedures for assembling the pump are basically the reverse order of disassembly procedures. During 16. Check shaft bearing (2) for galling, pitting, binding assembly, install new gaskets, seals, and O-rings. or roughness.
Page 443 Driveshaft Group NOTE: Be sure punch marks on cylinder bearing (26, Figure 6-14) will face toward shaft end of pump. The assembled rotating group weighs approxi- mately (30 lbs.). Assistance from others and use 10. Insert cylinder bearing (26) straight into pump of proper lifting techniques is strongly recom- housing.
Page 444 39. Carefully maneuver valve plate assembly, sup- ported by overhead hoist, over driveshaft and into pump housing so slot on control piston (11) en- gages control link (17). 40. With hole in control piston lined up with hole in the link, carefully insert control link pin (16).
Page 445 TROUBLESHOOTING CHART (Steering Circuit) POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Slow steering, hard steering or loss of power assist Overloaded Steering Axle Reduce Axle Loading Malfunctioning relief valve preventing adequate sys- Check system pressure. Adjust or replace relief valve. tem pressure build-up Worn or malfunctioning pump Replace pump.
Page 446 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Erratic steering Air in system due to low oil level, cavitating pump, Correct condition and add oil as necessary. leaky fittings, pinched hose, etc. Loose steering cylinder piston Repair or Replace steering cylinder. TROUBLE: Free wheeling - steering wheel turns freely with no back pressure. Front wheels do not steer. Splines of steering column/steering control unit cou- Repair or replace steering column or coupling.
Page 447 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Steering wheel oscillates or turns by itself Lines connected to wrong ports Check line routing and connections. Parts assembled wrong. steering control unit improp- Reassemble correctly and retime control valve. erly timed. TROUBLE: Steered wheels turn in opposite direction when operator turns steering wheel Lines connected to wrong cylinder ports Inspect and correct line connections.
Page 448 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Loss of pressure Defective pressure control Check unloader valve operation and adjust pressure if necessary. Check compensator adjustment pressure. Check system relief valves. Internal steering pump wear Repair or replace pump. Excessive leakage in brake system Inspect brake system and check pressures.
Page 449 (Flow Amplifier) POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Slow or hard steer Stuck amplifier spool Disassemble valve, check amplifier spool for damage or obstruction. Obstruction in orifice, directional spool Disassemble valve, check directional spool and ori- fices for damage or obstruction. Incorrect relief valve pressure setting Check and correct relief valve setting.
Page 450 NOTES L6-28 Steering Circuit Component Repair L06021...
Page 451 HOIST CIRCUIT Hydraulic oil from the hoist filters is directed to the hoist HOIST CIRCUIT OPERATION valve (7), mounted above the pumps. The following information describes the basic hoist The hoist valve directs oil to the body hoist cylinders system circuit as shown in Figure 7-1. Detailed com- (10) for raising and lowering of the dump body.
Page 452 COMPONENT DESCRIPTION HYDRAULIC TANK The hydraulic tank supplies hydraulic oil for the hoist, steering and brake circuits. The tank is located on the left hand frame rail forward of the rear wheels. The service capacity of the tank is 250 gal. (947 l). Type C-4 hydraulic oil is recommended for use in the hy- draulic system.
Page 453 The secondary low pressure relief is located between Tank Ports (Front) Spool Section the low pressure core and the outlet to the brake The primary low pressure valves are located in the cooling circuit. It provides for pressure relief if pressure front spool section of the hoist valve.
Page 454 BLEEDDOWN MANIFOLD OVERCENTER MANIFOLD The pilot valve/hoist valve hydraulic circuit is routed The overcenter manifold (4, Figure 7-4), located on the through the bleeddown manifold, located on the left pump module at the rear of the hoist valve (1) contains frame rail.
Page 455 HOIST CIRCUIT OPERATION The following pages describe the hoist circuit operation in the FLOAT, POWER UP, HOLD, and POWER DOWN positions. (Refer to Figures 7-5 through 7-9.) L07023 Hoist Circuit L7-5...
Page 456 FLOAT POSITION OF PILOT VALVE WITH Pressure builds to approximately 60 psi (414 kPa) on TRUCK BODY ON FRAME the pilot of the flow control valve (2) causing the valve to compress the spring and open, allowing the oil to Figure 7-5 shows the position of the hoist pilot valve flow the through hoist valve port (23) to the service when the truck body is resting on the frame.
Page 457 FIGURE 7-5. FLOAT POSITION 1. Hoist Relief Valve (2500 psi) 10. Tank Return Port 17. Anti-void Check Valve 2. Flow Control Valve 11. Supply Port 18. Load Check Valve 3. Secondary Low Press. Valve (250 psi) 12. Pilot Supply Port 19.
Page 458 POWER UP OPERATION (Figure 7-6) As the hoist cylinders extend, oil in the annulus area of all three stages must exit sequentially from the The hoist pilot valve spool is moved to the Power Up cylinders. Initially, the rod end spool (7) ports are position when the operator moves the lever rearward closed.
Page 459 FIGURE 7-6. POWER UP POSITION 1. Hoist Relief Valve (2500 psi) 10. Return Port 17. Anti-void Check Valve 2. Flow Control Valve 11. Supply Port 18. Load Check Valve 3. Secondary Low Press. Valve (250 12. Pilot Supply Port 19. High Pressure Passage psi) 13.
Page 460 HOLD OPERATION (Figure 7-7) Both pilot ports (14 & 15) in the pilot valve are closed by the pilot valve spool. In this condition pressure is The pilot valve spool is positioned to allow the pilot equalized on each end of each main spool (7 & 8) supply oil entering port (12) to return to the tank allowing the springs to center the spools and close all through Port (10).
Page 461 FIGURE 7-7. HOLD POSITION 1. Hoist Relief Valve (2500 psi) 10. Return Port 17. Anti-void Check Valve 2. Flow Control Valve 11. Supply Port 18. Load Check Valve 3. Secondary Low Press. Valve (250 12. Pilot Supply Port 19. High Pressure Passage psi) 13.
Page 462 POWER DOWN OPERATION (Figure 7-8) As oil attempts to return from the head end of the hoist cylinders, it initially encounters the closed head end When the operator moves the lever to lower the body, spool (8). Pressure increases on the bottom end of the the hoist pilot valve is positioned to direct the pilot spool causing it to move upward.
Page 463 FIGURE 7-8. POWER DOWN POSITION 1. Hoist Relief Valve (2500 psi) 10. Return Port 17. Anti-void Check Valve 2. Flow Control Valve 11. Supply Port 18. Load Check Valve 3. Secondary Low Press. Valve (250 12. Pilot Supply Port 19. High Pressure Passage psi) 13.
Page 464 FLOAT OPERATION (Figure 7-9) The 26 psi (179 kPa) in the low pressure passage causes oil to flow to the rod end of the cylinders to keep When the operator releases the lever as the body them full of oil as they retract . When the body reaches travels down, the hoist pilot valve spool returns to the the frame and there is no more oil flow from the FLOAT position.
Page 465 FIGURE 7-9. FLOAT POSITION 1. Hoist Relief Valve (2500 psi) 10. Tank Return Port 17. Anti-void Check Valve 2. Flow Control Valve 11. Supply Port 18. Load Check Valve 3. Secondary Low Press. Valve (250 psi) 12. Pilot Supply Port 19.
Page 466 NOTES L7-16 Hoist Circuit L07023...
Page 467 HOIST CIRCUIT COMPONENT REPAIR HOIST VALVE Removal 3. Thoroughly clean the exterior of the hoist valve. 4. Mark, disconnect and cap or plug all line connec- tions to help prevent hydraulic oil contamination, refer to Figure 8-1. Relieve pressure before disconnecting hydraulic lines.
Page 468 O-Ring Replacement NOTE: It is not necessary to remove the individual valve sections to accomplish repair, unless emergency field repair is required to replace the O-rings between sections to prevent leakage. Loosening and retighten- ing of the main valve tie rod nut could cause distortion resulting in binding or severely sticking plungers, pop- pet and spools.
Page 469 FIGURE 8-5. INLET SECTION DISASSEMBLY 1. Capscrew 5. Spring 8. O-Rings 11. Check Valves 2. Inlet Cover 6. Sleeve 9. Inlet Valve Body 12. Springs 3. Spring (Orange) 7. Secondary Low Pressure Relief 10. O-Rings 13. Cover 4. Flow Control & Main Relief Valve 14.
Page 470 Cleaning and Inspection REAR SPOOL SECTION (Work Ports) 1. Discard all O-rings and backup rings. Clean all parts in solvent and dry with compressed air. Disassembly 2. Inspect all springs for breaks or distortion. Inspect NOTE: It is not necessary to remove the inlet sections poppet seating surfaces for nicks or excessive (1 or 4, Figure 8-2) to accomplish spool section (2 or wear.
Page 471 FIGURE 8-9. WORK PORTS SPOOL SECTION ASSEMBLY 1. Spool Cover 8. O-Ring 15. Spool End 2. Spring Seat 9. Restrictor Poppet 16. Spring (Blue) 3. Plug 10. O-Ring 17. O-Ring 4. O-Ring 11. Spring 18. Poppet 5. O-Ring 12. Restrictor Poppet (Red) 19.
Page 472 Assembly ORIFICE POPPET COLOR DRILL SIZE DIAMETER 1. Lubricate O-rings (4, 5 & 10, Figure 8-9) with clean hydraulic oil. Install O-rings in spool hous- .140 in. (3.556 mm) ing. Install poppet (18). Install cover (19) and secure in place with capscrews. Tighten cap- Green .093 in.
Page 473 FRONT SPOOL SECTION (Tank Ports) Disassembly NOTE: It is not necessary to remove the inlet sections (1 or 4, Figure 8-2) to accomplish spool section disas- sembly and repair. 1. Match mark or identify each spool in respect to its mating bore when removed. 2.
Page 474 FIGURE 8-12. TANK PORTS SPOOL SECTION ASSEMBLY 1. Spool Housing 4. Spool Cover 7. Spool 2. Plug 5. O-Ring 8. Spring 3. O-RIng 6. O-Ring 9. Spool Cover L8-8 Hoist Circuit Component Repair L08024...
Page 475 HOIST PILOT VALVE Installation 1. Place the hoist pilot valve (1, Figure 8-13) into Removal position on the mounting bracket. Secure valve in place with mounting hardware (2). 1. Place the hoist control lever in the body down position. Make certain the body is in the full down 2.
Page 476 Disassembly 2. Remove machine screw (15, Figure 8-14) seal plate (16), wiper (13) and O-ring (12). 1. Thoroughly clean the exterior of the valve. Match mark components to assure proper reassembly. 3. Remove snap ring (1), capscrews (6), cap (24), spacer (23), and detent sleeve (22).
Page 477 Cleaning and Inspection 5. Install tie rods. Install tie rod nuts. Tighten tie rod nuts to the torques shown in Figure 8-16. 1. Clean all parts including housings in solvent and blow dry with compressed air. 6. Install a new O-ring (27, Figure 8-14) and wiper (26).
Page 478 HOIST CYLINDERS 4. At the upper mount, remove self-locking nut (4, Figure 8-18) from pin retaining capscrew. Re- move capscrew (5). Use a brass drift and ham- Removal mer to drive pin (1) from bore of mounting bracket. 5. Carefully lower cylinder until it lays against the inside dual tire.
Page 479 Installation 7. Start engine, raise and lower body several times to bleed air from cylinder. Check for proper op- eration and inspect for leaks. 8. Service hydraulic tank if necessary. Install a retaining strap or chain to prevent the cylinder from extending during handling. The hoist cylinder weighs approximately 2500 lbs.
Page 480 FIGURE 8-20. HOIST CYLINDER 1. Rod & Third Stage 2. Second Stage Cylinder 3. First Stage Cylinder 4. Housing 5. Plate 6. Rod Bearing Retainer 7. Capscrew 8. Seal 9. Snap Ring 10. Cover 11. Capscrews 12. O-Ring 13. Bearing 14.
Page 481 Disassembly NOTE: As internal parts are exposed during disassem- bly, protect machined surfaces from scratches or 1. If removal of the hoist cylinder eye bearings is nicks. necessary, remove retainer ring (4, Figure 8-19) and press out bearing (5). 2. Mount the hoist cylinder in a fixture which will 8.
Page 482 Cleaning and Inspection NOTE: Use only fresh cleaning solvent, lint free wiping cloth and dry filtered compressed air when cleaning and handling hydraulic cylinder parts. Immediately after cleaning and inspection, coat all surfaces and parts with clean hydraulic oil (Type C-4). 1.
Page 483 (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.
Page 484 Installation Of Check Balls And Plugs In Quill 1. Use the newer plugs and make certain threads in quill tube and on plugs are clean and dry (free of The check balls (4, Figure 8-22) in the side of the quill oil and solvent).
Page 485 Assembly of Cylinder NOTE: Check capscrews (1, Figure 8-24) carefully for distress and, if in doubt, replace them with new parts. 1. Install seals (15, Figure 8-20) and bearing (14) on second stage cylinder. Install bearings (19) and buffer seal (18), rod seal (20) and rod wiper 12.
Page 486 NOTE: If both trucks are a Model 930E-2, the hoses bottoms. will be installed at the quick disconnects shown in 5. Repeat step 4 to dump the disabled truck.
Page 487 HYDRAULIC SYSTEM FILTERS HOIST CIRCUIT FILTER The hoist circuit filter (Figure 9-1) is located on the fuel tank below the right frame rail. The filter provides sec- ondary filtering protection for hydraulic oil flowing to the hoist valve and hoist circuit components. An indicator switch (5) is designed to alert the operator of filter restriction before actual bypass occurs.
Page 488 Removal Installation 1. With the key switch “Off” allow at least 90 seconds 1. Install new element (9). Install new O-ring (6) and for the accumulators to bleed down. backup ring (7). 2. Remove bleed plug (11, Figure 9-1). Remove bot- 2.
Page 489 STEERING CIRCUIT FILTER The steering circuit filter (Figure 9-2) is located on the inboard side of the fuel tank. The filter provides secon- dary filtering protection for hydraulic oil flowing to the bleeddown manifold valve for the steering and brake systems.
Page 490 Removal INDICATOR SWITCH 1. With the key switch “Off” allow at least 90 seconds The hydraulic filter indicator switch is factory preset to for the accumulators to bleed down. actuate at 35 psid (240 kPa). Switch adjustment is not necessary or recommended, however the switch and 2.
Page 491 The indicator switch tester may be ordered from: Kent-Moore Heavy Duty Division Sealed Power Corp. 29784 Little Mack Roseville, MI 40866-9984 Phone: (313) 774-9500 FIGURE 9-3. INDICATOR SWITCH TESTER Kent-Moore Part No. J-33884-4 FIGURE 9-4. INDICATOR SWITCH PRESSURE TEST BLOCK L09008 Hydraulic System Filters L9-5...
Page 492 NOTES L9-6 Hydraulic System Filters L09008...
Page 493: Warnings And Cautions
HYDRAULIC CHECK-OUT PROCEDURE GENERAL INFORMATION STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE The hydraulic check-out procedure is intended to help the technician check, adjust, and diagnose problems The steering circuit hydraulic pressure is supplied from in the steering and hoist circuits. The technician should the piston pump and steering accumulators.
Page 494 Equipment Requirements The following equipment will be necessary to properly check-out the hydraulic steering circuit • Hydraulic schematic, refer to Section “R”. • Two 0-5000 psi (0-35,000 kPa) range cali- brated pressure gauges and hoses. • A graduated container marked to measure liq- uid volume in cubic inches or milliliters.
Page 495 6. Start engine and adjust pressure compensator Steering Control Unit and Flow Amplifier (3) to obtain 3325 psi (22,923 kPa) on the pres- Leakage Test sure gauge at the “GPA” pump port. Tighten 1. Disconnect the flow amplifier return hose (9, compensator jam nut.
Page 496 (greater than 10,000 nected from the bleeddown manifold. ft. (3,050 meters) above sea level). If the truck is operating at high altitudes, contact the Komatsu Area 3. Disconnect tank return line (15, Figure 10-2) Service Representative for instructions regarding from bleeddown manifold.
Page 497 SHOCK AND SUCTION VALVES The other gauge should read 3100 psi (21,370 kPa). Equipment Requirements * Record on Data Sheet The following equipment will be necessary to properly 8. If pressure is incorrect during step 6 or 7, the test the steering circuit shock and suction valves: shock and suction valves must be replaced.
Page 498 HOIST SYSTEM RELIEF VALVE AND Hydraulic oil temperature should be approximately 70°F (21°C) during test. BRAKE COOLING CIRCUIT PRESSURES NOTE: If relief valve or hoist valve assembly has been Pressure Checks replaced or rebuilt, hoist valve “power up” pressure 1. Install a 0-100 psi (0-1000 kPa) low pressure should be checked.
Page 499 Power Up Relief Pressure Test The hoist valve contains two relief valves. The rear inlet section (toward rear of truck) contains the relief valve for the rear section of the hoist pump. The front inlet section (toward front of truck) contains the relief valve for the front section of the hoist pump.
Page 500 Power Down Relief Pressure Test 2.) To decrease power down relief pressure, turn adjusting screw out (counter-clock- NOTE: The hoist system “power down” relief valve is wise). located on the hoist pilot valve, located in the hydraulic components cabinet, behind the cab. 2.
Page 501 Hoist Counterbalance Valve Adjustment Preparation: 1. With the engine shut down, the body resting on the frame, the hoist valve in the FLOAT position and hydraulic system pressure bled down, loosen locknut on adjustment stem of needle valve (3, FIGURE 10-8) on overcenter manifold (6).
Page 502 HYDRAULIC SYSTEM FLUSHING PROCEDURE The following instructions outline the procedure for flushing the hydraulic system. Flushing Procedure Preparation 1. Set all controls in the “Neutral” position. Do not 1. Verify and correct if necessary, the various relief steer the truck or operate controls until the next valves and adjustable hydraulic system compo- step is completed.
Page 503 Filter Element Replacement After the hydraulic system flushing procedure has been completed, all system high pressure filter ele- The following procedures involve raising and low- ments must be replaced. ering the dump body. Be certain adequate clear- 1. Close both hoist pump suction line shut-off ance is available before raising body to the full valves.
Page 504 NOTES L10-12 Hydraulic Check-out Procedure L10012...
Page 505 930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET MACHINE MODEL UNIT NUMBER SERIAL NUMBER __________ Steering Accumulators charged to 1400 psi (9650 kPa). Operate hydraulic steering system to obtain proper operating temperature. Refer to Check-out Procedures. PUMP PRESSURE CONTROL ADJUSTMENTS STEP 6___________ Steering pump compensator pressure STEP 11___________ Steering pump unload pressure.
Page 506 930E CHECK-OUT PROCEDURE BRAKE COOLING & HOIST SYSTEM DATA SHEET MACHINE MODEL UNIT NUMBER SERIAL NUMBER Operate hydraulic system to obtain proper operating temperature. Refer to Check-out Proce- dures. BRAKE COOLING CIRCUIT TEST STEP 1 ____________ Hoist pump outlet pressures, low idle, FLOAT position. ____________ Brake cooling circuit pressure, low idle, FLOAT position.
Page 507 SECTION M OPTIONS AND SPECIAL TOOLS INDEX FIRE CONTROL SYSTEMS ........M2 CHECKFIRE ELECTRIC DETECTION &...
Page 508 NOTES M1-2 Index M01034 03/01...
Page 509 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1 The Checkfire Electric Detection and Actuation System - Series 1 (Figure 2.3- 1) uses linear detection wire. This is a two conductor heat rated thermo cable. When the detection cable is subjected to 221°F (105°C) the insu- lating coating of the cable melts allowing the conduc- tors to short together closing the electric circuit to the squib which detonates to depress the puncture pin and...
Page 510 Actuator (Figure 2.3-3): Provides automatic and man- ual means of fire suppression system actuation. By pulling the ring pin under the knob and then depressing the red knob, the puncture pin will rupture the dia- phragm in the actuator and apply the system. Automat- ically, the squib is fixed to rupture the cartridge disc when the linear detection wire is exposed to tempera- tures in excess of its rated range.
Page 511 Securing the Detection Wire 1. The Power Wire a. Depress the button on top of the control module After the linear detection wire has been loosely in- and note green indicator light (Figure 2.3-9). stalled, secure it to the equipment being protected as With button, depressed, light should be on.
Page 512 c. Proceed to the end of the last length of detec- tion wire and remove the jumper assembly (Figure 2.3-12). Finally, put original plugged blank connector onto detection wire. The test module light should immediately go out. If light does not go out refer to "Troubleshooting". d.
Page 513 Installation Procedure for Squib Using wrench, insert squib into upper right inlet hole After all testing has been completed and all test kit on actuator body and firmly tighten (Figure 2.3-15). components removed, proceed to arm the system. After installing squib into actuator body, loosen protec- tive shipping cap from squib and remove bridge (Figure 2.3-16).
Page 514 4. Weigh the actuation cartridge on the Electric De- INSPECTION AND MAINTENANCE tection and Actuation System. Replace cartridge SCHEDULES FOR ELECTRIC if the weight is 1/4 oz. (7 g) less than that stamped DETECTION AND ACTUATION SYSTEM on cartridge. Check the cartridge threads for nicks, burrs, cross threading and rough on feath- ered edges.
Page 515 10. Remove the test kit from the system by discon- necting the squib connector from the test module (Figure 2.3-21). Failure to remove jumper assembly will cause sys- tem discharge when squib is installed into Electric Detection and Actuation System. 11.
Page 516 What to Expect When a fire suppression system discharges, there is some noise, accompanied by clouds of dry chemical. While breathing foreign particles is not pleasant, the agent is non-toxic. What to Do After the Fire is Out The machinery should not be restarted until it has been serviced and cleaned (water spray or steam may be used to remove the dry chemical).
Page 517 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM TROUBLE: Green Indicator Light on Control Module Does Not Go On When Button is Depressed. POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Blown fuse in battery connector assembly Look for possible short in external power wiring and change fuse Battery connection loose Clean and tighten...
Page 518 NOTES M2.3-10 Ansul "Checkfire" Electric Detection and Actuation System M02003...
Page 519 FIRE CONTROL SYSTEM (MANUAL) The fire control system aids in protecting the machine fluidized chemical to flow to the nozzles. The nozzles in the event of a fire. The system consists of: will direct the agent at the fire and extinguish the flames. •...
Page 520 3. Remove each extinguisher from its bracket. 4. Disassemble bursting disc union and replace the ruptured bursting disc with flat side toward ex- tinguisher. 5. Fill tank with dry chemical to not more than three inches (76 mm) from the bottom of the fill opening. 6.
Page 521 WIGGINS QUICK FILL FUEL SYSTEM FUEL RECEIVER Keep the cap on the receiver to prevent dirt build up in The fuel receiver (3, Figure 5-1) is normally mounted valve area and nozzle grooves. If fuel spills from tank on the fuel tank (1). Optional locations are the left hand breather valve, or tank does not completely fill, check frame rail (Figure 5-3) or at the Service Center in front.
Page 522 TANK BREATHER VALVE Removal Unscrew breather valve (2, Figure 5-1) from tank (1). Installation Screw breather valve into tank. Disassembly 1. Remove spring clamp (4, Figure 5-2) from outlet. 2. Pull off rubber cover and screen (3). 3. Unscrew nut (5) from top of breather valve. Re- move cover (6), spring (7), and steel ball (8).
Page 523 LEFT SIDE FILL Keep the cap on the receiver to prevent dirt build up in This location permits fueling the truck from the left side. valve area and nozzle grooves. If fuel spills from tank breather valve, or tank does not completely fill, check breather valve to see that float balls are in place and outlet screen is clean.
Page 524 NOTES M5-4 Wiggins Quick Fill Fuel System M05002 10/96...
Page 525: Special Tools
SPECIAL TOOLS PART NO. DESCRIPTION Suspension & NItrogen Charging EB1759 Accumulator Nitrogen Charging PART NO. DESCRIPTION Power Module EF4875 Roll-Out Assembly Removal & Installation PART NO. DESCRIPTION TG1106 Eye Bolt, 0.75–10 UNC Misc. lifting requirements WA4826 Eye Bolt, 1.25–7 UNC M08012 9/99 Special Tools M8-1...
Page 526 PART NO. DESCRIPTION Offset Box End Miscellaneous & PB8326 Wrench, 1 7/16" Cab Mounting PART NO. DESCRIPTION 3/4" Female Torque Wrench TZ2734 Adapter Extension PART NO. DESCRIPTION Use with TZ2733 Tubular Handle PB8326 & TZ2734 PART NO. DESCRIPTION Front & Rear Disc Seal Installation Brake FLoating BF4117...
Page 527 PART NO. DESCRIPTION Steering Linkage & Tie Rod EH4638 Alignment Sleeve Assembly. Refer to Section “G”. PART DESCRIPTION Measure Brake Disc Wear EF9302 Indicator Assembly Refer to Section “J”. PART NO. DESCRIPTION Payload Meter II Download EF9160 Electrical Harness Refer to Section “M”, Payload Meter.
Page 528 PART NO. DESCRIPTION Engine Turning To Rotate ED8860* Tool Engine Crankshaft (MTU Engine Only) NOTE: To use this tool for the MTU/DDC 4000 Series Engine, it must be used with the locally made Adapter Plate. * This tool may also be acquired as MTU Part Number F6 555 766.
Page 529 FRONT HYDRAIR/SPINDLE REMOVAL The contact area of the front Hydrair suspension ta- pered piston-to-spindle may become seized after a long period of time. In order to remove the front spindle from the tapered pistons for service work, it will be necessary to apply force, and occasionally heat, to the spindle to break it loose.
Page 530 PUSHER STRUCTURE HARDWARE (FIGURE 8-2) Quantity DESCRIPTION Pusher Structure Capscrews 24** KC7095 (1.25" UNF x 8", Grade 8) Flat Washers (Hardened) WA0366 (1.25") ** 15 capscrews are normally used, if steering arm is not completely removed. NOTE - Use the Hardened Flat Washers under heads of Pusher Structure Capscrews to prevent galling.
Page 531 FIGURE 8-3. 930E PISTON/SPINDLE PUSHER STRUCTURE DIMENSION “A” = 1.37 in. - Plate Bolt Hole Diameter DIMENSION “F” = 5.25 in. - Pusher Cylinder Height DIMENSION “B” = 21.62 in. - Plate Outside Diameter (O.D.) DIMENSION “G” = 12.37 in. - Pusher Cylinder O.D. DIMENSION “C”...
Page 532 NOTES M8-8 Special Tools M08012 9/99...
Page 533 AIR CONDITIONING SYSTEM Environmental Impact Environmental studies have indicated a weakening of the earth’s protective Ozone (O ) layer in the outer strato- ® sphere. Chloro-flouro-carbon compounds (CFC’s), such as R-12 refrigerant (Freon ), commonly used in mobile equipment air conditioning systems, has been identified as a possible contributing factor to the Ozone depletion. Consequently, legislative bodies in more than 130 countries have mandated that the production and distribution of R-12 refrigerant be discontinued after 1995.
Page 534 (HFC) refrigerant, commonly identified as HFC-134a, is being used in most current mobile air conditioning sys- tems. Additionally, the practice of releasing either refrigerant to the atmosphere during the charging/recharging pro- cedure is now prohibited. These new restrictions require the use of new equipment and new procedures which are significantly different from those traditionally used in air conditioning service techniques.
Page 535 THE REFRIGERATION CYCLE REFRIGERATION - THE ACT OF COOLING In an air conditioning system, the refrigerant is circu- • There is no process for producing cold; there is lated under pressure through the five major compo- nents in a closed circuit. At these points in the system, only heat removal.
Page 536 Condensing of the refrigerant is the change of state of AIR CONDITIONER SYSTEM the refrigerant from a vapor to a liquid. The action is COMPONENTS affected by the pressure of the refrigerant in the coil and air flow through the condenser. Condensing pres- COMPRESSOR (Refrigerant Pump) sure in an A/C system is the controlled pressure of the The compressor separates the low pressure and the...
Page 537 valve is warm to hot high pressure liquid; exiting it is All or most of the liquid that did not change to vapor in low pressure liquid and gas. The change to low pres- the expansion valve or connecting tubes boils (ex- sure allows the flowing refrigerant to immediately begin pands) and vaporizes immediately in the evaporator, changing to gas as it moves toward the evaporator.
Page 538 COMPRESSOR CLUTCH ELECTRICAL CIRCUIT An electromagnetic clutch is used in conjunction with The air conditioner’s electrical circuit is fed from an the thermostat to disengage the compressor when it is accessory circuit and is fused with a 30-ampere fuse not needed, such as when a defrost cycle is indicated or circuit breaker.
Page 539 Ensure sufficient ventilation whenever refrigerant SYSTEM SERVICING is being discharged from a system, keeping in Servicing an air conditioning system really means mind refrigerant is heavier than air and will seek closely monitoring refrigerant flow. For this reason, low areas of shop. the following procedures deal extensively with the When exposed to flames or sparks, the compo- proper use, handling, care and safety factors involved...
Page 540 SERVICE TOOLS AND EQUIPMENT RECOVERY/RECYCLE STATION Mixing different types of refrigerant will damage Whenever refrigerant must be removed from the sys- equipment. Dedicate one recovery/recycle station tem, a dual purpose station as shown in Figure 9-7, to each type of refrigerant processing to avoid performs both recovery and recycle procedures which equipment damage.
Page 541 FIGURE 9-5. R-134a SERVICE VALVE FIGURE 9-6. VACUUM PUMP 1. System Service Port 3. Service Hose Fitting Connection 2. Quick Connect SERVICE VALVES VACUUM PUMP Because an air conditioning system is a sealed system, The vacuum pump (Figure 9-6) is used to completely two service valves are provided on the compressor to evacuate all of the refrigerant, air, and moisture from enable diagnostic tests, system charging or evacu-...
Page 542 MANIFOLD GAUGE SET A typical manifold gauge set (Figure 9-7) has two screw type hand valves to control access to the system, two gauges and three hoses. The gauges are used to read system pressure or vacuum. The manifold and hoses are for access to the inside of an air conditioner, to remove air and moisture, and to put in, or remove, refrigerant from the system.
Page 543 INSTALLING MANIFOLD GAUGE SET Before attempting to service the air conditioning sys- tem, a visual inspection of both the engine and system components is recommended. Particular attention should be paid to the belts, hoses, tubing and all attaching hardware plus the radiator cap, fan clutch, and thermostat.
Page 544 Purging Air From Service Hoses Adding Refrigerant to the System (without a charging station) The purpose of this procedure is to remove all the air trapped in the hoses prior to actual system testing. After determining that the system is low and requires Environmental regulations require that all service additional refrigerant perform the following proce- hoses have a shutoff valve within 12 inches of the...
Page 545 5. When the gauges show a normal reading, close the hand valve on the refrigerant container. Do not open high side hand valve. High side sys- Stabilizing the AC System tem pressure is greater than refrigerant container. Serious personal injury may result if the container explodes.
Page 546 6. Start the recovery process by operating the equip- Evacuating the System ment as per the manufacturer’s instructions. 1. Attach the high and low side hoses to the appro- 7. Continue extraction until a vacuum exists in the AC priate connections. system.
Page 547 SYSTEM PERFORMANCE TEST SYSTEM LEAK TESTING This test is performed to establish the condition of all Refrigerant leaks are probably the most common components in the system. Observe these conditions cause of air conditioning problems, resulting from im- during testing: proper or no cooling, to major internal component damage.
Page 548 Tracer dyes SYSTEM REPAIR Tracer dyes are available that can be added to the The following service and repair procedures are not system as refrigerant is added. The system is then any different than typical vehicle service work. How- operated to thoroughly circulate the dye. As refrigerant ever, AC system components are made of soft metals escapes, it leaves a trace of the dye at the point of (copper, aluminum, brass, etc.).
Page 549 Receiver-Drier Sometimes it may be necessary to use shims or en- large the slots in the compressor mounting bracket to The receiver-drier can not be serviced or repaired. It achieve proper alignment. should be replaced whenever the system is opened for any service.
Page 550 EVACUATING THE SYSTEM Evacuating the complete air conditioning system is required in all new system installations, and when repairs are made on systems requiring a component replacement (system opened), or a major loss of refrig- erant has occurred. All these conditions will require that a vacuum be pulled using a vacuum pump that com- pletely removes any moisture from the system.
Page 551: Troubleshooting
TROUBLESHOOTING PRE-DIAGNOSIS CHECKS System Ducts and Doors - Check the ducts and doors for proper function. If the system indicates Insufficient cooling, or no cool- ing, the following points should be checked before Refrigerant Charge - Make sure system is prop- proceeding with the system diagnosis procedures.
Page 552 5. Carefully feel the hoses and components on the DIAGNOSIS OF GAUGE READINGS & SYSTEM high side. All should be warm-hot to the touch. PERFORMANCE Check the inlet and outlet of receiver-drier for even The following Troubleshooting Chart lists typical mal- temperatures, if outlet is cooler than inlet, a re- functions encountered in air conditioning systems.
Page 553 – – – TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS – – – Possible Causes Suggested Corrective Action TROUBLE: Insufficient Cooling Indications: Low side pressure LOW. High Side Pressure LOW. Discharge air is only slightly cool. Low refrigerant charge, causing pressures to be Check for leaks by performing leak test.
Page 554 Extremely Low Refrigerant Charge in the System Indications: Low side pressure LOW. High Side Pressure LOW. Air from vents in the cab seems warm. If there is a low pressure switch in the system, it may have shut off the com- pressor clutch.
Page 555 Excessive Air and/or Moisture in the System Indications: Gauge Reading- Low Side High Repair Procedure: Test for leaks, recover refriger- High Side High ant from the system and repair the leak. De- Air from the vents in the cab is only pending on the type of system, replace the slightly cool.
Page 556 Expansion Valve Stuck Open Indications: Test: Operate the AC system on it’s coldest setting Gauge Reading- Low Side High for a few minutes. Carefully spray a little nitro- High Side Normal gen or other cold substance, on the capillary Air from vents in cab is warm or only tube coil (bulb) or head of the valve.
Page 557 Compressor Malfunction Indications: Repair Procedure: If the belt is worn or loose, re- Gauge Reading- Low Side High place or tighten it and recheck system perform- High Side Low ance and gauge readings. If inspection of the The compressor may be noisy when it compressor is required, all of the refrigerant operates.
Page 558 Thermostatic Switch Malfunction Indications: Repair Procedure: Replace the thermostatic Gauge Reading- Low Side Normal switch. When removing the old thermostat, re- High Side Normal place it with one of the same type. Take care in The low side gauge needle may fluctu- removing and handling the thermostat and thin ate in a very narrow range compared to capillary tube attached to it.
Page 559 Preventive Maintenance Schedule for A/C System Last Maintenance Check:________________________ Truck Serial Number: ____________________________ Name of Service per- Site Unit Number: ______________________________ NOTE: Compressor should be run at least 5 minutes Date:______________Hour Meter:_________________ (40°F minimum ambient temperature) every month, in order to circulate oil and lubricate components. Maintenance Interval (months) COMPONENT...
Page 560 NOTES M9-28 Air Conditioning System M09010 6/97 for HFC 134a Refrigerant...
Page 561 24VDC ELECTRIC SUPPLY SYSTEM ELECTRICAL SYSTEM DESCRIPTION Excessive consumption of water indicates leakage or The Komatsu Truck utilizes a 24VDC electrical system overcharging. Normal water usage for a unit operating which supplies power for all non-propulsion electrical eight hours per day is about one to two ounces per cell components.
Page 562 Corrosion creates resistance in the charging circuit The rate of self-discharge of a battery kept at 100°F which causes undercharging and gradual starvation of (38°C) is about six times that of a battery kept at 50°F the battery. (19°C) and self-discharge of a battery kept at 80°F (27°C) is about four times that one at 50°F (10°C).
Page 563 BATTERY CHARGING SYSTEM (Niehoff) TROUBLESHOOTING PROCEDURES (On-Truck) General Description Most 24 volt charging system problems can be diag- The Niehoff model N1227 or C609 (Figure 13-1) is a nosed with the alternator installed on the truck, oper- heavy duty, 24 VDC unit rated at 220 amps. A solid ating under normal conditions.
Page 564 Preliminary Checks Test Procedure 1. Check the drive belt tension as follows: 1. Start engine, accelerate to high idle and observe meters. a. Apply 20.9 lbs. (9.5 kg) force at center of belt span. b. Belt should deflect 0.50 in. (12.7 mm). c.
Page 565 FIGURE 13-3. REGULATOR BYPASS TEST 1. Alternator Control Unit 2. “R” Terminal (Relay) FIGURE 13-2. TEST METER HOOKUP 3. “E” Terminal (Energize) 1. Alternator Under Test 4. Alternator “B+” Terminal 2. 0 to 400 AMP Ammeter 5. Alternator/Voltage Regulator Harness Plug 3.
Page 566 FIGURE 13-4. PARTS ILLUSTRATION 1. Locknut 10. Screw 19. Stud 28. End Housing 2. Flat Washer 11. Control Unit 20. Shell 29. Nut 3. Drive Pulley 12. Screw 21. Pan Head Screw 30. O-Ring 4. Pulley Bushing 13. Rotor 22. Field Coil 31.
Page 567 ON VEHICLE TROUBLESHOOTING GUIDE SELF ENERGIZED ALTERNATOR ALTERNATOR ELECTRICAL CONDITION - Low Voltage - High Voltage - No Voltage PRELIMINARY PROCEDURES NO VOLTAGE OUTPUT Common problems, all applications: Causes of no voltage output: Check alternator drive belt (s). No drive belt. Check alternator positive connection No battery (B+) voltage at alternator’s “B+”...
Page 568 Maintenance Free types: Medium amps are defined as some multiple of the low amp value, perhaps 30 amps for the Group- Immediately after engine start, system volts are 8D and 10-15 amps for the Group-31. This rate lower than regulator setpoint with low amps. of amperage will cause a rise in battery tempera- 15-30 minutes into charge cycle, still low volts and ture over a long period of time (4-8 hrs) and may...
Page 569 ADVANCED SYSTEM TROUBLESHOOTING 24V/220A Self Energized NO ALTERNATOR OUTPUT STATIC TEST - ENGINE OFF, KEY ON, BATTERY SWITCH ON. Identify and locate “B+”, “E”, and “R” and ground (“B-”) DAMAGE WILL OCCUR IF UNIT IS OPERATED terminals on alternator and check for link from terminal WITH STRAP CONNECTED AND B+ APPLIED! “R”...
Page 570 GO TO ’R’ TERMINAL ON ALTERNATOR GO TO REGULATOR (IF REQUIRED) With engine running, measure value of AC voltage Disconnect voltage regulator from alternator. There from “R” terminal to “Ground”. are no static tests available for the regulator. Continue test. If no AC volts are present, alternator is not GO TO capable of turning on regulator.
Page 571 NIEHOFF Alternator Overhaul Manual TABLE OF CONTENTS DIMENSIONS............................... M3-2 SPECIFICATIONS ............................... M3-3 SERVICE PARTS LIST ............................M3-4 EXPLODED VIEW..............................M3-5 ON VEHICLE TEST ............................. M3-6 BENCH TEST............................... M3-8 STATIC TESTS ..............................M3-9 ALTERNATOR DISASSEMBLY......................... M3-12 ALTERNATOR ASSEMBLY..........................M3-17 SERVICE TOOL INSTRUCTIONS........................M3-26 M13003 04/01 Niehoff Alternator Overhaul Manual M13-1...
Page 572 ALTERNATOR DIMENSIONS 1. Mounting Bolt - 1/2 UNC; 45 ft.lbs. (61 N.m) torque 5. Voltage Regulator 2. Mounting Bolt - 12/50 Dia; 65 ft.lbs. (88 N.m) torque 6. Fan Nut; 50 ft.lbs. (68 N.m) torque 3. Ground Bolt, 3/8 - 16; 11 ft.lbs. (15 N.m) torque 7.
Page 573 ALTERNATOR SPECIFICATIONS VOLTS.............24VDC AMPS ..............240 GROUND ..........NEGATIVE REGULATOR STEPS ..........2 REGULATOR SETTINGS ......27.6 / 28.6 WEIGHT ..........65 lbs. / 29.3 kg 1. Measurements listed on the curves are for a stabilized machine at maximum output at tem- peratures indicated for each curve.
Page 574 SERVICE PARTS REF. PART QTY. DESCRIPTION BF3715 LOCKNUT (1) BF1997 FLAT WASHER (1) EF3527 PULLEY BF1966 BUSHING, PULLEY BF1989 RING, RETAINER (1) BF1968 BEARING, FRONT BF1988 RING, RETAINER (1) BF1990 SCREW, PAN HEAD - #8 - 32NC X 3/8" (1) BF1970 PLATE, COVER BF3712...
Page 575 ALTERNATOR PARTS Refer to previous page for Parts List. M13003 04/01 Niehoff Alternator Overhaul Manual M13-5...
Page 576 ON-VEHICLE TEST Equipment: Belt Tension Gauge Voltmeter, 0 - 40 Volt range Ammeter, 0 - 400 Ampere range 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.
Page 577 Table 13-1. TROUBLESHOOTING AMPS VOLTS DIAGNOSIS Charging system is OK. Battery is not yet fully charged. Wait for charging system to bring to full HIGH charge: AMPS should fall and FIGURE 13-2. VOLTAGE STEP ADJUST VOLTS should stabilize within 1. Low 3.
Page 578 BENCH TEST TEST 2 - FULL LOAD TEST With load set to rated output (nameplate) +/- 10%, run Results of on-vehicle test should be confirmed by alternator at 5000 rpm. Refer to Table 13-4. these bench tests, if possible. When it is not possible to perform on-vehicle test, Table 13-4.
Page 579 STATIC TESTS TEST 2 - Check Function Of Clamping Diode Set ohmmeter to x100 scale and make sure ohmmeter Static tests are performed on the partially disas- is zeroed. Using the regulator connector plug, connect sembled alternator to confirm component failure one ohmmeter lead to terminal “F-“, connect the other indicated by on-vehicle test or bench tests.
Page 580 TEST 4 - Check For Grounded Field Coil Set ohmmeter to x10K scale and make sure ohmmeter is zeroed. Connect one ohmmeter lead to terminal “F-“ of the control unit harness. Connect the other ohmme- ter lead to the front housing ground stud. The ohmme- ter should read very high.
Page 581 Note: Do not allow sleeving on leads to slide down STATOR TESTS leads; phase terminal without sleeves can short NOTE: The front stator related Phase leads are “P1”, against alternator body. “P2”, & “P3”; The rear ststor phase leads are “P4”, The diode heat sink assembly is normally checked “P5”, &...
Page 582 ALTERNATOR DISASSEMBLY Notes: Disassemble alternator only as far as neces- REGULATOR REMOVAL sary to replace defective part(s). 1. Disconnect regulator from alternator harness. For stator removal, refer to BF4822 Stator Service Tool 2. Remove mounting hardware from regulator Instructions. mounting feet (Figure 13-9). In this publication, Front Housing refers to the Drive 3.
Page 583 END HOUSING REMOVAL 1. Remove nine flanged locknuts from stator-tube assembly studs at rear of end housing. 2. With a gear puller, remove end housing from alternator (Figure 13-10). FIGURE 13-12. 1. Machine Screws Alternate Method 2b. Using an air hammer (air chisel) with a blunt tipped tool, vibrate the area around the rotor element to rotor core attaching studs.
Page 584 FRONT HOUSING REMOVAL Note: All control box and front housing connections are coated with RTV Silicone Rubber. Remove RTV Sili- cone Rubber as alternator is disassembled. 1. Remove five screws from control box cover. 2. Remove control box cover (Figure 13-13 A). 3.
Page 585 CONTROL UNIT ASSEMBLY REMOVAL (These instructions may be used with control unit assemblies having SAE or Metri-Pak connector.) Refer to Figures 13-14 and -15 for the following steps: 1. Remove the top cover of the control unit assembly (Five screws). Before removing the old control unit assembly, observe wire position by wire function, not wire color.
Page 586 FRONT BEARING REMOVAL 1. Remove retaining ring (1, Figure 13-23) from front outer side of front housing. 2. Remove retaining ring (3, Figure 13-23) from rear inner side of front housing. 3. Support front housing on blocks and with a press, remove front bearing (4, Figure 13-23) from front housing.
Page 587 4. After rotating field coil bobbin, remove field coil ALTERNATOR ASSEMBLY through back of stator and shell assembly (end away from leads) while allowing field leads to FIELD COIL ASSEMBLY slide through opening in front stator assembly. 1. Lay stator and shell assembly on its side, phase Notes: As field coil is removed from stator and shell leads to the left (Figure 13-20).
Page 588 4. Seat field coil bobbin ears over stator tabs (Figure 5. Make sure field coil leads (white spade terminals) 13-21) by inserting field winding and rotating are pulled through proper stator openings with no about 20 degrees after insertion with tool BF4820. slack at the field coil and that neither wire is Align screw holes in bobbin ears with screw holes pinched by the bobbin ears.
Page 589 4. Using tool BF4818 and a press, press front bear- ing into front housing until bearing seats against retaining ring (Figure 13-24). Outer ring will be installed after housing is placed on shaft. FIGURE 13-24. 1. Tool BF4818 FRONT ROTOR ASSEMBLY 1.
Page 590 FRONT HOUSING – STATOR, FIELD COIL & 5. Route the two field leads (white wires) through the SHELL ASSEMBLY hole in the front housing to the control box. Con- nect the field leads to the control box terminal 1. Support stator, field coil & shell assembly on strip;...
Page 591 FIGURE 13-30. CONTROL UNIT ASSEMBLY 1. Ignition (E) (Harness Lead #4) 2. Relay (R) 3. Terminal Block 4. F- (Harness Lead #1) 5. F+ (Harness Lead #3); 10 in. lbs. (1.3 Nm) torque 6. Terminal Block Screw; 30 in. lbs. (3.5 Nm) torque 7.
Page 592 8. Position the control unit-face plate and attach the NOTE:Align stud or screw holes of core with scribe regulator harness lead “4” to “E” terminal on the marks on rotor, or center studs or screw holes of core face plate. in the center of slots in rotor plate as shown in Figure 13-32.
Page 593 To use new service parts on product manufac- Install New Shaft/core Assembly tured before the modification date, follow these (Figure 13-35) instructions: Remove the ring seal from the new shaft/core Fan Replacement (Fan with Ring Seal) assembly, if present.Install the shaft/core assem- bly into the alternator (as directed in this manual).
Page 594 REAR BEARING ASSEMBLY REGULATOR ASSEMBLY 1. Assembly alternator, including end housing, but 1. Set regulator on rear housing with regulator plug leave out rear bearing and fan. Make sure mount- toward control box. ing feet are aligned.Install front pulley bushing on 2.
Page 595 FAN ASSEMBLY PULLEY ASSEMBLY 1a. Place fan assembly on shaft (Figure 13-39). NOTE: Do not hold fan to prevent shaft rotation. Fan damage may result. Note: If fan hub has ring seals and carrier as ring seal must compress ring enters housing. 1.
Page 596 BF4822 STATOR SERVICE TOOL INSTRUCTIONS Function of Service Tool 8. Lift the top thrust plate up and off the guide pin. Turn the top thrust plate so that the guide pin does This tool has been designed to remove and install not re-enter the slot.Lower the top thrust plate and stators in alternators.
Page 597 16. If the tool assembly attempts to rotate after sig- 5. Position the shell assembly on the support ring. nificant resistance is felt, insert torque arm into Shell bore to receive new stator must be facing the large diameter holes in top thrust plate and down.
Page 598 PRESSURE PLATE SET UP (Refer to Figure 13-42) 8. Place thrust washer on jack screw. Lube the jack screw for 1”, about 1” from the tip of the jack screw. Lubricate approximately 1” of the jack screw where it enters the pressure plate with white lube or a wheel bearing type of grease.
Page 599 PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS) INDEX GENERAL INFORMATION ..............M20-3 LIGHTS, SWITCHES, and COMPONENTS .
Page 600 DOWNLOAD OF PAYLOAD AND FAULT CODES ..........M20-18 DISPLAY OF FAULT CODES .
Page 601: General Information
PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS) GENERAL INFORMATION The payload meter stores in memory various operating data. This data includes: The Payload Meter II On Board Weighing System 1) The payload, time, distance, and travel speed for displays and records the payload weight along with each cycle.
Page 602 LIGHTS, SWITCHES, and COMPONENTS On The Face Of The Payload Meter (Refer to Figure 20-1) 1. Display Panel 7. Total/Shift Switch Digital display area for the data being recorded in Used to display payload and overall number of memory. This will include items such as: cycles each time the load is dumped.
Page 603 There is one green light, one amber light, and one red light. (Figure 20-3) * For most Komatsu Trucks: Use only the Brake Lock switch to hold the truck While the truck is stopped being loaded and the hoist stationary at the loading and dumping area.
Page 604 THEORY OF OPERATION Linkage Factor The linkage factor is part of the complex calculations Basic Description performed by the payload meter to determine the load in the truck. The linkage factor is dependent on the load The payload meter uses the four suspension pres- on the rear suspensions.
Page 605 Brake Lock Typical Data From Service Check Mode The Brake Lock only applies the rear brakes. This Number Data Description allows the front wheels to rotate slightly as the truck is 13:09 Current Time being loaded. This is important because the payload meter assumes that the front wheels can rotate freely.
Page 606 In order to adjust this gain: Calculation of the Calibration Load 1. Start with the payload meter in normal operation This procedure is similar to the manual calculation of mode. load. This calibration load is used as item #13 from the manual calculation procedure.
Page 607 TYPES OF DATA STORED Cycle Data One cycle is considered to be from the point where a load is dumped to the point where the next load is dumped. Data between these two points is recorded in memory. Examples of the data are shown below. The maximum number of cycles that can be stored in memory is 2900 cycles.
Page 608 Engine ON/OFF Data When the engine is started or stopped, the following data is recorded. ITEM UNIT RANGE REMARKS Advances by one each time the Engine Operation Number Number 1 - 65535 engine is started. Last Two Digits Of The Year Year 0 - 99 Month...
Page 609 Engine Operation ITEM UNIT RANGE REMARKS Every time the engine is started Number when Canceled Number 1 - 65535 the number advances by one. Last Two Digits Of Year Year 0 - 99 Month Month 1 - 12 1 - 31 Time Hour Hour 24 Hour Clock...
Page 610 OPERATOR FUNCTIONS Clearing the Operator Load Counter 1. Press the TOTAL/SFT switch once. The number Using the Operator Load Counter displayed is the total tons hauled since the last time the counter was cleared. The total is dis- Description played in hundreds of tons. The Payload Meter makes available to the operator a Total Load Counter and Haul Cycle Counter.
Page 611 INITIAL SETUP OF PAYLOAD METER There are nine switches located behind the panel on the left side of the payload meter. Figure 20-8 shows There are several things that must be checked and the switch numbers. The following switch positions programmed when a Payload Meter is first installed.
Page 612 TOTAL/SFT switches. The display An alternative method is to use a Personal Computer will show. running the Komatsu Payload Download Program for windows. The "Monitor Pressures" section of the pro- 3. Press the CAL/CLR switch once. gram displays live inclinometer data. The inclinometer The display will show.
Page 613 Calibrating a Truck The payload meter should be calibrated whenever one of the following occurs: 1. When a new payload meter is installed. 2. When a suspension sensor has been changed. 3. Whenever the suspensions have been serviced or the Nitrogen levels have changed. 4.
Page 614 DISPLAYS AT START-UP 7. The display will show: POWER ON: This display indicates the Machine ID code where “xxx” indicates a value between 0 and 200. ALL external display lamps (Figure 20-2) will come on and stay on for approximately 27 seconds during the 8.
Page 615 SETUP AND MAINTENANCE 7. Press the LIGHT/INC switch to change the “tens digit” to the desired number. 8.Press the MODE switch to return to normal opera- tion. Speed Limit 9. The Option Code selects the PLM communication A warning can be displayed if the machine exceeds a mode as follows: preset speed.
Page 616 9. Press the LIGHT/INC switch to change the first 7. Press the LIGHT/INC switch to change the hours. digit to the desired number. The clock is a 24 hour clock. 10. Press the MODE switch to return to normal op- 8.
Page 617 • Condition of the Engine Oil Pressure signal. DISPLAY OF FAULT CODES :C3:XX The panel will display “ ” for 3 seconds, 1. Press and hold the MODE switch then indicate: until "Cd:dP" is displayed. C3:oo “ ” Engine is running. 2.
Page 618 M20-20 Payload Meter II M20007 10/00...
Page 619 M20007 10/00 Payload Meter II M20-21...
Page 620 Monitoring Input Signals Service Check Mode This procedure can be used to monitor the current 1. Press and hold the LIGHT/INC and MODE input signals to the payload meter. switches until "CHEC" is flashing. 1. Press and hold the LIGHT/INC and MODE 2.
Page 621 UP Factor - Payload Calculation Gain Careful consideration must be given to the use of PL:01 and PL:10. These modes divide the data trans- mitted by Modular Mining and the data stored in the Description of UP Factor payload meter’s memory. Additionally, each mode The payload calculation gain, or UP factor is multiplied handles the UP factor differently and can calculate to the actual calculated load.
Page 622 FINAL GEAR RATIO SELECTION For an 830E truck, the proper gear ratio has to be selected. 1. Press and hold the MODE and LIGHT/INC switches until “CHEC” is displayed. 2. Press and hold the TOTAL/SFT and LIGHT/INC switches until “S.SEL” is displayed.
Page 623 BATTERY REPLACEMENT PROCEDURE 4. Remove the electrical connector. Remove the screws on the top surface and the rear face. ERROR CODE, F-09, DISPLAYED Remove the cover (Figure 20-8). This will expose the battery, its wires, and the connector. Replacing the Battery The payload meter has an internal battery used to protect the memory from being erased when the key switch is turned to the OFF position.
Page 624 9. Forcibly clear the data for the total payload and overall number of cycles. With this operation performed, all the unwanted data inside the payload meter is cleared. Except for the calibration data, all the data recorded in the previous steps is also erased. 10.
Page 625 Installation Installation 1. Install new O-ring on sensor (4, Figure 20-11) and 1. Install inclinometer (3, Figure 20-13) with cap- install sensor into adapter (3). Tighten sensor to screws, nuts and lockwashers (4). 22–29 ft.lbs. (30–39 N.m) torque. 2. Install new O-ring on adapter (3) and install com- plete adapter/sensor assembly into valve (2).
Page 626 SCOREBOARD Description The Scoreboard from Komatsu Mining Systems uses information from the Payload Meter to display the current load. It uses ultra-high-brightness LED tech- nology to form 3 digits. The sign is fully sunlight read- able and housed in a rugged steel enclosure.
Page 627 M20007 10/00 Payload Meter II M20-29...
Page 628 Normal Operation of the Scoreboard On power up, the Scoreboard will display "888" and then display the current software version, "10". The sign will then go blank until the Payload Meter begins sending load information. There is also a small light that blinks once per second in the center of the top portion of the last digit that is visible by close inspec- tion.
Page 629 CONNECTIONS CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins White (RS-232C Port) Description Comments Description Power +24V (Battery) Lamp Relay 1 Lamp Relay 2 Lamp Relay 3 Lamp Relay 4 Lamp Relay 5 Speed Sensor (Signal) Speed Sensor (GND) Running - 28VDC Alternator R Terminal (Charge Signal)
Page 630 PAYLOAD CIRCUIT NUMBERS Circuit Designation Circuit Description 39F, 39F1...39F5 +18 volt sensor power supply 39FA Pressure signal Right Rear 39FB Pressure signal Left Rear 39FC Pressure signal Right Front 39FD Pressure signal Left Front 39FE Inclinometer signal 39FG Sensor ground PLM lamp output - green PLM lamp output - amber PLM lamp output - red...
Page 631 PAYLOAD METER II RE-INITIALIZATION PROCEDURE This procedure is designed to reset the Payload Meter II to clear repeated F.CAL errors. This procedure is necessary to fix a rare condition in 7. Set the time, date, OP, PL, and UP settings. All the operation of the meter.
Page 632 NOTES PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM L. G. HAGENBUCH holder of U.S. Patent Numbers 4,831,539 and 4,839,835 M20-34 Payload Meter II M20007 10/00...
Page 633 SECTION N OPERATOR’S CAB INDEX TRUCK CAB ..........N2 Description .
Page 634 NOTES N1-2 Index N01020 03/01...
Page 635 If modification or harnesses. Hydraulic components are located outside repairs are required, contact the servicing of the interior and are accessed through covers (2, Komatsu Distributor. Figure 2-1) on the front of the cab. FIGURE 2-1. CAB ASSEMBLY 1. Mounting Pad 6.
Page 636 Prior to cab removal or repair procedures, it may be PREPARATION necessary to remove the body to provide clearance for 1. Reduce the engine speed to idle. Place the selec- lifting equipment to be used. If body removal is not tor switch in NEUTRAL and apply the parking required, the body should be raised and the safety brake.
Page 637 FIGURE 2-2. CAB HYDRAULIC AND ELECTRICAL CONNECTIONS 1. Cab 3. Hydraulic System Hoses 2. Hydraulic Components Cabinet 4. Electrical Harnesses 4. Close heater shutoff valves located at the water 7. Evacuate air conditioning system: pump inlet housing on the right side of the engine a.
Page 638 9. Remove the capscrews and washers from each CAB DOOR mounting pad (1, Figure 2-1) at the corners of the The cab door assemblies are similar except for the cab. hinge side. Each is hinged on the rear edge with a 10.
Page 639 Door Adjustment 3. Hold a piece of paper such as a dollar bill between where the door seal (4) will hit the skin of the cab If adjustment is necessary to insure tight closure of and firmly close the door ensuring that it latches door, loosen striker bolt in the door jam, adjust, and on the second catch.
Page 640 Step B. If the door bucks back when trying to close it, Door Handle Plunger Adjustment the striker bolt (2, Figure 2-4) has probably loosened If the door handle becomes inoperative, it can either and slipped down from where the catch can engage be adjusted or replaced.
Page 641 • Carefully lower the door panel a few inches. Hold Replace Door Glass glass at top to prevent it from dropping. Slide the 1. Remove hair pin clip (1, Figure 2-6) and bolt (2) door panel toward the cab to disengage the win- from the door check strap closes to the door.
Page 642 5. Before removing all door panel mounting screws, 7. Remove 2 screws (Figure 2-8) holding the roller support the panel to prevent the assembly from track to the bottom of the door glass. dropping. Remove 15 mounting screws (5). NOTE: Remove panel screws across the top last. 6.
Page 643 Bracket (2, Figure 2-9) at bottom of glass must clear the door frame, if still on glass. FIGURE 2-10. 1. Screws 2. Rubber Felt Insert Remove the screw at the lower end of the window channels. It is necessary to pull the rubber felt insert (2, Figure 2-10) out of the channel in order to be able to remove the screws.
Page 644 FIGURE 2-13. 1. "L" Shaped Brackets FIGURE 2-14. 1. Capscrew & Nut 3. Mounting Screw - 2. Mounting Screws - Outside Door Handle Latch 4. Latch Assembly 5. Window Frame Be sure the one channel (5, Figure 2-14) which is next 17.
Page 645 a. If replacing the motor assembly of the window regulator, be sure the worm gear on the motor is engaged properly into the regulator gear. Also, the regulator should be in the "UP" posi- tion before replacing the motor assembly. Be sure the motor mounting screws are tight.
Page 646 Door and Door Hinge Seal Replacement 1. The door assembly seal has only three members to it (sides and top) and is glued on the door. This seal can be replaced by peeling the seal away from the door frame. Then use a suitable cleaner to remove the remaining seal and glue material.
Page 647 GLASS REPLACEMENT 3. Carefully clean and remove all broken glass chips from any remaining window adhesive. The surface should be smooth and even. ADHESIVE-BONDED WINDOWS NOTE: Removal of all old ahesive is not required; Recommended Tools/Supplies just enough to provide an even bedding base. •...
Page 648 WINDSHIELD & REAR GLASS Installation Two people are required to remove and install the 1. If the weatherstrip material previously removed is windshield and rear glass. One inside the cab, and the broken, weathered, or damaged in any way, use other on the outside.
Page 649 CAB COMPONENTS WINDSHIELD WIPER The windshield wipers are operated by a 24 volt elec- Motor Installation tric motor. The wiper can be adjusted for a variable 1. Align motor mounting holes with cab bracket. intermittent delay or a constant low or high speed by the switch mounted on the instrument panel.
Page 650 Installation 1. Insert wiper arm pivot shaft (5, Figure 3-2) through hole in windshield frame and install nut (6) and washer (7). 2. Install cap (4). Attach linkage to pivot arm by pressing over retainer (8) and turning retainer clockwise until locked. 3.
Page 651 HEATER/AIR CONDITIONER HEATER COMPONENTS The heater assembly incorporates all the controls nec- NOTE: Figures 3-4 and 3-5 illustrate both the heater essary for regulating the cab interior temperature; system and air conditioning system parts contained in heated air during cold weather operation, outside air the cab mounted enclosure.
Page 652 HEATER COIL Test The heater coil (12, Figure 3-5) receives coolant Visually inspect the flapper (8, 26, or 31) and linkage through the water control valve (44) when HEAT is for the function being diagnosed. Make certain the selected. If the selection control (19) is placed in flapper is not binding or obstructed, preventing move- between the red and blue area, or turned counterclock- ment from one mode to the other.
Page 653 FIGURE 3-5. HEATER/AIR CONDITIONER ASSEMBLY 1. Casing 16. Control Plate 30. Resistor, 24 volt 2. Cover 17. Blower Switch 31. Defroster Flapper 3. Louver 18. Toggle Switch 32. Grommet 4. Adaptor 19. Selection Control 33. Electrical Box Cover 5. Filter Grille 20.
Page 654 NOTES N3-6 Cab Components N03011 7/98...
Page 655 OPERATOR COMFORT Installation OPERATOR SEAT 1. Mount seat assembly to seat riser. Install cap- The operator’s seat provides a fully adjustable cush- screws (11, Figure4-1), lockwashers (12), flat- ioned ride for the driver’s comfort and ease of opera- washers (13) and nuts (14). Tighten capscrews to tion.
Page 656 HEATER/AIR CONDITIONER The heater assembly incorporates all the controls nec- essary for regulating the cab interior temperature; heated air during cold weather operation, outside air during mild temperatures and cooled, de-humidified air during warm weather operation. The following information primarily describes the heater system.
Page 657 Test HEATER COMPONENTS Verify the motor on the water control valve operates NOTE: Figures 4-3 and 4-4 illustrate both the heater when the control (6, Figure 4-2) is rotated throughout system and air conditioning system parts contained in the red area. If the motor fails to operate, the heater the cab mounted enclosure.
Page 658 FAN MOTOR AND SPEED CONTROL FILTER Fan speed is controlled by inserting resistor(s) in series Service with the supply circuit to the blower motor to reduce voltage. The number of resistors in series is determined Inlet filters in the heater cover and the cab access panel by the position of the fan speed selector switch.
Page 659 FIGURE 4-4. HEATER/AIR CONDITIONER ASSEMBLY 1. Casing 16. Control Plate 30. Resistor, 24 volt 2. Cover 17. Blower Switch 31. Defroster Flapper 3. Louver 18. Toggle Switch 32. Grommet 4. Adaptor 19. Toggle Switch 33. Electrical Box Cover 5. Filter Grille 20.
Page 660 NOTES N4-6 Operator Comfort N04020...
Page 661 The steering column and steering wheel used in the “Off” and allow the steering accumulators to Komatsu truck will adjust through a tilt angle to provide bleed down. Allow at least 90 seconds for bleed the most comfortable wheel position for all operators.
Page 662 FIGURE 5-2. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 7. Instrument Panel 13. Warning/Status Indicator Lights 2. Retarder Control Lever 8. Grade/Speed Chart 14. Payload Meter Download Connector 3. Retarder/Service Brake Pedal 9. Radio Speakers 15. Payload Meter II 4.
Page 663 STEERING WHEEL AND CONTROLS The steering wheel (1, Figure 5-3) will telescope “in” and “out” and adjust through a tilt angle to provide a comfortable wheel position for most operators. HORN BUTTON The horn (2, Figure 5-3) is actuated by pushing the button in the center of the steering wheel.
Page 664 When Dynamic Retarding is activated, an indicator For normal truck operation, Dynamic Retarding (lever light in the Overhead Display will illuminate. or foot-operated pedal) should be used to slow and control the speed of the truck. RETARDER CONTROL LEVER Service brakes should be applied only when dynamic The Retarder Control Lever (6, Figure 5-3) mounted retarding requires additional braking force to slow the on the right side of the steering column can be used to...
Page 665 HEATER / AIR CONDITIONER VENTS The operator has complete control of the air flow in the cab. The heater/air conditioner vents (5, Figure 5-2) are a flapper type which may be individually opened or closed and may be rotated 360° for optimum air flow. There are four (three not shown) across the top of the panel, two in front of the operator (one each in right and left panel modules), and four below the panel.
Page 666 RADIO SPEAKERS WINDSHIELD WIPERS Radio Speakers (9, Figure 5-2) for the AM/FM Stereo The windshield wipers (13, Figure 5-2) are powered by radio are located at the far left and right of the overhead an electric motor. Refer to INSTRUMENT PANEL panel.
Page 667 CENTER CONSOLE The Center Console (1, Figure 5-4) contains: (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”...
Page 668 HOIST CONTROL LEVER ASH TRAY The hoist control (3, Figure 5-4) is a four position The Ash Tray(4, Figure 5-4) is used for extinguishing hand-operated lever located between the operator and depositing smoking materials. DO NOT use for seat and the Center Console (see illustration below). flammable materials, such as paper wrappers, etc.
Page 669 OVERRIDE /FAULT RESET SWITCH RETARD SPEED CONTROL (RSC) ADJUST DIAL The RSC Adjust Dial (12, Figure 5-4) allows the opera- T h i s p u s h - b u t t on tor to vary the downhill truck speed that the Retard switch (9, Figure 5-4) Speed Control system will maintain when descending is spring-loaded to the...
Page 670 PSC DOWNLOAD PORT TCI DOWNLOAD PORT This connector (13, Figure 5-4) is for use by qualified This connector (15, Figure 5-4) is for use by qualified personnel to access diagnostic information for the personnel to access the Truck Control Interface (TCI) Propulsion System Controller (PSC).
Page 671 INSTRUMENT PANEL AND INDICATOR LIGHTS CONTROL SYMBOLS Many control functions are identified with “International” symbols that the operator should learn to recognize immediately. The operator must understand the function and operation of each instrument and control. This knowledge is essential for proper and safe operation of the machine. The following symbols are general indicators and may appear in multiple locations and combinations on the instrument panel.
Page 672 FIGURE 5-5. PANEL GAUGES, INDICATORS, AND CONTROLS 1. Keyswitch 15. Right Turn Signal Indicator Light 2. Engine Shutdown Switch with Timer Delay 16. High Beam Headlight Indicator Light 3. Backup Light Switch (N./O.) 17. Left Turn Signal Indicator Light 4. Ladder Light Switch (3 - Way) 18.
Page 673 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-5) KEY SWITCH Normal Engine Shutdown The key switch (1, Figure 5-5) is a three position (Off, 1. Stop truck. Reduce engine RPM to low idle. Place Run, Start) switch. Selector Switch in “Neutral” and apply Parking Brake switch.
Page 674 ENGINE SHUTDOWN SWITCH, with 5 Minute Idle 2. With keyswitch “Off”, and engine stopped, wait at Timer delay least 90 seconds. Insure steering circuit is com- pletely bled down by turning steering wheel back This switch (2, Figure 5-5) is a and forth several times.
Page 675 PANEL ILLUMINATION LIGHTS WHEEL BRAKE LOCK CONTROL These lights (6, Figure 5-5) provide illumination for the The Wheel Brake Lock (12, Figure 5-5) instrument panel. Brightness is controlled by the panel should be used with engine running for light dimmer switch (28). dumping and loading operations only.
Page 676 TACHOMETER VOLTMETER The tachometer (14, Figure 5-5) registers engine The voltmeter (19, Figure 5-5) indi- crankshaft speed in hundreds of revolutions per min- cates the voltage of the 24V battery ute (RPM). system. Normal indicated voltage at high RPM is 27 to 28 volts with bat- Governed RPM (Cummins QSK60-C Engine): teries in fully charged condition.
Page 677 AC DRIVE SYSTEM TEMPERATURE GAUGE REST SWITCH The “REST” switch (26, The AC Drive System Temperature Figure 5-5) is a “rocker” Gauge (23, Figure 5-5) indicates type switch with a locking the drive system temperature. device for the OFF (left There are three colored bands: side) position.
Page 678 LIGHT SWITCH PANEL LIGHT DIMMER The instrument panel lights, clear- The Panel Light Dimmer Control ance lights, and the headlights are (29, Figure 5-5) is a rheostat which controlled by this three position allows the operator to vary the rocker type switch (27, Figure 5-5). brightness of the instruments and “Off”...
Page 679 FIGURE 5-6. OVERHEAD STATUS / WARNING INDICATOR LIGHTS Row / Indicator Indicator Color - Row / Indicator Indicator Color - Column Description Wire Index Column Description Wire Index Not Used Red - 12FD/34TL No Power Red - 12M/75-6PI Low Steering Pressure Red - 12F/33A Propulsion System Amber - 12F/79WI...
Page 680 STATUS / WARNING INDICATOR LIGHT SYMBOLS AMBER (Yellow) color indicator lights alert the opera- ered “normal”, and truck operation may continue. tor that the indicated truck function requires some precaution when lighted. • • • • If the indicator light illuminates at higher truck RED color indicator lights alert the operator that the speed and high engine RPM, DO NOT OPER- indicated truck function requires immediate action by...
Page 681 Parking Brake AMBER Low Hydraulic Tank Level Not Used Service Brake AMBER Circuit Breaker Tripped AMBER Body Up AMBER D2 Hydraulic Oil Filter Monitor AMBER Dynamic Retarding AMBER Low Fuel AMBER Stop Engine A2. Low Hydraulic Tank Level A3. Parking Brake This warning light indicates the oil level in the hydraulic This amber parking brake indicator will illuminate when the parking brake is applied.
Page 682 E3. Stop Engine (Continued) • • • • Dynamic Retarding will still be available if needed Not Used to slow or stop the truck. Manual Backup Lights AMBER Stop the truck as quickly as possible in a safe area Engine Shutdown Timer - AMBER and apply parking brake.
Page 683 D5. HIGH HYDRAULIC OIL TEMPERATURE No Power This red warning light indicates high oil temperature in the hydraulic tank. Continued operation could damage components in the hydraulic system. Propulsion System AMBER If this condition occurs, the operator should safely stop Warning the truck, move Selector Switch to Neutral, apply the Park Brake, and operate engine at 1200 - 1500 RPM...
Page 684 D6. REDUCED PROPULSION No Propel The amber “Reduced Propulsion” light is used to indi- cate that the full AC Drive System performance in propulsion is not available. At this time, the only event that should activate this light is the use of “Limp Home Propel System @ Rest AMBER Mode”.
Page 685 HAZARD WARNING LIGHTS LINK-ON WARNING LIGHT The hazard warning light The “LINK-ON”, or “LINK ENER- switch (7, Figure 5-6) flashes GIZED”, indicator light is located all the turn signal lights. next to the D.I.D. display panel be- Pressing the bottom side of hind the passenger seat and indi- the rocker switch (toward the cates the AC DRIVE system is...
Page 686 NOTES N5-26 Operator Cab Controls N05044...
Page 687 SECTION P LUBRICATION AND SERVICE INDEX LUBRICATION AND SERVICE ........P2-1 Service Capacities .
Page 688 NOTES P1-2 Index P01024...
Page 689 LUBRICATION AND SERVICE Preventive Maintenance will contribute to the long life HYDRAULIC TANK SERVICE and dependability of the truck and its components. The There are two sight gauges on the side of the hydraulic use of proper lubricants and the performance of tank.
Page 690 COOLANT LEVEL CHECK COOLING SYSTEM ANTI - FREEZE RECOMMENDATIONS Inspect the coolant sight gauge. If coolant cannot be (Ethlyene Glycol Permanent Type Anti-Freeze) seen in the sight gauge, it is necessary to add coolant Percentage of Protection to the cooling system before truck operation. Refer to Anti-Freeze the procedure below for the proper filling instructions.
Page 691 P02034 Lubrication and Service P2-3...
Page 692 10 HOUR (DAILY) INSPECTION Truck Serial Number______________________ Prior to each operating shift, a “walk around” inspec- tion should be performed. Check the truck for general Site Unit Number_________________________ condition. Look for evidence of hydraulic leaks; check Date:______________Hour Meter___________ all lights and mirrors for clean and unbroken lenses; check operator’s cab for clean and unbroken glass;...
Page 693 10 HOUR (DAILY) INSPECTION (continued) √’d COMMENTS INITIALS 9. WHEELS AND TIRES - a. Inspect tires for proper inflation and wear. b. Inspect for debris embedded in cuts or tread. c. Inspect for damaged, loose, or missing wheel mounting nuts or studs. 12.
Page 694 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number_______________________ Site Unit Number__________________________ Date:___________Hour Meter______________ Name of Service person______________________ √’d COMMENTS INITIALS MOTORIZED WHEELS - Check for correct oil level. Refer to G.E. Motorized Wheel Service & Maintenance Manual for lubrication specifications. * The following checks are required only after the initial hours of operation (such as: new truck com- missioning, or a new/rebuilt component installation),...
Page 695 Truck Serial Number_______________________ Site Unit Number__________________________ 100 HOUR LUBRICATION AND Date:___________Hour Meter______________ MAINTENANCE CHECKS Name of Service person______________________ * These checks are required only after the initial √’d COMMENTS INITIALS hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation), check: *1.
Page 696 250 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number _______________________ Maintenance for the 10 hour Lubrication and Mainte- nance Checks should also be carried out at this time. Site Unit Number __________________________ Date:____________Hour Meter_______________ NOTE: “Lube Key” references are to the Lubrication Specification Chart.
Page 697 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) 3. HYDRAULIC PUMP DRIVESHAFT & U-JOINTS - COMMENTS √’d INITIALS Add one or two applications of grease to each grease fitting. Check that each bearing of the cross & bearing assembly is receiving grease. Lube Key “D”.
Page 698 500 HOUR LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10, 50, & 250 hour Lubrication and Maintenance Checks should also be carried out Truck Serial Number _____________________ at this time. Site Unit Number ________________________ NOTE: “Lube Key” references are to the Lubrication Date:____________Hour Meter_____________ Specification Chart.
Page 699 1000 HOURS LUBRICATION AND Truck Serial Number _____________________ MAINTENANCE CHECKS Site Unit Number ________________________ Date:____________Hour Meter_____________ Maintenance for every 10, 50, 250, & 500 hour Lubri- cation and Maintenance Checks should also be carried Name of Service person___________________ out at this time. NOTE: “Lube Key”...
Page 700 Truck Serial Number _____________________ Site Unit Number ________________________ Date:____________Hour Meter_____________ Name of Service person___________________ 2500 HOUR MAINTENANCE CHECKS COMMENTS √’d INITIALS MOTORIZED WHEELS - Drain and replace gear oil. Refer to G.E. Motorized Wheel Service & Maintenance Manual for lubrication specifications. Lube Key “C”. 5000 HOUR MAINTENANCE CHECKS COMMENTS √’d...
Page 701 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION During the down stroke, the pump cylinder is extended into the grease. Through the combination of shovel The Lincoln Automatic Lubrication System is a pres- action and vacuum generated in the pump cylinder surized lubricant delivery system which delivers a chamber, the grease is forced into the pump cylinder.
Page 702 FIGURE 3-2. AUTO LUBE SYSTEM INSTALLATION NOTE: The above illustration shows the standard location for the lube pump & reservoir (right platform). This assembly may be located on left platform on some models. 1. L.H. Suspension, Top Bearing 13. R.H. Hoist Cylinder, Top Bearing 2.
Page 703 SYSTEM COMPONENTS Vent Valve (6, Figure 3-1) With the vent valve closed, the pump continues to Filter (21, Figure 3-2) operate until maximum grease pressure is achieved. A filter assembly mounted on the grease reservoir As this occurs, the vent valve opens and allows the filters the grease prior to refilling the reservoir from the grease pressure to drop to 0, so the injectors can shop supply.
Page 704 System Operation 5. During this period, the injectors will meter the appropriate amount of grease to each lubrication Normal Operation: point. 1. During truck operation, the lubrication cycle timer 6. When grease pressure reaches the pressure (1, Figure 3-4) will energize the system at a preset switch (3, Figure 3-4) setting, the switch contacts time interval.
Page 705 Pressure Failure Detection Circuits: 3. If a problem occurs and the system is not able to attain 2000 psi (13.8 MPa), the delay timer (11) 1. When the lubrication cycle is initiated, 24VDC will energize relay RB7K4 (12) after 60 seconds, flows through relay RB7K1 (7, Figure 3-4) N.C.
Page 706 INJECTOR OPERATION 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 lubri- cant (6), the slide valve (5) is about to open the passage (4) leading to the measuring chamber (1) above the injector piston (2).
Page 707 GENERAL INSTRUCTIONS LUBRICANT REQUIRED FOR SYSTEM Pump Pressure Control Grease requirements will depend on ambient tempera- High pressure hydraulic fluid from the truck steering tures encountered during truck operation: system is reduced to 325 to 350 psi (2 240 to 2 413 kPa) by the pressure reducing valve located on the •...
Page 708 INJECTORS (SL-1 Series “H”) Injector Specifications • Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of external lubricating equipment. • Injector output is adjustable: Maximum output = 0.08 in (1.31 cc).
Page 709 LUBRICATION CYCLE TIMER CHECK Lubrication Cycle Timer Adjustment To check the solid state timer operation without waiting The timer is factory set for a nominal 2.5 minute (off for the normal timer setting, proceed as follows: time) interval. Dwell time is approximately 1 minute, 15 seconds.
Page 710 PUMP REBUILD 13. Using a .50 in. (13 mm) diameter wooden or plastic rod, push the cup seal (22) and the pump cylinder (24) from the reciprocating tube. 14. Remove the pump plunger (20) from the plunger link rod (17). (A spanner wrench, which uses the holes in the the pump plunger, is required.) Be certain to bleed steering accumulators to re- lieve hydraulic pressure and to relieve pump outlet...
Page 711 FIGURE 3-9. LUBE PUMP ASSEMBLY 1. Screw 16. Cup Seal 31. Cover Gasket 45. Pipe Plug 2. Outer Weight 17. Plunger Rod 32. Gauge 46. Pump Housing 3. Inner Weight 18. Spring 33. Screw 47. Backup Ring 4. Retaining Ring 19.
Page 712 Assembly 8. Assemble crank rod assembly, to pump with bushings (13) and button head screws (12). ® Note: Use Loctite 242 (or equivalent) thread locker Tighten screws to 100 - 110 in. lbs. (11.3 - 12.4 on all torqued, threaded connections. Use extreme N.m) torque.
Page 713 SYSTEM TROUBLESHOOTING CHART If the following procedures do not correct the problem, contact a factory authorized service center. POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pump Does Not Operate Lube system not grounded. Correct grounding connections to pump assembly and truck chassis. Electrical power loss.
Page 714 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pressure Gauge Does Not Register Pressure No system pressure to the pump motor. Check hydraulic hose from steering system. No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system. Pressure reducing valve set too low. Refer to “Pressure Control Valve Adjustment”.
Page 715 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) 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 capacitor may be generated into vehicle electrical system causing uncontrolled turn-on of its output relay.
Page 716 Preventative Maintenance Procedures The following maintenance procedures should be 4. Inspect all bearing points for a bead of lubricant used to insure proper system operation. around the bearing seal. It is good practice to manually lube each bearing Daily Lubrication System Inspection point at the grease fitting provided on each Injec- 1.
Page 717: Alphabetical Index
SECTION Q ALPHABETICAL INDEX Brake Circuit ....J2-1 Abbreviations, Propulsion System ..E2-41 Bleeding Procedures Accelerator Pedal ....E2-51 Service Brakes .
Page 718 ® HYDRAIR II Suspensions Front ..... H2-1 Decks ..... B2-3 Rear .
Page 719 Spindle, Front Wheel Hub ..G3-1 Starter Disconnect Relay ..D2-3 Parking Brake ....J7-1 Status/Warning Indicator Lights .
Page 720 Valves Weights (Truck) ....A2-4 Bleeddown Solenoid ... . . L4-3 Wheel Bearing Adjustment Brake ..... J3-1 Front Wheel .
Page 721 SECTION R SYSTEM SCHEMATICS INDEX HYDRAULIC BRAKE SYSTEM SCHEMATIC ......HH341 HYDRAULIC SUPPLY & BRAKE COOLING SCHEMATIC (w/HUSCO VALVE) ..HH347 ELECTRICAL SCHEMATIC .
Page 737 NOTES R1-2 930E Schematics R01048 with Cummins QSK60 Series Engine...

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