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KOMATSU 930e-2 - (In) - Serie - A30181 - Thru - A30223 - W-Cummins - qsk60 - Engine
KOMATSU 930e-2 - (In) - Serie - A30181 - Thru - A30223 - W-Cummins - qsk60 - Engine
Shop
Manual
930E-2
DUMP TRUCK
This manual should be kept in or near the machine for reference, and periodically reviewed by
all personnel who will come into contact with it.
This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or
disclosed except in accordance with written authorization from KAC.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The
Company reserves the right to make changes or add improvements at any time without incurring any
obligation to install such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication.
Customers should contact their local Komatsu distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. Wash hands after handling.
NOTES
FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician become fully
knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per-
sonnel should read and understand the materials in this manual before performing maintenance and/or operational
checks on the truck. All safety notices, warnings and cautions should be understood and followed when accom-
plishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other gen-
eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major ser-
viceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator
group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire
mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed
repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict
a specific model.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to "Right",
"Left", "Front", or "Rear" are made with respect to the operator's normal seated position, unless specifically stated
otherwise.
Standard torque requirements are shown in torque charts in the general information section and individual torques
are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have
æ10% tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig-
nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
(Gross Vehicle Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers
represent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an
Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the original man-
ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo-
nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
(GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the
GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often
as practical.
Exceeding the allowable payload will reduce expected life of truck components.
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
HYDRAIR® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
GENERAL INFORMATION
INDEX
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Precautions When Handling At High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Prevention Of Injury By Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Precautions When Using ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety At The Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ventilation For Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
In Operator’s Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check When Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ensure Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operate Carefully On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Damage To Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
When Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Read and follow all safety precautions. Failure to do so may result in serious injury or
death.
Safety Rules
• Only trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
• When working with another operator or a person on work site traffic duty, be sure all personnel understand all
hand signals that are to be used.
Safety Features
• Ensure all guards and covers are in their proper position. Have any damaged guards and covers repaired. (See
Walk-Around Inspection, Operating Instructions - Section 3)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• Never remove any safety features. Always keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.
Unauthorized Modification
• Any modification made to this vehicle without authorization from Komatsu America Corp. can possibly create
hazards.
• Before making any modification, consult the authorized regional Komatsu America Corp. distributor. Komatsu
will not be responsible for any injury or damage caused by any unauthorized modification.
Fire Prevention
• Thoroughly remove wood chips, leaves, paper and other flammable items
accumulated in the engine compartment, as they could cause a fire.
• Check fuel, lubrication, and hydraulic systems for leaks. Repair any leaks.
Wipe up any excess oil, fuel or other flammable fluids, and dispose of properly.
• Ensure a fire extinguisher is present and in proper working condition.
• Do not operate the machine near open flames.
The tire and rim assembly may explode if subjected to excessive heat. Personnel should move to a remote
or protected location if sensing excessively hot brakes, smell of burning rubber or evidence of fire near
tire and wheel area.
If the truck must be approached, such as to fight a fire, those personnel should do so only while facing the
tread area of the tire (front or back), unless protected by use of large heavy equipment as a shield. Stay at
least 50 ft. (15 m) from the tread of the tire.
In the event of fire in the tire and wheel area (including brake fires), stay away from the truck for at least 8
hours or until the tire and wheel are cool.
• Keep serviceable fire fighting equipment on hand. Report used extinguishers for replacement or refilling.
• Always have parking brake applied when the truck is parked and unattended. DO NOT leave the truck
unattended while the engine is running.
• Park the truck a safe distance away from other vehicles as determined by the supervisor.
• Stay alert at all times! In the event of an emergency, be prepared to react quickly and avoid accidents. If an
emergency arises, know where to get prompt assistance.
Traveling
• When traveling on rough ground, travel at low speeds. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is in motion, the emergency steering system will be activated.
Apply the brakes immediately and stop the machine as quickly and safely as possible (off of the haul road, if
possible).
The following actions are effective in preventing accidents while working near high voltages:
• Wear shoes with rubber or leather soles.
• Use a signalman to give warning if the machine approaches an electric cable.
• If the work equipment should touch an electric cable, the operator should not leave the cab.
• When performing operations near high voltage cables, do not allow anyone to approach the machine.
• Check with the electrical maintenance department about the voltage of the cables before starting operations.
When Loading
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
• Do not leave the operator's seat during the loading operation.
TOWING
When Towing, Fix Wire To Hook
• Improper towing methods may lead to serious personal injury and/or damage.
• Use a towing device with ample strength for the weight of this machine.
• Never tow a machine on a slope.
• Do not use tow rope that has kinks or is twisted.
• Do not stand astride the towing cable or wire rope.
• When connecting a machine that is to be towed, do not allow anyone to go between the tow machine and the
machine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing portion of the tow machine, and
secure it in position.
(For towing method, see the Operation and Maintenance Manual, Section 3, Operating Instructions - Towing.)
Proper Tools
• Use only tools suited to the task. Using damaged, low quality, faulty, or
makeshift tools could cause personal injury.
Attachments
• Place attachments that have been removed from the machine in a safe place and
manner to prevent them from falling.
Use Of Lighting
• When checking fuel, oil, coolant, or battery electrolyte, always use
lighting with anti-explosion specifications. If such lighting equipment is
not used, there is danger or explosion.
• Immediately after stopping operation, engine coolant and operating oils are
at high temperature and under high pressure. In these conditions, if the cap
is removed, the oil or water drained, or the filters are replaced, it may result
in burns or other injury. Wait for the temperature to cool and pressure to
subside, before performing the inspection and/or maintenance in as
outlined in the service manual.
Waste Materials
• Never dump waste oil in a sewer system, rivers, etc.
• Always put oil drained from your machine in appropriate containers. Never
drain oil directly onto the ground.
• Obey appropriate laws and regulations when disposing of harmful objects
such as oil, fuel, coolant, solvent, filters, batteries, and others.
The tire inflation pressure and permissible speeds are general values. The actual values may differ depending on
the type of tire and the condition under which they are used. For details, please consult the tire manufacturer.
When tires become hot, a flammable gas is produced, and may ignite. It is particularly dangerous if the tires
become overheated while the tires are pressurized. If the gas generated inside the tire ignites, the internal pres-
sure will suddenly rise, and the tire will explode, resulting in danger to personnel in the area. Explosions differ from
punctures or tire bursts because the destructive force is extremely large. Therefore, the following operations are
strictly prohibited when the tire is pressurized:
• Welding the rim
• Welding near the wheel or tire.
• Smoking or creating open flames
If the proper procedure for performing maintenance or replacement of the wheel or tire is not used, the wheel or tire
may burst and cause serious injury or damage. When performing such maintenance, consult your authorized
regional Komatsu distributor, or the tire manufacturer.
Any operating fluid, such as hydraulic oil or brake fluid escaping under pressure, can have sufficient force
to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper
medical treatment by a physician familiar with this injury is not received immediately.
Do not stand in front of a rim and locking ring when inflating a tire mounted on the machine. Observers
should not be permitted in the area and should be kept away from the sides of such tires.
Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of tire and rim.
14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation should
move the truck under its own power in the repair facility or during road testing after repairs are complete.
Before opening any cabinets or touching a grid element or a power cable, the engine must be shutdown
and the red drive system warning lights must not be illuminated.
Leave the drive system in the “rest” mode until the truck is to be moved.
10. Before leaving this position, look under the 19. Move around the fuel tank. Inspect the fuel
lower edge of the chassis to be sure the flexible quantity gauge, (this should agree with what will
duct that carries the air from the main blower to show on the gauge in the cab). Inspect the
the final drive housing is in good condition with attaching hardware for the fuel tank at the upper
no holes or breakage. Also look up at the main saddles, and then at the lower back of the tank
hydraulic pumps to see that there is no leakage for the security and condition of the mounts.
or any other unusual condition with pumps or Check hoist filters for leaks.
pump drive shafts. 20. Move in behind the right front wheel, and
11. Move on around the dual tires, check to see that inspect the steering cylinder. Check the greas-
all nuts/studs are in place and tight. Inspect ing and attaching hardware. Check suspension
wheel for any oil that would indicate brake leak- attaching hardware and suspension extension.
age or wheel motor leakage. Be sure the suspension protective boot is in
good condition. Inspect the hub and brakes for
Check dual tires for cuts, damage or bubbles. any unusual conditions. Check entire area for
Verify that inflation appears to be correct. If the leaks.
truck has been run on a "flat", the tire must be
cooled before moving the truck inside. 21. Move out and around the right front wheel;
Check for any rocks that might be lodged inspect that all nuts/studs are in place and tight.
between dual tires. Check rock ejector condi- 22. Move in behind the front of the right front wheel,
tion and straightness (so that it can not damage check hub and brakes for leaks and any
a tire). unusual condition. Inspect steering cylinder for
12. Inspect left rear suspension for damage and for security and for proper greasing. Inspect the
correct rod exposure. Check for leaks. Ensure engine compartment for any leaks and unusual
that the covers over the chrome piston rod are conditions. Inspect the fan guard and belts.
in good condition and inspect for proper greas- Check for any rags or debris behind radiator.
ing. 23. Inspect auto lube system. See Automatic Lubri-
13. Open rear hatch cover. Inspect for leaks around cation System in Section P, for specific details
the parking brakes. Inspect condition of cooling concerning the auto lube system.
air exhaust ductwork to be certain that it is intact 24. Move around to the right front of the truck, drop
and that there are no obstructions. the air cleaner pans to remove dirt, latch up,
14. While standing in front of the rear hatch, look up and secure. Inspect battery box cover for dam-
to see that rear lights are in good condition, age and be sure it is in place and secure.
along with the back-up horns. Look up at pan- 25. As you move in front of the radiator, inspect for
hard rod to see that it is getting proper greasing. any debris that might be stuck in front of the
Also look at both body hinge pins for greasing radiator and remove it. Check for any coolant
and any abnormal condition. Check hoist limit leaks. Inspect headlights and fog lights.
switch and clear any mud/debris from contacts.
If any of the red warning lights come on or if any 8. Check brake lock performance periodically for
gauge reads in the red area during truck opera- safe loading and dump operation.
tion, a malfunction is indicated. Stop the truck as 9. Proceed slowly on rough terrain to avoid deep
soon as safety permits, and shut down the ruts or large obstacles. Avoid traveling close to
engine. Have the problem corrected before soft edges and the edge of fill area.
resuming truck operation.
10. Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
operating the truck.
10. If the "emergency steering" light and/or "low b. When the lever is rotated to full "down"
brake pressure warning" light (if equipped) illu- (clockwise) position, it is in the full "ON/
minate during operation, steer the truck imme- Retard" position.
diately to a safe stopping area, away from c. For long downhill hauls, the lever may be
other traffic if possible. Refer to item 7 above. positioned to provide a desired retarding
11. Check tires for proper inflation periodically dur- effort. It will remain where it is positioned.
ing shift. If truck has been run on a "flat", or NOTE: The retarder control lever must be rotated
under-inflated tire, it must not be parked in a back to the OFF position before the truck will resume
building until the tire cools. the “propel” mode of operation.
In the event that the equipment is being worked in If engine does not shutdown with keyswitch,
consecutive shifts, any questionable truck perfor- use engine shutdown switch on operator cab
mance the operator may have noticed must be center console, and hold this switch down until
checked by maintenance personnel before the truck engine stops.
is released to another operator. 4. With keyswitch OFF, and engine stopped, wait
at least 90 seconds. Insure steering circuit is
1. The truck should be parked on level ground, if
completely bled down by turning steering wheel
at all possible. If parking must be done on a
back and forth several times. No front wheel
grade, the truck should be positioned at right
movement will occur when hydraulic pressure is
angles to the grade.
relieved. If the vehicle continues to steer after
2. The parking brake must be applied and/or shutdown, notify maintenance personnel.
chocks placed fore/aft of wheels so that the
5. Verify all link voltage lights are off (one on back
truck cannot roll. Each truck should be parked
interior wall of operator cab, two on electrical
at a reasonable distance from another.
cabinet, on deck), and notify maintenance per-
3. Haul roads are not safe parking areas. In an sonnel if remains illuminated longer than five
emergency, pick the safest spot most visible to minutes after the engine is shut down.
other machines in the area. If the truck
6. Close and lock all windows, remove key from
becomes disabled where traffic is heavy, mark
keyswitch and lock cab to prevent possible
the truck with warning flags in daylight or flares
unauthorized truck operation. Dismount truck
at night.
properly. Put wheel chocks in place.
The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrica-
tion and Service, in this manual for more complete lubrication instructions.
SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B FT. LBS. CODE (O.D.) UNF-2B FT. LBS.
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10
FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage
FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page A5-5 regarding Table usage
PSI 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page A5-5 regarding Table usage
PSI 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may 3. Multiply by 10:
be used as in the following example: 970 psi = 6688 kPa.
Example: Convert 975 psi to kilopascals (kPa). 4. Go to PSI row 0, column 5; read 34.475
psi = 34.47 kPa. Add to step 3.
1. Select Table X.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
2. Go to PSI row 90, column 7; read 668.8
97 psi = 668.8 kPa.
Multiply Multiply
To Convert From TO By To Convert From TO By
inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394
inch – in. centimeter (cm) 2.54 centimeter (cm) inch – in. 0.3937
foot – ft. meter (m) 0.3048 meter (m) foot – ft. 3.2808
yard – yd. meter (m) 0.914 meter (m) yard – yd. 1.0936
mile – mi. kilometer (km) 1.61 kilometer (km) mile – mi. 0.6210
2 2 6.45 2 2 0.1550
sq. in. – in. sq. centimeters (cm ) sq. centimeters (cm ) sq. in. – in.
sq. ft. – ft.2 sq. centimeters (cm2) 929 sq. centimeters (cm2) sq. ft. – ft.2 0.001
cu. in. – in.3 cu. centimeters (cm3) 16.39 cu. centimeters (cm3) cu. in. – in.3 0.061
cu. in. – in.3 liters (l) 0.016 liters (l) cu. in. – in.3 61.02
cu. ft. – ft.3 cu. meters (m3) 0.028 cu. meters (m3) cu. ft. – ft.3 35.314
cu. ft. – ft.3 liters (l) 28.3 liters (l) cu. ft. – ft.3 0.0353
ounce – oz. kilogram (kg) 0.028 grams (g) ounce – oz. 0.0353
fluid ounce – fl. oz. milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl. oz. 0.0338
pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046
pound (force) – lbs. Newton (N) 4.448 Newton (N) pound (force) – lbs. 0.2248
in. lbs. (force) Newton.meters (N.m) 0.113 Newton.meters (N.m) kilogram.meters (kg.m) 0.102
ft. lbs. (force) Newton.meters (N.m) 1.356 Newton.meters (N.m) ft. lbs. (force) 0.7376
ft. lbs. (force) kilogram.meters (kg.m) 0.138 kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters kilogram.meters (kg.m) Newton.meters (N.m) 9.807
Newton.meters (N.m) 9.807
(kg.m)
Kilopascals (kPa) psi (pressure) 0.1450
psi (pressure) kilopascals (kPa) 6.895
megapascals (MPa) psi (pressure) 145.038
psi (pressure) megapascals (MPa) 0.007 2 2
kilograms/cm (kg/cm ) psi (pressure) 14.2231
psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 2 2 kilopascals (kPa) 98.068
kilograms/cm (kg/cm )
ton (short) kilogram (kg) 907.2
kilogram (kg) ton (short) 0.0011
ton (short) metric ton 0.0907
metric ton ton (short) 1.1023
quart – qt. liters (l) 0.946
liters (l) quart – qt. 1.0567
gallon – gal. liters (l) 3.785
liters (l) gallon – gal. 0.2642
HP (horsepower) Watts 745.7
Watts HP (horsepower) 0.00134
HP (horsepower) kilowatts (kw) 0.745
kilowatts (kw) HP (horsepower) 1.3410
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Clean the radiator; refer to Engine Service Man- 10. Exhaust openings and air cleaners should be
ual and the Vehicle Service Manual for the covered tightly with moisture barrier paper and
proper cleaning instructions. sealing tape.
6. The cooling system should be completely 11. All lubrication points (grease fittings) should be
drained, chemically flushed, and refilled with a serviced with the prescribed lubricants.
conditioned water/antifreeze solution suitable 12. Relieve tension from all drive belts. The engine
for the lowest temperature anticipated. Refer to manufacturer recommends insertion of heavy
Section P, Lubrication and Service, for the kraft paper between belts and pulleys to prevent
proper anti-freeze and conditioner concentra- sticking.
tions. After refilling the system, always operate
the engine until the thermostats open to circu- 13. All vandalism covers and locks should be in
late the solution through the cooling system. place and secured.
The engine should be stored in a building which is An engine prepared in this manner can be returned
dry and can be heated during the winter months. to service in a short period of time by removing the
Moisture absorbing chemicals are available commer- seals at the engine openings, checking the engine
cially for use when excessive damage prevail in the coolant, fuel oil, lubricating oil, transmission oil and
storage area. priming the raw water pump (if used).
Temporary Storage (30 Days Or Less) Extended Storage (more Than 30 Days)
To protect an engine for a temporary period of time, To prepare an engine for extended storage, (more
proceed as follows: than 30 days), follow this procedure:
1. Drain the engine crankcase. 1. Drain the cooling system and flush with clean,
soft water. Refill with clean, soft water and add
2. Fill the crankcase to proper level with the rec-
a rust inhibitor to the cooling system.
ommended viscosity and grade of oil.
2. Remove, check and recondition the injectors, if
3. Fill the fuel tank with the recommended grade necessary, to make sure they will be ready to
of fuel oil. Operate the engine for two minutes at operate when the engine is restored to service.
1,200 rpm and no load. Shut down engine, do
not drain the fuel system or the crankcase after 3. Reinstall the injectors, time them and adjust the
this run. exhaust valve clearance.
4. Check the air cleaner and service, if necessary. 4. Circulate the coolant by operating the engine
until normal operating temperature is reached
5. If freezing weather is expected during the stor- 160° - 185° F ( 71° - 85° C).
age period, add an ethylene glycol base anti-
freeze solution in accordance with the 5. Stop the engine.
manufacturer's recommendations. 6. Drain the engine crankcase, then reinstall and
tighten the drain plug. Install new lubricating oil
filter elements and gaskets.
7. Fill the crankcase to the proper level with a 30-
weight preservative lubricating oil MIL-L-
21260C, Grade 2.
Storage Instructions and Procedures Perform the following instructions when preparing
General Electric equipment for storage. There are
This instruction provides the recommended proce- three main equipment categories to consider:
dures for protecting equipment from damage during
1. When storing a truck that is operational.
both short-term and long-term storage periods and
for maintaining adequate protection while in storage. 2. When storing a truck that is not operational.
Also included are instructions for placing this equip- 3. When storing major components (Motorized
ment into service after having been stored. Wheel, alternator, etc.).
For the purposes of this instruction, a short-term stor- These three major categories are the basis for deter-
age period is considered to be less than three mining required protective measures.
months; a long-term storage period is considered to
NOTE: In addition to these instructions, refer to truck
be three months or longer.
storage instructions.
General Electric recommends a maximum storage
period of three years, with these storage procedures
being repeated after each year. After a storage
period of three years or more, the motorized wheels
should be removed and sent to an overhaul facility
for teardown and inspection of seals and bearings. Storing A Truck That Is Operational
These should be replaced if necessary.
When a fully operational truck is being placed into
Periodic (every three months) inspections should be storage for less than three months, the best protec-
made to determine the lasting qualities of long-term tive measure which can be taken is to drive the truck
storage protection measures. Such inspections will once a week for at least 30 minutes. Prior to driving
indicate the need for renewing protective measures the truck, the rotating equipment should be Meg-
when necessary to prevent equipment deterioration. gered and:
Proper storage of this equipment is vital to equipment 1. If greater than 2 megohms, run normally.
life. Bearings, gears, and insulation may deteriorate
2. If less than 2 megohms, isolate condition and
unless adequate protective measures are taken to
correct before running.
protect against the elements. For example, bearings
and gears in the motorized wheel gear case are sus- Driving the truck circulates oil in the gear case to
ceptible to the formation of rust; insulation in rotating keep gears and bearings lubricated and free from
electrical equipment can accumulate moisture; and rust. It also prevents deterioration of the brushes,
bearings may become pitted. commutators and slip rings.
When a fully operational truck is being placed into
storage for three months or longer, and the truck
cannot be operated weekly throughout the storage
Never apply any spray, coating, or other protec- period as indicated above, perform the following:
tive materials to areas not specifically recom-
1. Drain the oil from the gear case and install rust
mended.
preventive 4161 (product of Van Straaten
It is also important to note that these instructions Chemical Co.) or equivalent. Fill per General
cannot possibly anticipate every type of storage con- Electric Motorized Wheel Service Manual.
dition and, therefore, cannot prevent all equipment 2. Megger the wheels as indicated in the instruc-
deterioration problems caused by inadequate stor- tions above. Operate the truck for at least 30
age. However, these instructions should be consid- minutes to insure that the rust preventive com-
ered as a minimum procedure to achieve the best pound has been thoroughly circulated through-
possible equipment life and the lowest operating cost out the gear case. Stop the truck and drain the
when the equipment is returned to service. rust preventive compound.
NOTE: Local conditions and/or experience may NOTE: Do not run a loaded truck with rust preventive
require additional procedures and/or additional stor- compound in the wheel motor gear cases.
age precautions.
STRUCTURES
INDEX
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LEFT DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Remove hardware attaching diagonal ladder (4, 1. Move hood and grille assembly (1, Figure 2-2)
Figure 2-1) to front bumper. from work area to truck and lift into place.
2. Attach lifting device to the ladder and lift struc- 2. Align mounting holes with brackets attached to
ture off truck. radiator assembly. Install side mounting cap-
screws (2).
3. Disconnect wiring harnesses and remove cable
clamps as necessary to allow hood removal. 3. Lift diagonal ladder into position over mounting
pads on front bumper. Align mounting holes and
4. Attach lifting device to the hood and grille
install hardware. Tighten capscrews to standard
assembly (1, Figure 2-2).
torque.
5. Remove all side mounting capscrews and lock-
4. Connect harnesses, hoses etc. that were
washers (2).
removed previously. Install all clamps removed.
6. Verify all harnesses, cables, hoses etc. are
removed.
7. Lift hood and grille assembly from truck and
move to work area.
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BODY UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FIGURE 3-7. ROCK EJECTOR INSTALLATION FIGURE 3-8. ROCK EJECTOR MOUNTING
BRACKET (Detail View)
1. Rock Ejector Arm 3. Rear Wheel Spacer 1. Rock Ejector Arm 3. Stop Block
2. Wear Plate Ring 2. Pin 4. Mounting Bracket
Inspection
1. The rock ejectors must be positioned on the
center line between the rear tires within 0.25 in.
(6.0 mm).
2. With the truck parked on a level surface, the
arm structure should be approximately 17.9 in.
(454.5 mm) from wheel housing (2). Refer to
Figure 3-10.
NOTE: With rock ejector arm (1, Figure 3-9) hanging
vertical as shown in Figure 3-10, there must be NO
GAP at stop block (3, Figure 3-9).
3. If arm (1) becomes bent, it must be removed
and straightened.
4. Inspect mounting brackets (4, Figure 3-9), pins
(2) and stops (3) at each shift change for wear
and/or damage, and repair as necessary.
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation
1. Clean mating surfaces, and install a new gas-
ket.
2. Reinstall the sender unit in the tank. Use care
and ensure that the float is oriented properly
and works freely in the vertical plane during
installation.
3. Reinstall the four socket head capscrews and
tighten to standard torque. Reconnect the wire
to the terminal.
4. Refill the tank and check for leaks.
Removal
Unscrew breather valve (5, Figure 4-1) from fuel tank
(1).
Installation
Screw breather valve (5, Figure 4-1) into fuel tank
(1).
Disassembly
1. Remove clamp (3, Figure 4-2).
2. Remove cover (2) and screen (1).
3. Remove ball cage (10), solid ball (11), and float
balls (12).
4. Unscrew end fitting (7) from body (4). FIGURE 3-2. BREATHER VALVE
5. Remove stem (8) and valve spring (5).
1. Screen 7. End Fitting
Assembly 2. Cover 8. Stem
3. Clamp 9. O-Ring
1. Clean and inspect all parts. If damaged compo- 4. Body 10. Ball Cage
nents are evident, replace the entire assembly. 5. Valve Spring 11. Solid Ball
2. Place valve spring (5) into position in body (4). 6. O-Ring 12. Float Ball
3. Insert stem (8) into end fitting (7).
4. Screw end fitting (7) into body (4). Ensure the
components are properly aligned and seated.
5. Place screen (1) and cover (2) into position on
the breather. Install clamp (3).
6. Insert the balls into ball cage (10) with solid ball
(11) on top.
7. Insert the ball cage onto the stem. A minimum
of two cage coils must be seated in the groove
on the stem. Ensure the solid ball is able to seat
NOTE: This illustration represents a typical installation. Installation may vary depending on truck model.
ENGINE
INDEX
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
POWER MODULE
INDEX
POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The complete power module, including the hood FIGURE 2-2. MAIN ALTERNATOR BLOWER DUCT
and grille weighs approximately 37,386 lbs.
(16,958 kg). Make sure lifting device to be used 1. Electrical Cabinet 6. Wheel Motor Duct
has adequate capacity. 2. Intake Duct 7. Main Alternator
3. Alternator Inlet Duct 8. Alternator Inlet
1. If radiator removal is required, refer to Section 4. Blower Assembly Transition Structure
B, Structural Components, for hood and grille 5. Wheel Motor Duct- 9. Blower Subframe
removal instructions. (Power module may be Transition Structure Structure
removed with hood installed if desired.)
2. Remove driveshaft guard cover (2, Figure 2-1).
Disconnect hydraulic pump drive shaft (4) at the 4. Remove engine air intake duct support rods (9,
drive shaft U-joint companion flange mounted Figure 2-3). Remove any hoses or electrical
on the alternator (5). cables attached to center deck structure.
3. Remove main alternator blower ducts to provide 5. Attach overhead hoist to center deck structure.
clearance to raise the engine off the subframe Remove deck mounting hardware, lift deck from
mounts. (Refer to Figure 2-2): truck and move to storage area.
6. Disconnect the air cleaner restriction indicator
a. Disconnect cables and hoses as required.
nylon tubes at ports on inlet ducts.
b. Remove alternator inlet transition structure
7. Loosen clamps (5) on hump hoses (4) between
(8) and gasket.
the four engine air inlet ducts and air cleaner
c. Remove wheel motor cooling air duct transi- outlet ducts.
tion structure (5). 8. Disconnect inlet ducts at each of the four turbo-
d. Cover all openings to prevent entrance of chargers. Remove inlet ducts from truck. Cover
foreign material. openings at turbochargers.
Install safety chain around the engine subframe Lift power module only at the lifting points on
cross member and main frame to prevent the subframe and engine/alternator cradle structure.
power module from rolling when the subframe (Refer to Figure 2-5 and 2-7.)
rollers are installed.
FIGURE 2-6. SUBFRAME ROLLERS 6. Roll the power module forward sufficiently so
that adequate clearance is provided in front of
1. Roller Assembly 3. Capscrews electrical cabinet for the lifting device to be
2. Subframe attached to the engine/alternator cradle struc-
ture (2, Figure 2-5) and front subframe lifting
points (9). Place stands or block under front of
subframe and lower hoist until front of subframe
is supported. Install safety chain to prevent sub-
4. Locate a jack under the rear of the power mod-
frame from rolling.
ule. Raise the rear portion of engine subframe
and install subframe rollers (Refer to Figure 2- 7. Attach lifting device (1, Figure 2-7) to hoist and
6). Lower the rear portion of the subframe care- attach to engine/alternator cradle structure and
fully until the rollers rest on the main frame front subframe lifting points as shown in Figure
guide rail. 2-7. Remove safety chain.
8. Raise the power module slightly to determine if
NOTE: Subframe rollers are supplied in the truck tool
module is on an even plane. Move the power
group and can be installed in the storage position
module straight out of truck to a clean work area
after use, as shown in Figure 2-6.
for disassembly.
5. Position hoist to front subframe lifting points (9,
Figure 2-5). Raise the engine subframe until the For further disassembly of the engine, alternator, and
engine is on a level plane. Remove the safety radiator, refer to the appropriate section of this man-
chain. ual.
COOLING SYSTEM
INDEX
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RADIATOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal - Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE/ALTERNATOR MATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Measuring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Determining Shims:
Compare “Measurement C” (Step 3.c.) with
“Measurement A” (Step 4.f.).
AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Precleaner Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Dust Cap 6. Wing Nut Gasket 10. Safety Filter Element 13. Clean Air Outlet
2. Dust Cap Gasket 7. Safety Element 11. Main Filter Element 14. Pre-Cleaner Gasket
3. Tube Indicator 12. Main Element Gasket 15. Safety Filter Element
4. Unfiltered Air Inlet 8. End Cover Gasket
5. Wing Nut
INDEX
NOTE: Electrical system wiring hookup and electrical schematics are located in Section “R” of this Manual.
DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNING AND CONTINUE
TO EXIST AFTER SHUTDOWN IF THE REQUIRED SHUTDOWN PROCEDURES ARE NOT FOL-
LOWED. Before attempting repairs or working near propulsion system components, the following
precautions and truck shutdown procedure must be followed:
•DO NOT step on or use any power cable as a handhold when the engine is running.
•Never open any electrical cabinet covers or touch the retarding grid elements. Additional pro-
cedures are required before it is safe to do so. Refer to Section E for additional propulsion
system safety checks to be performed by a technician trained to service the system.
•ALL removal, repairs and installation of propulsion system electrical components, cables etc.
must be performed by an electrical maintenance technician properly trained to service the
system.
•In the event of a propulsion system malfunction, a qualified technician should inspect the
truck and verify the propulsion system does not have dangerous voltage levels present
before repairs are started.
•Prior to welding on the truck, maintenance personnel should attempt to notify the Komatsu
Factory Representative. The welding ground electrode should be attached as close as possi-
ble to the area to be welded. Never weld on the rear of the electrical control cabinet or the
retard grid exhaust air louvers.
After the truck is parked in position for the repairs, the truck must be shut down properly to ensure the
safety of those working in the areas of the deck, electrical cabinet, traction motors, and retarding grids. The
following procedures will ensure the electrical system is properly discharged before repairs are started.
AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR AND ITS
CIRCUITS TO DE-ENERGIZE.
Do not attempt to perform auxiliary blower motor or blower electrical circuit repairs until it has
been verified the system is de-energized.
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting
Two most common troubles that occur in the charg-
Lead-acid storage batteries contain sulfuric acid,
ing system are undercharging and overcharging of
which if handled improperly may cause serious
the truck's batteries.
burns on skin or other serious injuries to person-
nel. Wear protective gloves, aprons and eye pro- An undercharged battery is incapable of providing
tection when handling and servicing lead-acid sufficient power to the truck's electrical system.
storage batteries. See the precautions in Section
Some possible causes for an undercharged battery
A of this manual to insure proper handling of bat-
are:
teries and accidents involving sulfuric acid.
Sulfated battery plates
During operation, the storage batteries function as an Loose or corroded battery connections
electrochemical device for converting chemical Defective wire in electrical system
energy into the electrical energy required for operat-
ing the accessories when the engine is shut down. Loose alternator drive belt
A defective alternator
Overcharging, which causes overheating, is first indi-
BATTERIES cated by excessive use of water. If allowed to con-
tinue, cell covers will push up at the positive ends
Maintenance and Service and in extreme cases the battery container will
The electrolyte level of each cell should be checked become distorted and cracked.
at the interval specified in Lubrication and Service, Leakage can be detected by continual wetness of the
Section P, and water added if necessary. The proper battery or excessive corrosion of the terminals, bat-
level to maintain is 3/8 - 1/2 in. (10-13 mm) above the tery carrier and surrounding area. (A slight amount of
plates. To insure maximum battery life, use only dis- corrosion is normal in lead-acid batteries). Inspect
tilled water or water recommended by the battery the case, covers and sealing compound for holes,
manufacturer. After adding water in freezing weather, cracks or other signs of leakage. Check battery hold
operate the engine for at least 30 minutes to thor- down connections to make sure the tension is not
oughly mix the electrolyte. great enough to crack the battery, or loose enough to
allow vibration to open the seams. A leaking battery
should be replaced.
24VDC Battery Charging Alternator The battery control box (4) is located near the right
corner of the front bumper. This box contains the
Refer to Section N, Operator Comfort for informa- battery disconnect switches and other components
tion regarding the truck battery charging alternator. listed below.
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant Level/Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Temperature Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Relay Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Body Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Minute Idle Contactor The AID system enables the indicating lights to be
flashing or constant. The AID also has the capability
The contactor (7) energizes the idle timer and main- of operating an audible alarm along with the light.
tains current flow to the engine "run" circuit if the The eight printed circuit cards are (refer to Figure 3-
operator turns the key switch off. 2):
5 Minute Idle Circuit Test • Diode Matrix (With Sound) Card (Slot 1)
Check 5 minute idle timer circuits as follows: • Diode Matrix (Without Sound) Card (Slot 2)
1. With the key switch ON, press the engine shut- • Hot Switch Inverter Card (Slot 3)
down switch firmly to the momentary position • Hot Switch Inverter Card (Slot 4) (Not Used)
and release (switch will return to the ON posi-
• Temperature Card (Slot 5) (Optional)
tion).
2. Turn the key switch OFF and verify the follow- • Oil Level Card (Slot 6) (Optional)
ing: • Temperature and Latch Card (Slot 7)
Circuit 712 (to ground) remains 24 volts for • Coolant Level and Flasher Card (Slot 8)
approximately 5 minutes. After 5 minutes, the
voltage drops to 0. NOTE: Each card is identified with a number which
corresponds with a mating number on the housing. If
The 5 minute idle indicator lamp on the cards are removed, make sure card numbers
overhead display is on when circuit 712 reads correspond with housing numbers during installation
24 volts.
(See Figure 3-2).
3. Repeat step 1. While monitoring voltage at cir-
cuit 712, turn the key switch OFF. Turn the The following briefly describes each card and its
engine shutdown switch OFF. function. Refer to Section R for circuit components
described below.
Verify voltage at circuit 712 drops to 0 when
the shutdown switch is turned to OFF.
Coolant Level/Flasher
Inclinometer The coolant level and flasher card contains two sepa-
rate circuits. The flasher circuit at the top of the card
The inclinometer is used by the on-board load weigh- has Q12 transistor biased to be saturated when no
ing system to determine whether the truck is on a malfunction is present, resulting in there being 24 volt
level surface or tilted fore or aft. The information pro- positive output on pin "H" of the card and on wire
vided by the inclinometer is sent to the weighing sys- 12F. When a indicating circuit is activated, the ground
tem for use in calculating the payload. Refer to side of the circuit connected to card pin "K" is
Section M, Payload Meter, for detailed information on grounded. Q12 will turn off initially and then after a
the inclinometer and the on-board weighing system. delay, adjusted by R20, will turn on and off to give the
intermittent 24 volt output.
Oil Level Card The diode matrix with sound card works very much
like the other diode matrix card, except that it con-
The oil level card (optional) is used to turn on the low tains extra diodes to activate the alarm horn in addi-
oil level indicator light to warn the operator engine oil/ tion to the flasher. The circuits connected to terminals
hydraulic tank oil level is below acceptable levels. A1 through A8 operate in the same manner.
The oil float is connected to a variable resistor. As the
oil level decreases, the resistance goes down caus-
ing Q3 to turn on, grounding the indicator light and
Lamp Test Switch
alarm horn.
All of the card circuits are connected to the lamp test
switch on the overhead display area. In normal oper-
Temperature Card ation, these circuits are open and not functional.
When the operator pushes the lamp test switch, it
The temperature card (optional) is used to turn on activates all the indicator circuits by grounding them.
the high oil temperature indicator light. The indicator This is used to verify that all lamps are functional.
light tells the operator hydraulic tank oil temperature
has exceeded acceptable levels. Normal tempera-
ture setting is 250°F (121°C). As the temperature
goes up the resistance in the probe decreases pro-
viding a ground path for the indicator light and alarm
horn.
1. Relay Board
2. Main Harness Connector
3. Screw
4. Circuit Breaker
5. Circuit Panel Card
6. Screw
7. Breaker Open Light (Red)
8. Bleed Down Light (Green) (Relay
Board 4 Only)
9. K1, K2, K3, K4 Lights (Green)
10. Screw
11. Relay
12. Circuit Harness Connector
13. Circuit Harness Connector
>K4 light will be flashing when the turn signals or 1- steering pressure bleed down timer module card.
hazard lights are in operation. 1 - bleed down light (green): This light is on when the
NOTE: If circuit breakers (CB13 & CB15) are in the bleeddown solenoid is being energized. The bleed-
OFF position, no warning will be noticed until the down timer will energize the solenoid for 90 seconds
clearance light switch is turned ON. after key switch is turned OFF.
3 - 15 amp circuit breakers (CB13, CB14, CB15) 1 - 15 amp circuit breaker (CB21)
4 - relays 4 - relays
• right turn/clear light relay (K1) • park brake failure relay (K1)
• left turn/clear light relay (K2) • engine cranking oil pressure interlock relay (K2)
1 - payload stored light (Green): This light is on for 1 - lights control light (green): This light is on when 24
one second when the payload meter actually stores volts is being supplied to the battery terminal of the
the load data into memory. light switch.
1 - 5 amp circuit breaker (CB29) (To payload meter) 5 - 15 amp circuit breakers
1 - 15 amp circuit breaker (CB28) (To payload lights (CB23, CB24, CB25, CB26, CB27)
& relays) 4 - relays
4 - relays • left low beam relay (K1)
• light relay 1 (Green) (K1) • right low beam relay (K2)
• light relay 2 (Amber) (K2) • left high beam relay (K3)
• light relay 3 (Red) (K3) • right high beam relay (K4)
• light control relay (K4) Relay Board 6 & 7 (RB6, RB7)
Relay boards 6 & 7 (Figure 3-7) do not contain circuit
Relay Board 3 (RB3) breakers or modular cards. Additional circuits may be
added by utilizing a spare relay socket.
1 - light module display card
The following relays are installed on RB6:
Operation
When the hoist cylinders approach maximum stroke,
and the body pivots on the pins, actuator arm (3)
moves close enough to the magnetically operated
switch to close the electrical contacts. When the con-
tacts close, an electrical signal is sent to the hoist-up
limit solenoid valve (located in the hydraulic compo-
nents cabinet) to prevent further oil flow to the hoist
cylinders.
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch assem-
bly.
Adjustment
With body raised and hoist cylinders within 6 in. (152
mm) of maximum travel, make the following adjust-
ment.
1. Adjust limit switch to achieve an air gap (dimen-
sion "A") of 0.50 to 0.56 in. (12.70 to 14.30 mm)
between sensing area and actuator arm (3).
Retighten capscrews.
Keep sensing area clean, free of metallic dust and 1. Body 4. Switch Mounting
other debris that may damage or inhibit operation of 2. Frame Plate
the limit switch. If the switch is not functioning or 3. Actuator Arm 5. Hoist Limit Switch
damaged the unit must be replaced.
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Go To Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ALTERNATOR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ALTERNATOR DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ALTERNATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ON-VEHICLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preliminary Checks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ON-VEHICLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bypass Test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Regulator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ALTERNATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ASSEMBLY- ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Troubleshooting
2. Open battery disconnect switch. Remove bat- HIGH NORMAL Watch until amps decrease or
voltage exceeds 28.8 volts. If
tery cable from alternator B+ terminal. amps decrease and volts remain
Refer to Figure 10-2 for the following steps. Meters normal, system is OK. If voltage
exceeds 28.9 volts, regulator and/
should be installed directly at the alternator as shown or alternator defective. Go to
to eliminate variations in readings due to cable Static Test.
lengths etc.:
HIGH HIGH STOP TEST! Regulator and/or
3. Install the ammeter (negative lead) to the bat- alternator defective. Go to Static
tery positive cable removed in step 2. Install the Test.
ammeter positive lead to the alternator B+ ter- LOW LOW 1. Recheck voltmeter leads. If
minal. connections are OK, alternator
and/or regulator defective.
4. Install a voltmeter between the alternator B+
2. Perform Regulator Bypass Test
terminal (positive lead) and the ground terminal per instructions on following page:
(voltmeter negative lead). a. If volts and/or amps
5. Secure all test equipment leads to prevent dam- increase, alternator is OK but reg-
ulator is defective.
age or short circuits when engine is started.
b. If no effect, replace alternator
Reconnect battery disconnect switch.
LOW NORMAL Charging system is OK.
LOW HIGH STOP TEST! If battery and volt-
meter check is OK, regulator and/
or alternator defective.
DEFINITIONS
NOTE: Charge voltage and amp rates vary from B+ voltage is battery positive voltage, but does
battery type to battery type, based on battery not refer to a specific value as does battery volt-
construction technology and physical size of battery. age.
Low amps are the necessary amps that a bat- Surface charge is a higher than normal terminal
tery will take continuously over a period of time voltage a battery has when it comes off a
without damage to the battery when the battery charger or after extended time in vehicle opera-
is in an operating system and is constantly tion. The surface charge must be removed to
cycling. Batteries such as the Group-8D may determine true battery voltage.
accept rates up to 15 amps over several hours
without raising their internal temperature more
than a few degrees. Group-31 batteries may
accept rates up to 5 amps over several hours
with minimal temperature rise.
Remove strap between "R" and "E" terminal. NOTE: Alternator may not be turned on when engine
is operating. Go to "R" terminal test next, to prove if
Connect a 12 gauge jumper wire from the "B+" termi- vehicle "E" circuit will turn alternator on.
nal on alternator to the "E" terminal on alternator.
Vehicle Charging Circuit Test Is Now Complete: • If meter shows battery voltage, circuit is good.
Continue test.
Remove all jumper wires from alternator used to test
Insert "+" probe of voltmeter into "B" pin in connector.
charging circuit.
Insert negative probe of voltmeter into "B-" pin in
connector. (This is power circuit for voltage regula-
tor.)
Re-test Charging Circuit For Operation With The
Engine Running: • If circuit shows open (no voltage), alternator is
defective. Replace alternator.
Check charging system voltage with engine running.
• If circuit shows B+ voltage, regulator is
If no charge voltage, test for voltage at "E" defective. Replace the regulator, only.
terminal of alternator, with engine running.
NOTE: Turn key and battery switch OFF before
If no voltage on "E" terminal, shut engine installing new regulator. Turn battery switch and key
down and inspect link from "R" terminal to back on AFTER installing new regulator. Continue
"E". test.
Run engine and re-test charging circuit.
ALTERNATOR DIMENSIONS
1. Mounting Bolt - 1/2 UNC 6. Fan Nut; 50 ft.lbs. (68 N.m) torque
2. Mounting Bolt - 12/50 Dia; 65 ft.lbs. (88 N.m) torque 7. Slip Bushing
3. Ground Bolt, 3/8 - 16; 11 ft.lbs. (15 N.m) torque 8. Allowable Mounting Bracket Dimensional Span
Either Side; R.H. side shown 9. F+ Stud (NOTE: F+ Stud Not On All Models)
4. Locknut (5/16 - 18 UNF-2B) & Washer (to secure Pulley)
NOTE: (1) NOT SERVICED SEPARATELY - SUPPLIED ONLY IN BF1986 KIT.NOTE: (2) NOT SOLD
SEPARATELY
Preliminary Checks:
1. Check Belt Tension. Use Belt Tension Gauge to
measure belt tension: Poly V Belt Adjustment
(20 lbs./strand): 240 lbs. maximum for 12
groove Poly V-belt.
2. Check Battery.Batteries must be in good condi-
tion and fully charged. If any battery condition is
marginal, it should be replaced with one known
to be in good condition.
For split battery pack, dual voltage systems,
battery rest voltages should agree within 0.3 V.
When "12V" battery voltage is more than 0.3 V
lower than "24V" battery voltage, check the
"12V" battery circuit to verify adequate charge.
Polarity of battery and alternator must agree;
FIGURE 10-5.
reverse polarity will damage the alternator. The
alternator is NEGATIVE ground.
1. Alternator 3. Ammeter
3. Check electrical connections in charging circuit. 2. Voltmeter 4. Battery
Make sure all connections are clean, tight, and
free of corrosion. Battery connections are espe- 7. Attach meters as indicated by Figure 10-5, be
cially important. sure to measure voltage and amperage at alter-
4. Check Energize circuit.If alternator is not charg- nator, not at batteries or intermediate point.
ing, check for voltage at the alternator energize If an in-line ammeter is used, disconnect battery
terminal. Refer to Figure 10-5 for energize ter- ground cable before connecting ammeter. Then
minal location on the outside of the control box. reconnect battery ground cable. Ammeter con-
Check for battery voltage at the "E" terminal nections must carry rated output of alternator.
with engine running.
Test Procedure
Test Set-up
8. Start engine. Accelerate to high idle.
5. Discharge Battery as Follows:
d.Disable fuel system.
e.Turn all lights and accessories "ON". Crank
the engine for 10 - 15 seconds to discharge
If voltmeter reading exceeds 32V for 24V system,
battery, then stop cranking engine.
stop engine immediately and refer to Table 10-3.
f. Turn all lights and accessories off.
9. Watch meter reading.If battery is sufficiently dis-
g.Enable fuel system. charged, amps should be high within ± 10% of
6. Determine setpoints of regulator. The setpoint output specified by performance curve (refer to
of the alternator is 28V. "Normal" range is within SPECIFICATIONS, alternator RPM = engine
±0.2V of setpoint. RPM x pulley ratio). Volts should be within or
below the "normal" range as battery
approaches full charge. Amps should fall as
Volts rise. When amps and volts stabilize, note
readings and refer to Table 10-3.
ON-VEHICLE TEST
Bypass Test:
Disconnect plug between alternator and regulator
and momentarily touch "F-" terminal from alternator
plug to ground.
FIGURE 10-7.
1. F+ Stud (some units have F+ Stud & Phase taps)
Refer to Figure 10-8 for location of control box termi- Check to make sure that all phase leads are discon-
nal strip connections. Refer to Figure 10-7 for loca- nected from the heat sink (refer to Figure 10-10).
tion of control box external connections to regulator
and ignition circuit.
Table 10-8:
CONTROL BOX CONTINUITY CHECKS
OHMETER TERMINAL CONTROL READING
SCALE STRIP BOX
CONNECTION EXTERNAL
CONNECTION
(Figure 10-5)
x 10K F- GND* (B-) VERY
HIGH
x1 F- (F-) PIN ZERO
x1 F+ (F+) ZERO FIGURE 10-10.
TERMINAL
*GND connections are made to ground terminal 1. Positive Diode Studs 2. “S” Phase Terminal
located on outside of front housing.
NOTE: Heat sink diodes are de-rated for heavy duty
With regulator disconnected, test for continuity from performance. If diode failure is detected, the entire
"E" terminal on control unit to connector Energize charging system should be examined for loose
("E") pin on regulator harness (See Figure 10-9). connections (especially battery). If diode failure is
indicated, stator failure must also be suspected.
Stator Tests
NOTE: The front stator related Phase leads are "P1",
"P2", & "P3"; The rear stator phase leads are "P4",
"P5", & "P6"
The Alternator has two separate assemblies that will
be checked individually. Make sure all phase leads
are disconnected from the heat sink (Refer to Figure
10-6).
Fan Removal
1. Remove fan guard.
2. Use a 3/4" socket wrench to loosen nut attach-
ing fan to alternator. Keep shaft from rotating by
holding the pulley in a vise, jaws padded with
brass or aluminum (Figure 10-11).
3. Remove nut and hardened washer.
4. Remove fan assembly from alternator.
FIGURE 10-12.
FIGURE 10-11.
Pulley Removal
1. Use a 15/16" socket wrench on the pulley nut.
Clamp the pulley in a vise, jaws padded with
brass or aluminum, and loosed pulley nut (Fig-
ure 10-13).
2. Remove pulley nut and hardened washer.
3. With a gear puller remove the pulley from the
shaft.
4. Remove woodruff key from shaft.
5. Remove pulley bushing from shaft.
FIGURE 10-13.
FIGURE 10-16.
1. Machine Screws
Alternate Method
Rear Rotor Removal 2b.Using an air hammer (air chisel) with a blunt
tipped tool, vibrate the area around the
1. Remove six flanged locknuts from core studs or rotor element to rotor core attaching studs.
six self tapping screws (1, Figure 10-15). Scribe The vibrations should loosen any built up
location of stud or screw holes on rotor face rust in that area. Remove the rotor ele-
plate. ment. If resistance is still felt, use the
method described in "2a.", plus the air
hammer.
FIGURE 10-21.
1. Jack Screws
FIGURE 10-20.
FIGURE 10-24.
FIGURE 10-25.
1. Field Coil Bobbin Ear
FIGURE 10-27.
FIGURE 10-26.
FIGURE 10-28.
1. Tool (BF4818)
FIGURE 10-32.
FIGURE 10-37.
1. Bearing Seal 4. Fan Guard Screws
2. Bearing 5. Fan Mounting
3. Ring Seal Groove Hardware
FIGURE 10-39.
FIGURE 10-41.
FIGURE 10-40.
FIGURE 10-42.
Stator Installation
(Refer to Figure 10-45)
Shell Assembly Preparation
The bore that is to receive the new stator should be
clean and free from burrs.
1. Position the bottom thrust plate in the work
area.
2. Place the pressure plate, threaded hub facing
down, on the bottom thrust plate. Align the
smooth bored hole in the pressure plate with
the keyed hole in the bottom thrust plate. Insert
the correct length locating rod through the pres-
sure plate and into the bottom thrust plate.
NOTE: The correct length locating rod is a rod that
has a hole that will allow the locating pin to pass
through both the locating rod and shell drain hole.
3. Place new stator on the stator indexing pins on
the bottom thrust plate.
NOTE: Proper placement of the stator is achieved
when the single stator lead aligns with a stator slot FIGURE 10-44.
next to the other stator's single lead. The finished
shell assembly will have a slot arrangement of two
1. Bottom Thrust Plate 5. Locating Rod (Long)
leads-space, two leads-space, two leads-space.
2. Stator Index Pins 6. Locating Pin
The front stator is placed on the stator indexing 3. Guide Pins 7. Locating Rod (Short)
pins with the leads pointing down. 4. Jack Screw 8. Pressure Plate
The rear stator is placed on stator indexing pins
with leads pointing up.
Position the stator leads so they will not be
damaged during stator installation.
INDEX
NOTE: Propulsion system electrical schematics are located in Section “R” of this manual.
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Input Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
STATE MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
State Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DC Link State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Self-load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
EVENT PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Event Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Power On Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Initiated Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Periodic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EVENT RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Data Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Event Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OUTPUT PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Fast Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
The TCI panel provides the following functions: ›› 17FB144 CPU Card: Provides high speed
RS422 serial communications to PSC and
• Communicates with the Propulsion System
RS232 serial communication with the PTU.
Controller (PSC) to exchange propulsion control
system status and control data and to provide the
›› 17FB160 Analog I/O Card: Provides RS232
PSC with truck systems status data.
serial communications with Diagnostic Informa-
• Communicates with the Diagnostic Information tion Display and an optional Modular Mining
Display (DID) to exchange PSC and/or TCI Dispatch System. Provides RS422 serial com-
diagnostic and parameter data. munication with the Auxiliary Blower Sys-
• Communicates with the Auxiliary Blower System tem.Receives signals for front wheel speed,
to exchange diagnostic data. motor cooling and barometric air pressures,
accelerator, retard speed setting, payload,
• Communicates with a Portable Test Unit (PTU) to
exchange TCI data. ambient and hydraulic oil temperature, and
engine cranking voltage. Outputs drive cab
• Communicates with a Modular Mining Dispatch mounted temperature gauges etc.
System to exchange truck status data.
• Monitors engine control system, payload ›› 17FB104 Digital I/O Card: Receives operator
information, ambient and propulsion system control, engine and body-up signals. Provides
temperature, operator control inputs etc. engine start controls, drives cab mounted indi-
cator/warning lamps, etc.
• Controls the engine start sequence.
*NOTE: The 17FL373 Panel does not contain the
• Provides signals to activate many of the cab
17FB127 card.
mounted warning lamps and gauges. Controls
the park brake solenoid.
• Processes front wheel speed signals for the PSC
and speedometer.
In addition, the DID panel can be used by to perform No Propel “NO PROPEL" (red) light illuminates.
• No propulsion allowed
the self-load test.
• Retarding allowed
• Link power allowed
Speed Limit “PROPEL SYSTEM CAUTION"
(amber) light illuminates.
• Propel, retard and DC link power
still allowed.
• Speed is limited to 10 MPH
(16 KPH)
INV1 Disable Prohibits system from enabling
inverter #1 drive signal.
INV2 Disable Prohibits system from enabling
inverter #2 drive signal.
Engspd/RP Raises engine speed to account for a
possible stuck RP contactor. Closes
RP1
None No restrictions. Event is for informa-
tion purposes only.
000 NO FAULT None Displayed when all faults have been reset.
002 GROUND FAULT No power A ground fault is detected if leakage current to ground
(truck chassis) exceeds 145 mA for more than 0.05 sec-
onds.
003 FAILED DIODE No power Shorted diodes in main rectifier.
004 GFCO OPEN and not in REST None GF Cutout Switch is open with the system not in REST.
005 DRIVE SYSTEM OVERTEMP Temperature exceeds a limit for a sufficient time.
:01 auxiliary phase control Temperature exceeds a limit for a sufficient time.
:02 auxiliary inverter Temperature exceeds a limit for a sufficient time.
:03 afse Temperature exceeds a limit for a sufficient time.
:04 alternator Temperature exceeds a limit for a sufficient time.
:05 left stator Temperature exceeds a limit for a sufficient time.
:06 left rotor Temperature exceeds a limit for a sufficient time.
No Propel
:07 right stator Temperature exceeds a limit for a sufficient time.
:08 right rotor Temperature exceeds a limit for a sufficient time.
:09 chopper GTO Temperature exceeds a limit for a sufficient time.
:10 chopper diode Temperature exceeds a limit for a sufficient time.
:11 left GTO module Temperature exceeds a limit for a sufficient time.
:12 left diode Temperature exceeds a limit for a sufficient time.
:13 right GTO module Temperature exceeds a limit for a sufficient time.
:14 right diode Temperature exceeds a limit for a sufficient time.
:15 rectifier diode Temperature exceeds a limit for a sufficient time.
006 BOTH INVERTERS COMMUNICATION FAILED No power Lost Communication with both inverters.
008 DC LINK OVERVOLTAGE DC link voltage exceeds limit for a sufficient time.
:01 not in retard Occurs while not in retard, exceeds propel voltage limit.
No power
:02 in retard Occurs while in retard, exceeds retard voltage limit.
:03 instantaneous Occurs instantaneously in propel or retard, exceeds link
voltage limit.
009 ALT FIELD OVERCURRENT Alternator field current exceeds limit.
No power
:01 normal Exceeds current limit over time.
:02 instantaneous Exceeds current limit with no persistence.
011 RETARD LEVER BAD Incorrect input from retard lever.
None
:01 voltage too high Incorrect input from retard lever.
:02 voltage too low Incorrect input from retard lever.
012 RETARD PEDAL BAD Incorrect input from retard pedal.
:01 voltage too high None Incorrect input from retard pedal.
:02 voltage too low Incorrect input from retard pedal.
013 LINKV TEST FAILED No power Incorrect link volts
014 ANALOG SENSOR FAULT Incorrect input from a sensor.
:01 alt field amps Incorrect input from a sensor.
:02 link amps Incorrect input from a sensor.
:03 load box amps Incorrect input from a sensor.
:04 3 phase alt volts Incorrect input from a sensor.
:05 alt field volts Incorrect input from a sensor.
:10 PSC link volts Incorrect input from a sensor.
Speed limit
:11 inv1 link volts Incorrect input from a sensor.
:12 inv2 link volts Incorrect input from a sensor.
:13 A2D ground Incorrect input from a sensor.
:14 A2D gain Incorrect input from a sensor.
:15 fault current Incorrect input from a sensor.
:16 ATOC Incorrect input from a sensor.
:21 blower 1 amps Incorrect input from a sensor.
:22 blower 2 amps Incorrect input from a sensor.
015 ANALOG SENSOR FAULT (resrtictive) Speed limit Incorrect input from a sensor.
:02 link amps Incorrect input from a sensor.
016 PSC CPU CARD (FB147) Problem has occurred in the system CPU card.
:01 task_1
:02 task_2
:03 task_3
:04 task_4
:05 task_5 No power
:06 task_6
:07 maintenance task
:09 BRAM CRC CRC on BRAM does not match expected value.
:10 flash CRC Flash CRC computation did not match expected value.
:11 excess timeouts On power up, excessive timeouts occurred.
:12 invalid pointers On power up, the status of data in BBRAM is invalid.
017 DIGITAL I/O CARD FAULT (FB104) No power System CPU cannot communicate with digital I/O card.
018 ANALOG I/O CARD FAULT (FB143) System CPU cannot communicate with analog I/O card.
No power
:01 analog card no response Card missing.
:02 analog card timeout Read timeout.
019 RIDING RETARD PEDAL None Brake pedal applied while truck speed is >5 mph
020 LO SPEED HI TORQUE TIMEOUT No propel Torque limit exceeded
021 TCI COMM. FAULT No propel No serial data received from TCI over period of time.
022 PERSISTENT TCI COMM FAULT No power No serial data received from TCI and truck is stopped for
10 seconds.
023 TERTIARY OVERCURRENT No propel Current in alternator field tertiary winding exceeds limit
over time.
024 PSC CONFIG FILE INCORRECT Incorrect PSC configuration file.
:01 no file No configuration file selected
:02 bad CRC No power
:03 wrong version Wrong configuration file version
:04 overspeeds incorrect Incorrect overspeed values
025 AUX INVERTER FAULT Auxiliary Blower System fault.
:01 not ok or no speed feedback Aux speed feedback indicates no or incorrect blower
No power
speed.
:02 numerous shutdowns Aux ok goes low twice when speed command is greater
than running speed.
103/203 (cont.)
:21 link V too hi Link voltage too positive
:22 infilV too hi Input filter voltage too positive
:23 DB chop VCO hi High freq. on VCO DB chopper channel
:24 DB chopV too hi DB chopper voltage too positive
:25 VA VCO hi High freq. on VCO VA channel
:26 VB VCO hi None High freq. on VCO VB channel
:27 VC VCO hi High freq. on VCO VC channel
:28 VA volts too hi VA voltage too positive
:29 VB volts too hi VB voltage too positive
:30 volt scale C flt Scale C volts out of range 70%, 120%
:31 VC volts too hi VC voltage too positive
104/204 FIBER OPTIC CARD
:01 fo ps low Fiber optic power supply monitor
INV1 (INV2) off
:02 fo card disable Fiber optic card disabled
:03 fo card enable Fiber optic card enabled and no dir
105/205 POWER SUPPLY CARD
:01 P5V not ok +5 volt not in tolerance
:02 P15V not ok INV1 (INV2) off +15 volt not in tolerance
:03 N15V not ok -15 volt not in tolerance
:06 P24V not ok +24 volt not in tolerance
:07 N24V not ok -24 volt not in tolerance
106/206 DC WIRING
INV1 (INV2) off
:01 DC pwr conn open DC power connection open
:02 link V phase V mismatch Link and phase voltage mismatch
107/207 GDPS FAILURE
:01 gate dr ps off No power to gate drive power supply or it failed
INV1 (INV2) off
:02 gate dr ps off S No power to gate drive power supply or it failed with
enable/DC volts
:03 multiple GTO not off S Multiple GTOs not off with enable/DC volts
109/209 LINK VOLTS SENSOR
:01 linkV sensor flt INV1 (INV2) off Link voltage sensor failed
111/211 INPUT VOLTS SENSOR
INV1 (INV2) off
:01 Vfil not ok Filter voltage outside limits
113/213 (cont.)
:29 C volt hi Adn Phase C volt too high while phase A down on
:30 C volt lo Aup Phase C volt too low while phase A up on
:31 C volt hi Bdn Phase C volt too high while phase B down on
:32 C volt lo Bup Phase C volt too low while phase B up on
:33 C volt hi Cdn Phase C volt too high while phase C down on
:34 C volt lo Cup Phase C volt too low while phase C up on
:35 Aup fault cur Phase A fault current when phase A up on
:36 Adn fault cur Phase A fault current when phase A down on
:37 Bup fault cur Phase B fault current when phase B up on
:38 Bdn fault cur Phase B fault current when phase B down on
:39 Cup fault cur Phase C fault current when phase C up on
INV1 (INV2) off
:40 Cdn fault cur Phase C fault current when phase C down on
:48 A volt hi off Phase A voltage high with all GTOs off
:49 A volt lo off Phase A voltage low with all GTOs off
:50 B volt hi off Phase B voltage high with all GTOs off
:51 B volt lo off Phase B voltage high with all GTOs off
:52 C volt hi off Phase C voltage high with all GTOs off
:53 C volt lo off Phase C voltage high with all GTOs off
:54 phase short pos Possible phase to DC+ short
:55 phase short neg Possible phase to DC- short
:60 linkV too hi PTL Link volts above PTL
:70 Aph neg I low Phase A negative current low (unbalance)
:71 Bph neg I low Phase B negative current low (unbalance)
113/213 (cont.)
:72 Cph neg I low Phase C negative current low (unbalance)
:73 Aph neg I hi Phase A negative current high (unbalance)
:74 Bph neg I hi Phase B negative current high (unbalance)
:75 Cph neg I hi Phase C negative current high (unbalance)
:76 Aph pos I low Phase A positive current low (unbalance)
INV1 (INV2) off
:77 Bph pos I low Phase B positive current low (unbalance)
:78 Cph pos I low Phase C positive current low (unbalance)
:79 Aph pos I hi Phase A positive current high (unbalance)
:80 Bph pos I hi Phase B positive current high (unbalance)
:81 Cph pos I hi Phase C positive current high (unbalance)
:82 no current w run No current while running
114/214 INVERTER, GENERAL (NR)
:22 IA VCO lo Low frequency on IA channel
:24 IB VCO lo Low frequency on IB channel
:26 linkV VCO lo Low frequency on VCO link filter V channel
:28 infilV VCO lo Low frequency on VCO in filter V channel
:38 LinkV too lo Link voltage too negative
:40 infilV too lo Input filter voltage too positive
None
:46 DB chop VCO lo Low frequency on VCO DB chopper channel
:48 DB chopV too lo DB chopper voltage too negative
:50 VA VCO lo Low frequency on VCO VA channel
:52 VB VCO lo Low frequency on VCO VB channel
:54 VC VCO lo Low frequency on VCO VC channel
:56 VA volts too lo VA voltage too negative
:58 VB volts too lo VB voltage too negative
:61 VC volts too lo VC voltage too negative
624 BODY UP AND PAYLOAD INDICATION Speed Limit Full payload and body up signal received at same time.
625 DUMP BODY UP WITH SPEED None Dump body raised while truck is moving.
626 LOAD BRAKE APPLIED WITH SPEED None
628 CONNECTED BATTERY VOLTS One of the connected batteries' volts incorrect with engine
speed above low idle.
:01 control battery low Control battery voltage below minimum limit
None
:02 control battery high Control battery voltage above maximum limit.
:03 crank battery low Cranking battery voltage below minimum limit.
:04 crank battery high Cranking battery voltage above maximum limit.
629 BAROMETRIC PRESSURE SIGNAL Barometric pressure signal outside operational limits.
:01 low None Voltage below minimum operational limit.
:02 high Voltage above maximum operational limit.
630 MOTOR BLOWER PRESSURE Motor inlet and outlet pressure signal outside operational
limits.
:01 no cooling air No voltage signal feedback
Speed Limit
:02 low Voltage feedback below minimum operational limit.
:03 high voltage Voltage above maximum operational limit.
:04 sensor reversed
631 AMBIENT TEMPERATURE Ambient temperature signal outside operational limits.
None
:02 high Voltage above maximum operational limit.
632 TCI CONFIGURATION DATA No propel Problem with TCI configuration file.
:01 no file No propel No configuration file loaded.
:02 bad CRC No propel
:03 version incorrect No propel Wrong version of file loaded.
633 BBRAM CORRUPTED None Battery backed RAM has failed.
634 TRUCK OVERLOADED - RESTRICTIVE Speed limit The over-payload signal is on, speed is reduced.
635 TRUCK OVERLOADED - NON-RESTRICTIVE None The over-payload signal is on, propulsion allowed.
636 AUX INVERTER None An Auxiliary Blower Control failure has occurred.
:01 buss volts low None Low dc bus detected during powerup.
:02 buss volts high None High dc bus detected during powerup.
:03 overcurrent None Overcurrent condition detected during operation.
:04 battery loss None Loss of blower control battery voltage has occured.
:05 high dc buss when running None High dc bus voltage detected during operation.
:06 high dc buss after pc powerup None High dc bus voltage detected after phase controller
powerup.
:07 Low dc buss after pc powerup None Low dc bus voltage detected after phase controller
powerup.
:08 high dc buss when running None High dc bus voltage detected during operation.
:09 overcurrent after pc powerup, current overload None Overcurrent condition detected after phase controller
power up.
:10 current overload None Sustained current overload exists.
:11 low dc buss overcurrent None Overcurrent due to low dc bus voltage.
:12 low dc buss current overload None Sustained current overload due to low dc bus voltage.
:13 gate drive trip None IGBT protection circuit detected overload.
:14 no input voltage None Zero input voltage detected.
638 ENGINE CRANKING TIMEOUT None
639 ENGINE START REQUEST WHILE RUNNING None
640 ACCEL PEDAL TOO HIGH No Propel Accelerator pedal voltage high
641 ACCEL PEDAL TOO LOW None Accelerator pedal voltage low
642 ENGINE STARTED USING OVERRIDE None
696 UNEXPECTED TCI CPU RESET None TCI CPU reset without request.
698 DATA STORE None A data snapshot has been manually initiated.
Ready State:
STATE MANAGEMENT Ready state is the default powered state. The system
will be in this state whenever the engine and control
State Machine system are ready to provide power, but none is
As part of the total software package, a particular requested.
group of regulatory software commands is included Ready state also is the state where the DC link is dis-
called a "state machine". The state machine controls charged in preparation for Shutdown, Rest, or in
the various functions of truck operation. reaction to certain event conditions. Therefore,
The software implements the state machine by keep- Ready state should not be considered strictly a pow-
ing track of which state the truck is in, and which ered state (as are Propel and Retard described
state the truck is allowed to move into if the operator below).
requests a different mode of operation. Each soft-
ware state is defined as follows:
Rest State:
Rest is an unpowered state whose purpose is to con-
Startup/Shutdown State: serve fuel while the truck idles for an extended period
The purpose of this state is to ensure the system is in of time. Rest state also provides an environment
a desired known state upon startup or shutdown. where maintenance personnel can control the engine
This is an unpowered state. without causing power to be applied to the DC link.
The system will transition from Rest state to Test 1. Overspeed is not active.
state upon release of the TCI rest request. 2. At least one of the following conditions is true:
NOTE: A transition directly from Rest state to Ready a. The retard pedal or lever is not pressed or is
state is not allowed because the system is essentially pressed such that an insignificant amount of
off and should be brought back on-line and checked retarding effort is requested.
out before Ready state is entered. b. Truck speed is such that retard is not
allowed.
Transition from Propel State to Ready State: 3. At least one of the following conditions exists:
The system will transition from Propel state to Ready a. Retard speed control is not selected.
state if all of the following conditions exist: b. Truck speed is low enough such that retard
1. The accel pedal is not pressed. speed control is not active.
2. The retard pedal or lever is not pressed or is c. The accel pedal is pressed, and the truck is
pressed such that an insignificant amount of configured such that the accel pedal over-
retarding effort is requested. rides retard speed control. This allows the
3. Truck speed is less than the motor overspeed configuration constant to determine if press-
limit. ing on the accel pedal kicks the truck out of
retard, even if retard speed control is still
4. At least one of the following conditions is true:
active.
a. Retard speed control is not selected.
4. The retard torque control logic exit sequence is
b. Truck speed is below the set retard speed, complete.
and acceleration is such that no retard effort
is (currently) required to maintain this condi-
tion.
The Auxiliary Blower Control regulates the tempera- Three power-on tests are executed once every time
tures of the AFSE, auxiliary blower system, rectifier power is applied to the PSC. They are as follows:
diodes, phase modules, chopper modules, and trac- 1. CPU Card Checks - Upon powerup, the PSC
tion motors by controlling the speed of the auxiliary will confirm the integrity of its CPU card hard-
blower. Additionally, this software function checks for ware before transferring execution control to
faults in the auxiliary blower. the application program residing in its FLASH
This software function is performed using the follow- memory.
ing process: 2. Battery-backed RAM (BBRAM) Test/Adjustable
Parameter Initialization - A battery backed RAM
1. The commanded auxiliary blower speed will be
(BBRAM) check will be performed to check for
calculated to control all system temperatures.
BBRAM data integrity. If the check fails, all TCI/
The control priorities will be:
PTU-adjustable parameters will be initialized to
a. Keep all temperatures below allowable maxi- their default values.
mums. 3. Inverter Powerup Tests - The purpose of these
b. Keep the GTO temperatures as constant as tests is to verify that each inverter sub-system is
possible. functional:
2. If the aux blower system status (AUXOK) indi- a. Enabling Inverter Powerup Tests - The pow-
cates the aux blower system is not okay, a reset erup tests for a given inverter will be enabled
pulse will be sent. Additional reset pulses will be if all of the following conditions are true:
sent at periodic intervals if the aux blower sys-
tem does not respond. 1.) The system is in Test state for the purpose
of powerup.
4. DC Link Capacitance Test - Test will run once NOTE. Limp Home mode is a state which is entered
every 24 hours when conditions allow, normally when the truck has suffered a failure and is not able
after a VI-test during normal powerup to continue normal operation but is still capable of
sequence. This test can also be run from the "limping" (getting either back to the maintenance
DID panel to aid in troubleshooting. During test area or at least out of the way of other trucks).
execution, engine speed is set to 1500 rpm and Event Restrictions associated with a given event are
the link is charged to 1200VDC. The engine is listed in Table I, page E2-5.
then returned to idle while the link is allowed to
discharge to 100 volts.Total link capacitance is
then calculated using the time it took to dis-
charge. If capacitance is getting low, but still
OK, event 70 logs. If capacitance is below the
EVENT LOGGING AND STORAGE
minimum allowable level, event 71 logs and the
truck is restricted to 10 MPH. If test is not able This software function is responsible for the record-
to complete after numerous attempts, event 72 ing of event information. There are two basic levels
logs, indicating a problem in the truck's ground of event storage: event history buffer and data packs.
detection circuit, and truck speed is limited to 10 The event history buffer provides a minimum set of
MPH. information for a large number of events, while data
packs provide extensive information for a limited
number of events.
The following requirements apply to both data packs
and the event history buffer:
The following Tables list component abbreviations The GE part number for major components is shown
used in schematics and system description informa- in parentheses. A short description of the compo-
tion. Refer to Figures 2-3 through 2-8 for the location nent's primary function is also listed.
on the truck of components listed in the "Ref. No."
column.
REF.
NO. COMPONENT FUNCTION
AFSE 36 Alternator Field Static Exciter Regulates current in the alternator field based on firing
Panel (17FM466) pulses from the PSC.
Alternator Field Voltage Divider Attenuates high voltage output from the AFSE to an
AFVLT 21 Panel (17FM363) acceptable level for use by the Analog I/O card in the
PSC.
ALT Alternator (5GTA34) Main alternator, propulsion and control system.
ANALOG I/O CARD System analog input/output card Provides signal conditioning for analog signals to and
(17FB143) from the TCI and PSC.
REF.
NO. COMPONENT FUNCTION
BATFU 19 System Fuse Provides overload protection for control equipment and
the System Batteries.
BATTSW Battery Disconnect Switch Connects and disconnects the 12 VDC and 24 VDC cir-
(System Batteries) cuit batteries (located at right front corner of truck).
BDI 68 Battery Blocking Diode Works in conjunction with BFC and BLFP to maintain
battery voltage to CPU.
BFC 67 Battery Line Filter Capacitor Additional capacitance for BLFP to prevent nuisance
CPU resets.
BLFP 10 Battery Line Filter Panel Reduces voltage ripples in System Battery power sup-
(17FM311) plied to the PSC.
BM1, 2 63 Grid Blower Motors 1 and 2 DC motors driving blowers to provide cooling air for the
(5GY19) retarding grids.
BM1I 65 Current Sensing Module Monitors current flowing through grid blower motor #1
BM2I 66 Current Sensing Module Monitors current flowing through grid blower motor #2
CCLR1, 2 20 Capacitor Charge Resistor Panels Connected across the DC link to provide a voltage atten-
1 and 2 uated sample of the DC link voltage to the Capacitor
Charge Indicating lights.
CCL1, 2 61 Capacitor Charge Indicating Lights Illuminated when 50 volts or more is present on the DC
1 and 2 link (the DC bus connecting the Alternator output, Chop-
per Module/Resistor Grid circuits and traction Inverters).
CIF11, 12, 13, 14, 40 Inverter 1 Filter Capacitors Stores the Inverter 1 DC bus voltage to provide instanta-
15, 16 neous power when the PM1 GTO Phase Modules first
turn on.
CIF, 21, 22, 23, 24, 41 Inverter 2 Filter Capacitors Stores the Inverter 2 DC bus voltage to provide instanta-
25, 26 neous power when the PM2 GTO Phase Modules first
turn on.
CLSW 59 Cabinet Light Switch Controls electrical cabinet interior lights.
CMAF 27 Alternator Field Current Sensing Detects amount of current flowing through the Alternator
Module field winding.
CMT 28 Alternator Tertiary Current Sensing Detects amount of current flowing through the Alternator
Module tertiary winding.
CM1, 2 5, 6 Chopper GTO Phase Module 1 and Controls the DC voltage applied to the grids during
2 (17FM630) retarding.
CM1A, 1B 45 Current Sensing Modules, Phase Detects amount of current flow through the A and B
1A and 1B phases of Traction Motor 1.
CM2A, 2B 44 Current Sensing Modules, Phase Detects amount of current flow through the A and B
2A and 2B phases of Traction Motor 2.
CPR 53 Control Power Relay (17LV66) Picks up when the Key Switch and Control Power Switch
are closed.
CPRD Dual Diode Module Allows two separate voltages to control the CPR coil.
CPRS Control Power Relay Suppression Suppresses voltage spike when CPR coil is de-ener-
Module gized.
REF.
NO. COMPONENT FUNCTION
Detects amount of current flow through the Alternator ter-
CT 34 Battery Boost Current Transformer tiary winding. Signal turns off the AFSE battery circuit
when the tertiary winding voltage level is able to excite
the Alternator field.
CTR CT Voltage Limiting Resistor Provides a resistive load for the CT.
GDFU1, 2 1 Gate Driver Power Source Fuse 1 Provide overload protection for the Gate Drive Power
and 2 Supply.
GDPC1 17 Gate Drive Power Converter 1 Converts 19 to 95 VDC from the Gate Drive Power Sup-
(17FM670) ply to 25 kHz, 100 VRMS, square wave power to drive
Inverter 1 GTO Phase and Chopper Modules.
GDPC2 16 Gate Drive Power Converter 2 Converts 19 to 95 VDC from the Gate Drive Power Sup-
(17FM670) ply to 25 kHz, 100 VRMS, square wave power to drive
Inverter 2 GTO Phase and Chopper Modules.
GDPS 18 Gate Drive Power Supply Provides a 19 to 95 VDC output, at approximately 3kW,
(17FM645) from one of two input power sources; either the main
Alternator or the System Batteries.
GF 49 Alternator Field Contactor Connects the AFSE to the Alternator field.
(17CM53)
GFCO 62 Generator Field Contactor Cutout Disables Alternator output.
Switch
GFIP 22 Ground Fault Current Panel Reduces Alternator field voltage input to provide a low
(17FM363) voltage signal for use by the PSC. Used to provide
ground fault warning.
GFM 8 Gate Firing Module (17FM415) Receives pulses from the Analog I/O card in the PSC,
amplifies the pulses, and then splits the pulses to drive
two SCR circuits in the AFSE.
REF.
NO. COMPONENT FUNCTION
GFR 52 Alternator Field Relay (17LV66) Picks up with GF contactor and applies B+ to the AFSE
(battery boost) during initial acceleration phase.
GFRS 50 Alternator Field Relay Coil Sup- Suppresses voltage spikes when GF coil is de-ener-
pression Module gized.
Inverter 1 Central Processing Unit Generates Phase Module turn-on/turn-off commands for
INV1 TMC CARD Card and Input/Output Card the Inverter 1.
Monitors voltages and currents from various areas for
(17FB172) Inverter 1. Monitors Traction Motor 1 speed.
Inverter 2 Central Processing Unit Generates Phase Module turn-on/turn-off commands for
INV2 TMC CARD Card and Input/Output Card the Inverter 2.
Monitors voltages and currents from various areas for
(17FB172) Inverter 2. Monitors Traction Motor 2 speed.
I1CO 57 Inverter 1 Cut Out Switch Cuts out inverter 1 when in the "cutout" position. Located
on switch/LED panel, left front corner of electrical cabi-
net.
I2CO 58 Inverter 2 Cut Out Switch Cuts out inverter 2 when in the "cutout" position. Located
on switch/LED panel, left front corner of electrical cabi-
net.
KEYSW Key Switch Connects battery voltage to CPR and control circuits
when closed. (Located on instrument panel.)
LDBXI 48 Load Box Current Sensing Module Monitors current during load box test.
LED's indicate status of the following:
CPR: Illuminated when CPR is energized.
SYS RUN: Illuminated when the PSC power-up
sequence has completed successfully and control logic
LEDP 60 Light Emitting Diode Panel is executing.
NAFLT: When illuminated, indicates a fault has occurred
that prevents propulsion or retarding.
TEST: Illuminated when system is in the Test state.
REST: Illuminated when system is in Rest state and
there is essentially no voltage on the DC link.
LINKI 7 Link Current Sensing Module Detects amount of current flow through the DC link.
LINKV 3 Link Voltage Measuring Module Attenuates the high voltage from the DC link to a level
(17FM458) acceptable to the electronics on the Analog I/O card in
the PSC.
L1, 2, 3 Cabinet Lights Provide interior cabinet illumination.
REF.
NO. COMPONENT FUNCTION
PSC 32 Propulsion System Controller The PSC is the main controller for the AC drive system.
(17FL320) All propulsion and retarding functions are controlled by
the PSC based on internally stored software instructions.
PM1A+, 1B+, 1C+ 13 GTO Phase Modules (17FM628) Provide positive driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 1.
PM1A-, 1B-, 1C- 12 GTO Phase Modules (17FM629) Provide negative driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 1.
PM2A+, 2B+, 2C+ 15 GTO Phase Modules (17FM628) Provide positive driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 2.
PM2A-, 2B-, 2C- 14 GTO Phase Modules (17FM629) Provide negative driving voltages (PWM or square wave,
depending on truck speed) for each of the three windings
of Traction Motor 2.
RD 2 Rectifier Diode Panel (17FM528) Converts Alternator 3-phase, AC voltage to DC voltage
to power the two Inverters.
RG1A, 1B, 1C, 2A,
2B, 2C, 3A, 3B, 3C, 64 Retard Grid Resistors Dissipate power from the DC link during retarding, load
box testing, and Inverter Filter Capacitor discharge oper-
4A, 4B, 4C, 5A, 5B, ations.
5C
When closed, connects Grid Resistors to the DC link dur-
RP1, 2, 3 47 Retard Contactors 1, 2 and 3 ing retarding, load box testing, and Inverter Filter dis-
charge operations.
(17CM55) Note: Some trucks do not have RP3 installed.
RP1S, 2S, 3S 55 Suppression Modules Suppresses voltage spikes in coil circuit when RP con-
tactors are de-energized.
RSN1, 2 Snubber Resistors Provide a current path for the associated Chopper Mod-
ule filter capacitors.
RS1A, 1B, 1C, 2A, Snubber Resistors Provide a current path for the associated Phase Module
2B, 2C filter capacitors.
R1 51 Battery Boost Resistor Limits surge current in the Alternator field circuit when
GFR contacts first close.
AUX SNUB 25 Snubber Suppresses voltage spikes in Aux Blower Motor circuit.
REF.
NO. COMPONENT FUNCTION
TCI Truck Control Interface Provides the main interface between the various truck
(17FL349 or 17FL373) systems, controls, and equipment and is used in con-
junction with the DID by maintenance personnel.
TH1 54 Alternator Field Thyrite (Varistor) Discharges the Alternator field when the AFSE is first
turned off.
VAM1 46 Voltage Attenuation Module Attenuates the three high voltage outputs applied to each
(17FM702) phase winding of Traction Motor 1 to a level acceptable
for use by the Analog I/O card in the PSC.
VAM2 46 Voltage Attenuation Module Attenuates the three high voltage outputs applied to each
(17FM702) phase winding of Traction Motor 2 to a level acceptable
for use by the Analog I/O card in the PSC.
SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TCI PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PSC PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INVERTER PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TCI CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Miscellaneous Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A3PV Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
LINKV Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
LOAD TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Preload Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
IGBT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DANGEROUS VOLTAGE LEVELS ARE PRESENT • If weld repairs are required, the welding
WHEN THE ENGINE IS RUNNING AND CONTINUE ground electrode should be attached as close
TO EXIST AFTER SHUTDOWN IF THE REQUIRED as possible to the area to be welded. NEVER
SHUTDOWN PROCEDURES ARE NOT FOLLOWED. weld on the rear of the Electrical Control Cabi-
Before attempting repairs or working near propul- net or the retard grid exhaust air louvers.
sion system components, the following precau- Power cables and wiring harnesses should be
tions and truck shutdown procedure must be protected from weld spatter and heat.
followed:
• Prior to welding, disconnect Engine Control
• DO NOT step on or use any power cable as a System (ECS) harnesses and ground wire
handhold when the engine is running. (MTU engine). If equipped with DDEC or
Komatsu engine, disconnect ECM harnesses.
• NEVER open any electrical cabinet covers or GE cards should be pulled forward far enough
touch the Retarding Grid elements until all to disconnect card from backplane connector.
shutdown procedures have been completed.
• Some power cable panels throughout the
• ALL removal, repairs and installation of pro- truck are made of aluminum or stainless steel.
pulsion system electrical components, cables They must be repaired with the same material
etc. must be performed by an electrical main- or the power cables may be damaged.
tenance technician properly trained to service
the system.
APPROX.
CIRCUIT LOCATION NOTES
VALUE
11B1 * ∞ * Measure at the 12VDC insulator in the Electrical Interface Cabinet
*Measure at the 24VDC insulator in the Electrical Interface Cabinet.
11 * ∞
All devices listed for 11A circuit reading must be OFF.
15V TB21 ∞
71GE TB22 120Ω
71TCI TB23 120Ω 17FL349 Panel Only (Not applicable on 17FL373 Panel.)
439 TB25 ∞
10V TB28 ∞
11SL TB28 ∞ Engine service lights turned OFF.
11ST TB28 ∞
15PV TB29 ∞
11S TB30 ∞ Ground level engine shutdown switch open
The following must be turned OFF:
Brake cabinet service light, operator cab light, passenger seat com-
11A TB30 ∞ partment service light, hazard lights, headlights, ground level engine
shutdown switch, engine governor heater switch (MTU 396 only - in
Electrical Interface Cabinet), left and right side engine service lights.
Engine governor heater switch in Electrical Interface Cabinet open.
11T TB30 >36Ω
(MTU 396 engine only)
11FR TB30 ∞ (MTU 396 engine only)
11HTR TB30 ∞ (MTU 396 engine only)
712 TB32 ∞ The Electrical Interface Cabinet service lights must be switched OFF.
71 TB32 ∞
11L CB30 ∞ Measure at circuit breaker CB30 in cab.
12M ∗ >10Ω *Measure at AID Module terminal B-13 under passenger seat in cab.
12F ∗ >200Ω *Measure at AID Module terminal B-12 under passenger seat in cab.
BE SURE TO VERIFY LINK VOLTAGE IS DIS- BE SURE TO VERIFY LINK VOLTAGE IS DIS-
CHARGED BEFORE PERFORMING THE FOLLOW- CHARGED BEFORE PERFORMING THE FOLLOW-
ING PROCEDURES. ING PROCEDURES.
1. Disconnect Circuits 21SS and 21SR, and insulate 1. Disconnect Circuits 21SS and 21SR and insulate
from engine starter if equipped with MTU 396 from engine starter if equipped with MTU 396
engine. If MTU/DDC 16V4000 or Komatsu engine engine. If MTU/DDC 16V4000 or Komatsu engine
is installed, disconnect and insulate 21B circuits is installed, disconnect and insulate circuit 21B at
at starter solenoids. Apply park brake and brake the starter solenoids. Apply park brake and brake
lock. lock.
a. Connect the serial communication cable from a. Connect the serial communication cable from
the PTU to the TCI port located behind the the PTU to the PSC port located behind the
center console in the cab on the passenger center console in the cab on the operator’s
side. side.
b. Be certain the Rest Switch in the cab is in the b. Be certain the Rest Switch in the cab is in the
REST position. REST position.
2. Turn the key switch ON. 2. Turn the Key Switch ON.
To program the 17FB144 CPU card: To program the 17FB147 CPU card:
Highlight “PROGRAM TCI PANEL” {enter} Highlight “PROGRAM PSC PANEL” {enter}
Cursor to the appropriate configuration file for Cursor to the appropriate configuration file for
the truck being programmed from the list of con- the truck being programmed from the list of con-
figuration files {enter} figuration files {enter}
3. Cycle keyswitch or CPS when requested on 3. Cycle keyswitch or CPS when requested on
screen. screen.
4. Verify the Object Code and Configuration file 4. verify the Object Code and Configuration file
shown on the screen for downloading is correct. shown on the screen for downloading is correct.
BE SURE TO VERIFY LINK VOLTAGE IS DIS- BE SURE TO VERIFY LINK VOLTAGE IS DIS-
CHARGED AND ENGINE IS NOT RUNNING CHARGED BEFORE PERFORMING THE FOLLOW-
BEFORE PERFORMING THE FOLLOWING PROCE- ING PROCEDURES.
DURES.
1. Disconnect Circuits 21SS and 21SR, and insulate
1. Open the right door on the Electrical Control Cab- from engine starter if equipped with MTU 396
inet and connect the serial communication cable engine. If MTU/DDC 16V4000 or Komatsu engine
from the PTU to one of the two ports located to is installed, disconnect and insulate 21B circuits
the right of the PSC Panel. (RS11 is used for the at starter solenoids. Apply park brake and brake
inverter card in slot No. 09, RS12 is used for the lock.
inverter card in slot No. 11.)
Log on to the TCI panel:
To program the Inverters:
2. Connect the serial communication cable from the
PTU to the TCI port located behind the center
c:\>ACNMENU {enter}
console in the cab on the passenger seat side.
Highlight “PROGRAM INVERTERS” {enter} Turn control power ON.
Cursor to “TCI Real Time Data” {enter} Verify the PTU is communicating on this screen
by observing a blinking cursor on the screen.
Verify PTU display indicates:
• COMMLINK=OK {escape} {escape}
{escape} {escape}
Notes: Only 4 command numbers are supported
On the PSC PTU: through this port.
When the PTU starts, it sends out 3 or 4 commands
Move the cursor to “Normal Operation” {enter} that the TCI will not respond correctly to. At the top TCI
screen, press the space key a number of times when
Cursor to “PSC Real Time Data” {enter} the screen indicates a mismatch until reaching the Real
Time Data screen.
Verify PTU display indicates:
• COMMLINK=OK
{escape} {escape}
1. Verify analog values and functions highlighted on the PTU are similar to the examples below:
Note: Actual values shown in illustrations will vary from those displayed on truck being serviced:
2. Press {enter} to display “TCI SERIAL LINK DATA” screen shown below:
LOCATION
STEP DO NAME DESCRIPTION
(Fig. 3-3)
1 RESTLT Rest Light B6
2 PSCNOTRDY Propel System Not Ready Light C6
3 REDUCELT Reduced Propulsion Level Light D6
4 LINKONLT Link ON light, DID Panel (Behind Operator's Seat)
5 TEMPWARNLT Propulsion System Temperature Warning Light C5
6 NORETARDLT No Retard, No Propel Light A5
7 NOPROPELLT No Propel Light A6
8 PSCWARNLT PSC Warning Light B5
9 RTRDCONTLT Reduced Retarding Light E6
10 HYDBHOTLT Hydraulic Brake Fluid Hot Light D5
Verify park brake switch is applied:
11 PKBRKON Measure Circuit 52CS @ TB26 to ground: Verify 0.0 volts A3
Press {enter} to turn PKBRKON on: Verify approx. 24 volts
12 RETARDLT Retard Light (on overhead display) D3
13 RETARDXLT Retard light (on top of cab and rear of truck)
Battery Separate Relay
14 BATSEPC Measure Circuit 21BSR @ TB28 to ground
With BATSEPC highlighted, press {enter}: Verify 0.0 VDC
15 SPEED1 not used
16 SPEED2 not used
17 REVERSELT Activates backup horn and backup lights B4
Refer to TCI Digital Output Test procedure step 5. before performing the following test:
18 ENGCRANK Engine Crank Signal
13. Release the key switch. B2* Autolube Low Pressure Amber
C2* Circuit Breaker Tripped Amber
14. Apply parking brake.
D2* Hydraulic Oil Filter Restricted Amber
E2* Low Fuel Amber
A3* Park Brake Applied Amber
AUX ERROR CODE Check:
B3* Service Brake Applied Amber
1. With the PTU still on the TCI Real Time Data C3* Body Up Amber
screen, check the AUX_ERROR_CODE at the
D3* Dynamic Retarding Applied Amber
upper right of the screen:
E3 STOP ENGINE Red
Value should be blank or (001)
A4* Spare
Note: A Value of (-01) may indicate the TCI is not B4* Manual Back-Up Lights Amber
communicating with the aux inverter.
C4* 5 Minute Shutdown Timer Amber
D4* Retard Speed Control Amber
E4* CHECK ENGINE Amber
A5 No Propel/Retard Red
B5 Propulsion System Caution Amber
C5 Propulsion System Temp. Caution Amber
D5 High Brake/Hydraulic Oil Temp. Red
E5* STOP ENGINE (Komatsu engine only) Red
A6 No Propel Red
B6 Propulsion System at Rest Amber
C6 Propulsion System Not Ready Amber
D6 Propel System at Reduced Level Amber
E6 Retard System at Reduced Level Amber
8. Press {enter}. Verify PTU screen values are similar to Figure 3-6.
10. Press {enter}. Verify the values on the PTU are similar to Figure 3-8 below:
Cursor to “Engine Stopped Tasks” {enter} Cursor to “Engine Stopped Tasks” {enter}
Cursor to “Manual Test Mode” {enter} Cursor to “Manual Test Mode” {enter}
Highlight GD1E on the digital output section and Highlight GD2E on the digital output section and
press {enter}. press {enter}.
When performing the following procedures, never When performing the following procedures, never
look directly into the fiber optic light. Eye damage look directly into the fiber optic light. Eye damage
could result. could result.
18. Carefully remove the grey plug on the top of each 26. Carefully remove the grey plug on the top of each
Phase Module for Inverter 1. Phase Module for Inverter 2.
Without looking directly into the plug on each Without looking directly into the plug on each
Phase Module, verify that a red light is Phase Module, verify that a red light is
present. present.
19. Carefully remove the grey plug on the top of 27. Carefully remove the grey plug on the top of
Chopper Module 1. Chopper Module 2.
Without looking directly into the plug on Chop- Without looking directly into the plug on Chop-
per Module One, verify that a red light is per Module 2, verify that a red light is present.
present. 28. Reconnect plug on each Phase Module 2 for
20. For step 15 (GD2E) in the PSC Digital Output Test inverter 2 and Chopper Module 2.
Table, use an AC voltmeter to check for 90 to 100
volts AC between the pins on each round connec-
tor removed in step 3 (cable side) to Inverter 2
(bottom row).
21. Use an AC voltmeter to check for 90 to 100 volts
AC between the pins on the round connector on
the top of Chopper Module 2 (CM2 G-X) removed
in step 3.
Cursor to “PSC Real Time Data Screen” {enter} Verify AUXIT is showing ambient temperature
Verify AFSET is showing ambient tempera-
Verify A3PV is approximately 1.17 X battery
ture
volts
8. Remove the jumper wires.
9. Reconnect the wires to terminals A and C.
17FM384 Panel Check
1. With the PTU connected to the PSC;
Type in: 25 {enter} Record the accel pedal voltage with pedal
released (typical value; 1.61)
Adjust speedometer internal adjustment pot
Record the accel pedal voltage with pedal
to obtain 25 mph (or 40 km/h).
fully depressed (typical value; 8.53)
Type in: 40
G: Retard Speed Pot Setting:
Verify speedometer in cab reads 40 mph (or
11. Pull the retard speed control button UP.
64 km/h).
Record value of RSC POT with knob fully
9. Press {escape} to return to Engine Stopped Menu counterclockwise (typical value; 10.75)
screen.
Record value of RSC POT with knob fully
Cursor to Exit {enter} clockwise (typical value; 0.01)
Press {enter} to go to TCI Analog Input Chan- On TCI Communication Menu, cursor to Exit
nels screen {enter} {enter} to return to Main Menu.
From the Main Menu, highlight “DOWNLOAD 7. With Retard Speed Control knob pulled up and
PSC PANEL” {enter} the knob turned fully clockwise, verify the follow-
ing is displayed:
Highlight “SELECT PSC SETUP” {enter} RSCMPH = 37 (see note below)
Cursor to configuration desired {enter} Note: In step 7, truck configurations 07E and 13E will
indicate 31 (instead of 37) for 38.1 gear ratio.
Highlight “DOWNLOAD PSC PANEL” {enter}
3. Place the Rest Switch in the REST position. 4. Connect one serial communication cable from the
PTU to the PSC port.
4. Make sure the wheels are chocked, and the park
brake switch is ON. C:\>ACNMENU {enter}
5. Remove the locking bar from the right side of the Highlight “PTU TCI & PSC” {enter}
auxiliary blower behind the inspection cover.
Type your name {enter}
6. Install locks on the three front doors of the electri-
Type your password {enter}
cal cabinet. Also secure the 3 top covers.
Cursor to “Normal Operation” {enter}
Preload Checks
Cursor to “PSC Real Time Data” {enter}
Alternator Speed Sensor Check: 5. Verify the analog values and the functions high-
1. Connect an AC voltmeter to circuits 74X (TB22) lighted on the PTU are similar to Figure 3-10.
and 74Z (TB22). 6. Connect a second serial communication cable
2. Place the GF Cutout Switch in the CUTOUT posi- from the PTU to the TCI port.
tion (down). C:\>ACNMENU {enter}
3. With Rest Switch in the REST position, start the
Highlight “PTU TCI & PSC” {enter}
engine and operate at low idle.
Verify approximately 4 VAC on the meter. Type your name {enter}
Verify tach (in cab) reads approximately 700 Type your password {enter}
RPM. Cursor to “Normal Operation” {enter}
4. Shut down the engine. Remove voltmeter. Cursor to “TCI Real Time Data” {enter}
Battery Boost Check: 7. Verify the analog values and the functions high-
lighted on the PTU are similar to Figure 3-11.
8. Start the engine.
9. Place the GF Cutout Switch in the NORMAL posi-
tion (up).
THE BATTERY BOOST CHECK MUST BE PER- 10. While observing the voltmeter installed in step 1,
FORMED EXACTLY AS DESCRIBED BELOW. FAIL- place the Rest Switch in the OFF position.
URE TO DO SO MAY RESULT IN SERIOUS INJURY. The voltmeter will momentarily show about 18
• The contactors in the cabinet with the R1 volts and then drop to zero
resistor may be energized with the engine run- 11. Place the Rest Switch in the ON position.
ning. DANGEROUS VOLTAGES ARE
PRESENT INSIDE THE CABINET. 12. Place the GF Cutout Switch in the CUTOUT posi-
tion.
• Engine must be OFF during setup prepara-
tion. 13. Shut down the engine.
• Rest switch in the cab must be in REST. 14. Verify ALL lights indicating link voltage are OFF.
• GF cutout switch must be in the CUTOUT 15. Remove the voltmeter and lock the cabinet door.
position, (down).
• ALL Link Voltage lights must be OFF.
5. Without touching them, check for air flow from the Press the {F2} key
grid blowers as follows:
Cursor to “record” and press {enter}
a. Increase engine RPM until two RP contactors
pickup. Type a filename and press {enter}
Hot air should be felt from one front section of
the grid.
b. Reduce RPM to idle and then increase RPM 11. Note the “ENGLOAD” value On the screen:
to pickup two RP contactors. If the value is 5 volts during load testing, load-
Hot air should be flowing from the other front ing is satisfactory.
section of the grid. If the value is below 5 volts, the electrical sys-
6. Warm-up engine with two RP contactors picked tem needs to remove horsepower loading.
up until the engine coolant temperature stabilizes. (This is an indication of a weak engine.)
7. Compare values displayed on the Loadbox Test If the value is above 5 volts, the electrical sys-
Screen with the sample screen in Figure 3-18. tem needs to load the engine more.(This is an
indication of a strong engine.)
8. Fully depress the accelerator pedal to pickup all
three RP contactors.
Note: Some trucks have RP1 & RP2 only
5ms/20ms = .25 X 10 = 2.5VDC If the GE drive system follows the signal and with
c. Verify circuit 0 is connected to ground. 5VDC the system can produce full power, but cannot
function normally, troubleshoot engine boost or fuel
d. If the signal “908M” is correct and the supply injection system.
voltage (15SIM) to the PVM is correct, but out-
put is incorrect, replace the PVM module.
2. Move cursor to the appropriate GD1E or GD2E To Remove the Phase Modules:
signal in the digital output area and turn it ON.
1. Open the battery disconnects to disconnect the
(GD1E turns on all Inverter 1 phase modules and
truck batteries.
chopper module 1. GD2E turns on all Inverter 2
phase modules and chopper module 2.) 2. Short out the DC link by installing jumpers from
(+) to (-) next to the AFSE and then to ground.
3. Disconnect the GRAY fiber optic cable on the
phase module or chopper module being checked. 3. Remove the front cabinet supports between the
doors.
4. Disconnect the fiber optic cables and the plug at
the top of each Phase Module. Tuck the removed
cables under the blue loom to protect the cables
In the following step, DO NOT look directly at the when the modules are pulled out.
red light. Eye damage could occur.
5. With a 15/16” inch socket, remove the four
4. There should be red light visible out of the GRAY mounting nuts on each Phase Module.
receptacle on the gate drive module.
6. Cut the tyrap by the capacitor on top of each
5. If there IS red light, the phase module or chopper Phase Module.
module is OK.
7. Partially pull out each Phase Module. Using a
6. If red light IS NOT visible, disconnect the round 7/16” inch socket, remove the snubber wire
power supply harness from the gate drive mod- behind the top capacitor.
ule.
8. Remove each Phase Module which weighs 65
7. Check the AC voltage in the two pins in the har- pounds (29.5 Kg). Mark each Module so that it
ness; There should be 100 VAC square wave on will be put back in the same location that it was
the harness. The actual reading on the VOM will removed from.
depend on the meter and how it is designed to
measure AC voltage. Most meters read less than
100 volts. Normally, there will either be proper
voltage on the harness or NO voltage at all on the
harness.
5. Remove the four screws holding the resistor to 5. Reconnect the fiber optic cables and the plug at
the base. (These screws have been installed and the top of each Phase Module.
retained with Loctite®, and will require extra force 6. Replace the front cabinet supports between the
to remove.) doors.
6. Remove the rubber grommet along with the resis- 7. Remove the ground jumpers from the DC link.
tor cables. 8. Close battery disconnect switches to reconnect
7. Remove the resistor from the base and remove the truck batteries.
and discard the gaskets.
Description: A low DC bus voltage was detected after Description: A high DC bus voltage was detected dur-
the phase controller power up sequence. ing operation.
1. Check the 3-phase input connections and fuses 1. Check Capacitor Bank and Controller connec-
F1 and F2. tions.
2. If no problem was found in step 1, use an ohm- 2. Check DC Sense connection (connector J13 to
meter to check for short circuits between AM101, IV+ (red wire) and IV- (black wire)).
AM201, and AM301 wires and between IV+ and
3. If problem still exists, replace controller.
IV-.
3. If no problem was found in step 1 or 2, replace
the controller.
Description: An overcurrent condition was detected Description: A sustained overload exists due to low
after the phase controller power up sequence. DC bus voltage.
1. Check Capacitor Bank and Controller connec- 1. Check the 3-phase input connections and fuses
tions. F1 and F2.
2. Verify the inductor connections match-up 2. Check Capacitor Bank and Controller connec-
(+ and -) from the Auxiliary Inverter and to the tions.
Auxiliary Capacitor bank (PH+ to IV+ and PH- to
3. After performing checks in step 1 and 2, attempt
IV-).
to restart.
3. If a problem was found and corrected in step 1 or 4. If problem still exists, replace the controller.
2, restart and check operation again.
4. If problem still exists, disconnect AM101, AM201
and AM301 wires connecting the Auxiliary
Inverter to the blower motor. Subcode 13:
5. Using an ohmmeter, check for shorts between Description: IGBT protection circuit detected an over-
blower motor cables and between blower motor current condition.
cables and chassis ground.
1. Disconnect AM101, AM201 and AM301 wires
6. Using an ohmmeter, check for shorts between connecting the Auxiliary Inverter to the blower
AM101, AM201 and AM301 wires and between motor.
IV+ and IV-.
2. Using an ohmmeter, check for shorts between
7. If no problem was found in above steps, replace blower motor cables and between blower motor
the Controller. cables and chassis ground.
3. Using an ohmmeter, check for shorts between
AM101, AM201 and AM301 wires and between
Subcode 10: IV+ and IV-.
4. If no problem was found in above steps, replace
Description: A sustained current overload exists that the Controller.
is below component safe operating range.
1. Verify the inductor connections match-up
(+ and -) from the Auxiliary Inverter and to the
Auxiliary Capacitor bank (PH+ to IV+ and PH- to Subcode 14:
IV-).
Description: Zero input voltage detected.
2. Check the blower fan for blockage or damage.
1. Check the 3-phase input connections and fuses
3. If no problem was found in step 1 or 2, the blower F1 and F2.
motor may be damaged.
2. If no problems were found in step 1, replace the
controller.
Subcode 11:
The Auxiliary Capacitor Panel remains charged for 9. Disconnect the blower motor cables from AM101,
at least 15 minutes after engine shutdown. Be cer- 201, & 301 (4) and megger the Aux Blower motor
tain LED’s D1 and D2 (4, Figure 3-22) are OFF and its wiring. Be sure to reconnect properly to
before working on Auxiliary Blower Control cir- assure proper rotation direction.
cuits. 10. Check the Gate Drive Power Supply AC input
fuses GDFU1 & 2 and replace if necessary.
The following items should be checked if an auxiliary
Inverter failure is suspected. 11. Disconnect the main rectifier Filter Panel wires
T103, T203, & T303 at the rectifier bus bars.
1. Observe the two LED’s on top of the Auxiliary Using an analog VOM on the ohms scale, mea-
Power Filter Capacitor Bank (AXCAP); Both sure between T103 & T203, between T203 &
LED’s should be ON (lit) when the Aux. Inverter is T303, and between T303 & T103. A capacitance
running and OFF after the circuit has discharged. deflection should show on each measurement.
2. Check for loose wires and check resistance 12. Disconnect the main rectifier from the circuits and
between the terminals on the Aux Snubber panel. perform a standard diode check with a VOM and
Measurements from 1 to AF1, 2 to AF2, & 3 to back-bias each diode with a 1000 volt megger.
AF3 should all be 0 ohms. Measurements from 1
to either AF2 or AF3 and similarly from 2 & 3 13. After all checks are made, and repairs completed
should be 2 ohms. if required, reconnect all wiring to their proper ter-
minals and reinstall fuses.
3. Check continuity from PH+ to INV+ and from PH-
to INV-. These circuits connect the Aux Phase
Control, Aux Inductor, Aux Capacitors, & Aux
Inverter. The resistance should be 0 ohms for
these two measurements to verify continuity
through the Aux Inductor.
4. Check the fuses on the Aux Capacitor panel.
(The fuses must be removed from the circuit to
check.)
5. Check for loose connections on all wires associ-
ated with the Aux Inverter circuits.
6. Check Aux Inverter Phase Control SCR’s (see
Table below). Measure between AC input termi-
nals 1, 2, & 3 and DC output terminals PH+ & PH-
A reading of less than 100 ohms indicates a
shorted SCR. Good SCR’s will measure more
than 100K ohms. Replace at least the connected
pair of SCR’s if one is shorted (preferably replace
all 6 SCR’s).
Measurement Points
INDEX
INDEX
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT TIRES AND RIMS 6. Grip tire and wheel assembly with tire handler.
Remove nuts (11) securing wheel assembly.
Removal 7. Care should be taken not to damage the infla-
1. Apply parking brake and block rear wheels to tion hose during tire removal. Move wheel
prevent movement of truck. assembly away from wheel hub and into clean
2. Following normal shutdown procedures, place work area.
rest switch in the ON position, shut down the
engine and verify the link voltage lights are
OFF. Allow at least 90 seconds for the accu-
mulators to bleed down. Turn the steering
wheel to be sure no pressure remains. As a
safety precaution, bleed down brake accumu-
Do not attempt to disassemble wheel assembly
lators.
until all air pressure is bled off.
3. Place jack under spindle or under frame at the
front cross tube. Always keep personnel away from a wheel
4. Raise front end of truck until tire clears ground assembly when it is being removed or installed.
and block up securely under frame.
5. Inspect hydraulic brake lines for damage or
leaking fittings.
8. Pull straight out to remove from wheel hub. 2. Grip inner wheel assembly with tire handler and
install onto wheel hub (5, Figure 2-5). Use care
to align tire inflation extension line (4) for mat-
ing with inner extension (7).
3. Lubricate all stud threads and nut seating
flanges with lithium base grease. Install and
NOTE: If the wheel motor is to be removed from the
tighten nuts in the following sequence:
truck for service, install approximately 8 flanged nuts
with appropriate spacers in place of the outer wheel a. Install six nuts at the 12 o'clock and six nuts
adaptor ring and nuts removed in step 4. This will at the 6 o'clock positions. Tighten each nut
provide additional support for the wheel motor to 1715 ± 100 ft. lbs. (2326 ± 136 N.m)
transmission (12) during removal and transportation. torque.
b. Install three nuts directly below the 3 o'clock
and three nuts directly above the 9 o'clock
Installation positions. Tighten these nuts to 1715 ± 100
ft. lbs. (2326 ± 136 N.m) torque.
c. Install three nuts directly above the 3 o'clock
and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 1715 ± 100
Always keep personnel away from a wheel ft. lbs. (2326 ± 136 N.m) torque.
assembly when it is being removed and d. Install the remaining nuts and torque in a
installed. clockwise direction to 1715 ± 100 ft. lbs.
(2326 ± 136 N.m) torque.
e. Re-torque all nuts in a clockwise direction to
NOTE: Clean all mating surfaces and check stud
the required 1715 ± 100 ft. lbs. (2326 ± 136
threads before installing wheel assemblies.
N.m) torque.
1. If either wheel motor has been removed, bleed
the disc brakes before installing the rear tires.
Refer to Section J, Wet Disc Brake Assembly -
Wet Disc Brake Bleeding Procedure.
INDEX
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TOE-IN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal
Remove the front tire and rim assembly. Refer to
Section G, Tires and Rims, Front Tire and Rim -
Removal
1. Close hydraulic pump shut-off valves.
2. Disconnect speed sensor connector(s) (5, Fig-
ure 3-1). Tie cables back away from the spindle
to prevent damage during spindle removal.
NOTE: The left wheel has two speed sensors
installed.
3. Disconnect disc brake cooling oil hoses (4) at
inlet and outlet ports on the brake housing.
Disconnect brake apply line. Cap hoses and
ports to prevent contamination. Remove the oil
in the brake housing and hub bearings by
removing hex plug (2) and draining into a suit-
FIGURE 3-1. FRONT WHEEL & SPINDLE
able container.
INSTALLATION
4. Remove the lubrication lines from the tie rod
1. Spindle 4. Brake Cooling Hose and steering cylinder.
2. Brake Housing 5. Speed Sensor 5. Disconnect the tie rod and steering cylinder rod
Drain Connector from the spindle being removed. Refer to
3. Disc Brake Housing Removal - Steering Cylinder and Tie Rod, in
this section.
b. Install speed sensor gear (35). 21. Attach an overhead hoist to wheel hub and
brake assembly. Rotate hub 180° in preparation
c. Install new O-ring (38) in the groove in the for lowering onto spindle.
hub. Ensure the O-ring is not twisted. Lubri-
cate the O-ring. NOTE: The hoist must be rigid enough to prevent
"springing" or "jerking" as the hub and brake
d. Install lift eyes on the brake assembly and assembly is lowered into position.
attach to an overhead hoist.
22. Lift the hub over the spindle and slowly lower
e. Lower the brake assembly onto the hub while aligning the brake mounting holes with the
while aligning the hub and seal carrier alignment studs.
mounting holes.
a. When the brake piston housing is approxi-
NOTE: Do not remove the shipping bars until the mately 0.50 in. (13 mm) from the adaptor,
inner gear ring of the brake assembly is attached to install four capscrews (20) and flatwashers
the hub. (21) spaced evenly in between the alignment
a. Install capscrews (14) and washers (15) from studs.
under hub flange. Tighten the capscrews to b. Carefully pull the brake and wheel hub
standard torque. assembly into position by tightening the cap-
b. Align the brake hub holes with the wheel hub screws evenly and in small increments.
and install hardened flatwashers (24) and c. Do Not allow the assembly to "cock" (angle).
capscrews (23). Tighten the capscrews to If the assembly is cocked, lift the assembly,
1995 ± 100 ft. lbs. (2705 ± 136 N.m). and inspect O-ring (22) for damage. Replace
c. Remove shipping bars from brake assembly. the O-ring if necessary, and repeat the pro-
cedure.
18. Install a new O-ring (25) to brake adapter (19).
Place the assembly into position on the spindle.
INDEX
PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANTI-SWAY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. If bearing carrier (3) is damaged or worn, refer FIGURE 4-2. PIVOT EYE BEARING
to Pivot Eye Repair in this section for repair pro- INSTALLATION
cedure.
Removal
1. Position the frame and the 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.
2. Securely install blocking between the frame and
the axle housing.
3. Disconnect the lubrication lines.
4. Position a fork lift or attach a lifting device to
anti-sway bar (11). The weight of the anti-sway
bar is 325 lbs (147 kg).
5. Remove capscrews (9) and locknuts (10) at
each mount.
6. Attach a puller and remove pin (4) from each
end of the anti-sway bar.
7. Remove the anti-sway bar from the mounting
brackets.
8. Remove bearing spacers (6). FIGURE 4-4. ANTI-SWAY BAR ASSEMBLY
INDEX
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filtering Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11. Open access covers inside axle housing. 17. Remove automatic lube system hoses and
clamps attached to housing. Secure hoses to
12. Disconnect parking brake supply line (13). Dis-
frame to prevent interference during axle hous-
connect and remove RH parking brake supply
ing removal.
line at tee.
18. Remove rear suspensions. Refer to Section H,
13. Disconnect air sensor hose from duct.
Rear Suspensions.
14. Remove wheel motor cooling air exhaust duct
19. Remove anti-sway bar as described in Section
(5) from between wheel motors.
G, Rear Axle Housing Attachment.
15. Disconnect wheel motor power cables (7) at
20. Remove pivot pin as described in Section G,
wheel motor terminals. Remove cable clamps
Rear Axle Housing Attachment.
and pull cables from axle housing.
21. Remove wheel motors as described in this
16. Disconnect air pressure sensor/rear light har-
section.
ness (8) inside axle housing and remove
clamps. Disconnect speed sensor harness (9) 22. Attach overhead hoist or crane to lift eyes on
connectors and remove clamps. Pull both har- rear axle housing and move from rear of
nesses from axle housing. frame.
Removal
• Do not step on or use any power cable as a
hand hold when the engine is running. NOTE: If suitable equipment is available to lift wheel
motor assembly from the axle housing it is not
• All removal, repairs and installation of
necessary to remove the truck body. The equipment
propulsion system electrical components,
cables etc. must be performed by an used must be capable of lifting and supporting the
electrical maintenance technician properly weight of the complete wheel motor assembly,
trained to service the system. 41,105 lbs. (18,645 kg.), must be mobile and must be
capable of aligning the wheel motor to the axle
• In the event of a propulsion system housing mounting flange during installation. If the
malfunction, a qualified technician should
wheel motor must be removed by use of a crane or
inspect the truck and verify the propulsion
system does not have dangerous voltage overhead hoist. Refer to Section B, Dump Body for
levels present before repairs are started. removal instructions.
MASTIC SEALANT
Vendor Product Name:
Punch Marks
• Uniseal 310S Sealant
Description:
• 2.00 in. wide x 0.125 in. thick x 120 in.
long roll
Vendor Source:
• Uniseal
1800 W. Maryland Street
Evansville, IN 47712
FIGURE 5-4. AXLE HOUSING DIMPLE MARKINGS
• Other sources may be available
throughout the world.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
If iron levels are high and other "Soft" iron contamination. Sources are likely to
200 elements are slightly elevated: be casting material.
Iron (Fe) 600
If iron levels are high and other "Hard" iron contamination. Sources are likely
100
elements ppm's are rising rapidly: to be bearing, gears, etc.
Action: A sun pinion and magnetic plug inspection should be done immediately. The magnetic plugs should be
inspected for metal chips and shavings. The sun pinion and low speed planet gears should be inspected for wear
or spalling per GE Transportation Systems AC Wheel (GDY85) Transmission Gear Use Criteria. If the low speed
planet gears fail to meet the inspection criteria the wheel should be removed, disassembled, and gears replaced. If
the low speed planet gears meet the re-use criteria, but the sun pinion fails to meet the reuse criteria, then replace
the sun pinion. Once the sun pinion has been replaced drain the oil and replace with fresh oil. This wheel should
then be monitored closely and replaced if the iron level spikes again.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
Chromium If chromium is high and iron is high: A bearing failure is likely in progress.
10 7
(Cr)
Action: The oil should be resampled immediately and a gear train inspection completed. If resampling shows high
chrome, the wheel should be removed from service, disassembled, and the bearings and gears inspected.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
If nickel is high and iron is high or rising: Nickel is likely from one or more of the gears.
Nickel (Ni) 10 5
Action: This could indicate a condition such as gear tooth pitting or spalling. The oil should be resampled immedi-
ately and a gear train inspection completed. If the resampling of the oil shows high nickel and chromium, the wheel
should be removed from service, disassembled, and the bearings and gears inspected.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
If copper is high with iron high: High iron will produce high copper from the thrust
15
washers and bearings.
Copper (Cu) 50 If copper is high with other elements A thrust washer is rapidly wearing with the likely cause
20 low: of the sun pinion gear thrusting inboard or outboard.
Action: This often indicates a normal wear condition such as minor thrust washer wear. It can also be an indicator
of bearing wear. If bearing wear is a concern review the chromium readings in conjunction with the copper read-
ings. If both the copper and chromium readings spike; remove the wheel from service, disassemble the wheel, and
inspect the bearings. If the only elevated reading is that of copper or lead; remove the sun pinion and check the
outer thrust washer for wear. If the outer thrust washer has worn less than the depth of the oil lubricating grooves
then reassemble the sun pinion, filter the oil and continue to monitor. If the outer thrust washers have worn more
than the depth of the oil lubricating grooves then replace the outer thrust washers, reassemble the sun pinion, filter
the oil and continue to monitor.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
Zinc (Zn) 75 40 If zinc, phosphorus, and calcium are high: Hydraulic oil has entered the drive train.
25 If zinc is high without high calcium and High mechanical wear of components is
phosphorus: occurring.
Action: If zinc and calcium increase proportionally then look at the oil viscosity. If the oil viscosity is below the 53
cSt at 100° C (212° F) or 588 cSt at 40° C (104° F) condemning limit, the oil should be resampled immediately. If
the resampling still shows a spike in calcium and low viscosity remove the wheel, disassemble, and replace the
internal brake seals. The oil removed from a low viscosity wheel should be disposed of and not reused under any
circumstances. If the oil viscosity is above 53 cSt at 100° C (212° F) or 588 cSt at 40° C (104° F) then monitor the
wheel for any further changes in viscosity.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
Phosphorus If phosphorus, zinc, and calcium are Hydraulic oil has entered the drive train.
400 150
(P) high:
Action: If the oil viscosity is below the 53 cSt at 100° C (212° F) or 588 cSt at 40° C (104° F) condemning limit, the
oil should be resampled immediately. If the resampling still shows a spike in phosphorus and low viscosity, remove
the wheel, disassemble, and replace the internal brake seals. The oil removed from a low viscosity wheel should
be disposed of and not reused under any circumstances. If the oil viscosity is above 53 cSt at 100° C (212° F) or
588 cSt at 40° C (104° F) then monitor the wheel for any further changes in viscosity.
Element Max ppm Max spike Indications of oil samples Possible cause of elevated ppm's
20 If silicon is high with other elements high: High wear of components.
Silicon (Si) 50 If silicon is high with other elements low: Dirt has entered the drive train. Flush wheel
25
motor.
Action: Flush the wheel motor and monitor element levels.
To fully utilize oil sampling analysis, complete information should be kept with the truck. Necessary information
includes: the truck identification number at the mine site, truck serial number, side of truck the wheel motor is on,
dates when wheel motors are changed (include serial numbers of wheels), the type of oil, viscosity of the oil, sam-
ple date, hours on wheel, hours on oil, and element count. Refer to the chart below. Information in this format can
be easily sent to equipment manufactures and gives required information to analyze the results of oil samples.
Separate records for each wheel motor should be kept in this format.
Contamination can reduce sun pinion gear life significantly, as well as the rest of the drive train. Additional
component (sun pinion gear, etc.) inspections may be required, in addition to normal maintenance interval
inspections, if oil samples from a wheel motor show elements are above normal or rapidly elevating.
HYDRAIR® II SUSPENSIONS
INDEX
FRONT SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
When using a cleaning agent, follow the manu- NOTE: The use of dry threads in this application
facturer's instructions for use, proper ventilation is not recommended. Due to the high tightening
and/or use of breathing apparatus. forces required to load these capscrews, dry
threads may cause damage to tools.
For the four inner, 14.0 in. (36 cm) long NOTE: If for any reason, these fasteners need to be
capscrews (6, Figure 2-3), tighten cap- checked for tightness after completing the above
screws initially to 100 ft. lbs. (136 N.m) procedure; loosen and inspect all 14 capscrews and
torque; then advance capscrew head 120° repeat entire process, starting with cleaning and
using steps d-1) through d-3). Refer to Fig- lubricating capscrews, washers, and nuts. In
ure 2-6. addition, the capscrew head will need to be
appropriately marked to show an additional use.
Assembly
NOTE: All parts must be completely dry and free of
foreign material. Lubricate all interior parts with clean
3. Install lower bearing (18) into lubricated sus-
Hydrair® suspension oil. Refer to the Oil and
pension housing. Install capscrews and hard-
Nitrogen Specifications Chart in Section H, Oiling
ened lockwashers (20 & 21) through bearing
and Charging Procedures.
flange and into tapped holes in housing. Tighten
to 500 ft. lbs. (678 N.m) torque.
Use care not to damage the machined or plated 4. Install new backup rings and O-rings (15, Fig-
surfaces, O-rings or seals when installing piston ure 2-7) in end cap grooves. Backup rings must
assembly. be positioned toward the flange on the end cap.
5. Install new bearing (14) on upper bearing
retainer (5).
1. Install new rod seal (28, Figure 2-8), step seal
(27), and rod wiper (29). 6. Slide upper bearing retainer assembly over cap
structure rod (16).
REAR SUSPENSIONS
INDEX
REAR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FIGURE 3-5. SUSPENSION PIN REWORK 10. Install the nitrogen charging kit and add nitrogen
to raise frame off stands or cribbing, or use a
lifting device if available.
11. Connect lubrication lines and pressure sensor.
12. Service the suspension. For instructions, refer
to Section H, Oiling and Charging Procedures.
13. Install piston rod shield (2, Figure 3-1) with the
capscrews, flat washers, and lockwashers.
2. Dry all parts completely using only dry, filtered 10. Using new O-ring, install charging valve.
compressed air and lint free wiping materials. Tighten large hex of charging valve to 16.5
ft.lbs. (22.4 N.m) torque.
3. Inspect all parts for evidence of wear or dam-
age. Inspect plated surfaces for scratches,
nicks or other defects. Replace or repair any
damaged parts.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
For best results, Hydrair® II suspensions should be FIGURE 4-1. HYDRAIR® CHARGING KIT
charged in pairs (fronts together and rears together).
If rears are to be charged, the fronts should be NOTE: Arrangement of parts may vary from
charged first. illustration above, depending on charging kit P/N.
NOTE: For longer life of suspension components, a 1. “T” Handle Valve
friction modifier should be added to the suspension 2. Charging Valve Adapter
oil. See Specifications Chart, Figure 4-5 at the end of 3. Manifold Outlet Valves (from gauge)
this chapter. 4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
NOTE: Set up dimensions specified in the charts
6. Manifold
must be maintained during oiling and charging
7. Charging Pressure Gauge (Suspensions)
procedures. However, after the truck has been
8. Dry Nitrogen Gas (Specifications Figure 4-5)
operated, these dimensions may vary.
REAR SUSPENSION DIMENSIONS (EMPTY) 3. Install the Hydrair® charging kit and a bottle of
pure dry nitrogen. Refer to Installation of Charg-
TRUCK MODEL OILING CHARGING *CHARGING
ing Kit in this section.
& OPTIONS HEIGHT HEIGHT PRESSURE
In. (mm) In. (mm) psi (kPa) 4. Charge the suspensions with nitrogen gas to 2
in. (50.8 mm) greater than the charging height
930E-1,
1.0 (25.4) 7.5 (190) 215 (1482) listed in Figure 4-4.
930E-2
5. Slowly release gas until the suspensions match
* Note: Charging pressures are for reference only and may vary the charging height listed in Figure 4-4.
depending on body weights.
BRAKE CIRCUIT
INDEX
BRAKE CIRCUIT
INDEX
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WARNING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
If a failure occurs in the pump, steering or either If the key switch is turned OFF (park brake
brake accumulator circuit, a low brake pressure switch ON or OFF), the park brake will not
apply until vehicle speed is less than 1/3 MPH
warning light (on the overhead display panel in the
(0.5 km/h).
cab) and an audible alarm will actuate and the vehi-
cle should be stopped as soon as practical. When If a loss of hydraulic supply pressure occurs,
the pressure in one accumulator circuit is less than with the parking brake switch OFF, the
the preset level, all the service brakes will be auto- parking brake solenoid will still be energized.
matically applied. Automatic brake application is The supply circuit (that lost pressure) is still
open to the parking brake calipers. To prevent
accomplished by the "automatic apply valve" (PS),
park brake pressure oil from returning to the
located in the brake manifold. This valve senses the supply circuit, a check valve (in the park
lower brake accumulator pressure, and when the brake circuit) traps the oil, holding the parking
pressure is less than 1650 psi (11.4 MPa), the valve brake in the released position.
shifts, operating the brake treadle valve hydraulically
NOTE: Normal internal leakage in the parking brake
which in turn applies pressure to the dual relay
solenoid may allow leakage of the trapped oil to
valves and applying all the brakes.
return back to tank, and eventually allow park brake
Regardless of the nature of location of a failure, application.
sensing the lowest brake accumulator circuit pres-
sure assures two to four full brake applications after
the low brake warning light and buzzer, and before If 24 volt power to the solenoid is interrupted,
automatic apply. This allows the operator the oppor- the park brake will apply at any vehicle
tunity to safely stop the truck after the warning has speed. The spring in the solenoid will cause it
turned on. to shift, opening a path for the oil pressure in
the park brake line to return to tank and the
springs in the parking brake will apply the
PARKING BRAKE CIRCUIT brake. The parking brake pressure switch
The parking brakes are spring applied and hydrauli- (21) will close, completing a path to ground,
cally released. illuminating the parking brake light on the
overhead display panel and interrupting
NOTE: Whenever the park brake solenoid is de- propulsion.
energized, a spring in the solenoid valve will shift the
spool, diverting oil pressure from the parking brakes
to direct the oil back to the hydraulic tank.
WARNING CIRCUIT
The brake warning circuit is equipped with a low
brake pressure warning light (on the overhead dis-
play panel) and an audible alarm (in the cab) to alert
the operator of low brake pressures. Several electri-
cal sensors, a relay and delay timer are used to
detect brake system problems. (See Figure 2-1 for
the following component references.)
• Brake lock degradation switch (23)
• Pressure sensor, system supply pressure Located on the junction block (26) in the
Located on the pump pressure sensing manifold. hydraulic components cabinet. When the brake
When system supply pressure drops below 2300 lock switch is turned on, the brake lock solenoid
psi (15.8 MPa), the low steering pressure light, (14) and brake warning relay are energized. The
low brake pressure light and buzzer will turn on. brake warning relay switches the electrical
• Pressure switch, low brake pressure (20) connection from the differential pressure switch
Located on the brake manifold. When the to the brake lock degradation switch (23). If the
accumulator with the lower pressure falls below brake lock apply pressure is less than 1000 psi
1850 psi (12.7 MPa), the low brake pressure light (6.9 MPa), a path to ground will be completed
and buzzer will turn on. and the low brake pressure light and buzzer will
turn on.
• Differential pressure switches (8)
Located on the dual controller valve (foot treadle) • Brake warning relay (28)
and on each dual relay valve. During brake Located on the RH wall of the hydraulic
application, if the difference in brake apply components cabinet. When the brake lock switch
pressure between the front and rear circuits is is turned on, the brake warning relay is energized
greater than a preset level, the differential and switches the electrical connection from any
pressure switch located on the dual controller of the differential pressure switches to the low
valve will turn on the low brake pressure light and brake lock degradation switch. When the brake
buzzer. If the difference in brake apply pressure lock switch is turned off, the relay is de-energized
between the left and right circuits of the front or and switches the connection from the brake lock
rear wheel brakes is greater than a preset level, degradation switch to the differential pressure
the differential pressure switch located on the switches.
dual relay valve at either the front or rear wheels • Brake warning delay timer (27)
will turn on the low brake pressure light and Located on the RH wall of the hydraulic
buzzer. The pressure differential switches components cabinet. The delay timer is
complete a path to ground in order to turn on the connected in series between the low brake
low brake pressure light and buzzer. The pressure light/buzzer and the brake warning
differential pressure switches provide detection of relay. If any of the differential pressure switches
faults such as a brake line rupture, poor brake or the brake lock degradation switch completes a
valve tracking, line blockage, excessive brake path to ground, the delay timer will not complete
displacement or air trapped in the system. the circuit for 1.2 seconds. This will allow
sufficient time for the hydraulic brakes to reach
the proper pressures after actuation to avoid
false warnings.
1. Actuator Cap
2. Adjustment Collar
3. Nut
4. Actuator Plunger
5. Wiper Seal
6. Poly-Pak Seal Assembly
7. Glyde Ring Assembly
8. Regulator Springs (B1)
9. Plunger Return Spring
10. Spring Seat
11. Spool Return Spring (B1)
12. Regulator Sleeve (B1)
13. Regulator Spool (B1)
14. Reaction Plunger (B1)
15. Base Plate
16. Reaction Plunger (B2)
17. Regulator Sleeve (B2)
18. Regulator Spool (B2)
19. Spool Return Spring (B2)
20. Regulator Springs (B2)
21. Staging Seat
NOTE:
B1 - Rear Brakes
B2 - Front Brakes
Rebuild Criteria
If any one of the following conditions exist, the brake
valve should be removed and repaired:
• Excessive cam rock in pedal actuator.
• Any sign of external leakage. FIGURE 3-1. BRAKE ACCUMULATOR
BLEEDDOWN
• Internal leakage at the tank port must be less
than 100 cc/minute with the valve in the released
1. Rear Brake Accumulator
position and system pressure supplied to the
2. Charging Valve
"P1" and "P2" inlet ports.
3. Front Brake Accumulator
• Tank port leakage must be less than 250 cc/ 4. Charging Valve
minute with valve pilot or manual applied at 2750 5. Brake Manifold
psi (18,960 kPa) system pressure. 6. Accumulator Bleed Down Valve (Front)
• Failure of the pedal to return to full release 7. Accumulator Bleed Down Valve (Rear)
position. 8. Automatic Apply Valve
ASSEMBLY
Actuator Base Threaded Inserts
1. If any inserts (7, Figure 3-3) were removed
from the actuator base (6), position the actuator
base upside down on the work bench and sup-
port directly under each of the four floor mount-
ing holes.
2. Install the threaded inserts into the actuator
base by tapping lightly with a small hammer
until the insert flanges become flush with the
actuator base. Be sure the base is supported to
avoid breaking the base.
3. Thoroughly clean the actuator base and set
aside.
Assembly of Valve
NOTE: Start with either side (circuit) of the valve and
build that side complete through Step 4. before
starting on the other side (circuit). Be careful to
assemble components into the circuit from which
they were removed.
1. If removed, install stud (4, Figure 3-4) in
plunger (3). Tighten nut (2).
2. Install new packing (5) on staging seat (6) and
insert in plunger bore. FIGURE 3-7. GLYDE RING INSTALLATION
3. Lightly lubricate the actuation plunger Glyde 1. Actuator Plunger 3. Glyde Ring
ring (7). 2. Valve Body 4. Sharp Edges
NOTE: Shut off valves (8) for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1, B2 Cylinders must be capable of a 10 cubic inch maximum displacement.
15. Insert pry bar under pivot pin to actuate the "B2" 21. Reinstall brake valve (with actuator pedal
section of valve. attached) on the test stand following Steps 2
through 9 under Test Setup Procedure.
16. Slowly depress plunger while observing ohm-
meter and the pressure gauge on "B2". The 22. With test stand pump adjusted for 2750 psi
switch contacts should close at the pressure (18,960 kPa) or with engine running and brake
specified in step 13. A slight adjustment may be system supply pressure at or above 2750 psi
necessary. (18, 960 kPa), depress the pedal as quickly as
possible. The pressure on the output circuits
17. Slowly depress both plungers equally from mini- must reach the minimum pressure listed below
mum to maximum application pressure. Switch at port "B1" and port "B2" within 1.0 second.
contacts must remain open. Measurement of time begins the moment force
18. Install plug (6) and tighten to 90 - 100 in. lbs. is applied to move the pedal.
(10.2 - 11.3 N.m) torque.
• Rear Brake - "B1": 2400 ± 75 psi
19. Shut down the test bench and relieve all (16,545 ± 517 kPa)
hydraulic pressure from the lines. • Front Brake - "B2": 2400 ± 75 psi
(16,545 ± 517 kPa)
23. With "B1" and "B2" plugged into a strip chart
recorder, (if available) check the modulation by
slowly applying pressure until the maximum
Avoid spillage and contamination! Avoid contact
pressure is reached. Make sure the pressure
with hot oil if the machine has been operating. increase is smooth and no sticking of the spools
The oil will be at very high pressure. is observed. Fully depress the pedal. Pressures
Hydraulic fluid escaping under pressure can must remain within specification at "B1" and
have sufficient force to enter a person's body by "B2" for 20 seconds.
penetrating the skin and cause serious injury and
24. Adjust set screw (21, Figure 3-10) until the set
possibly death if proper medical treatment by a
screw is not touching the actuator cap. Apply
physician familiar with this injury is not received
Loctite® 242 to the adjustment screw prior to
immediately.
setting the deadband.
25. Set the deadband by placing a 0.010 in (0.254
20. Remove hoses from valve and remove valve mm) thick shim at location (9) between the
from test stand. Refer to instructions below for pedal structure and return stop boss on pivot
pedal actuator installation prior to final test. structure.
26. Adjust the set screw (21) until the set screw is
just touching the cap.
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 to tank.
2. Open needle valves (6 & 7, Figure 3-1) on
brake manifold (5) and allow the four brake sys-
tem accumulators to bleed completely.
3. Remove charging valve guard (2, Figure 3-25)
and loosen small hex on charging valve (3) FIGURE 3-25. CHARGING VALVES
three complete turns. Depress the valve core 1. Accumulator 3. Charging Valve
until all nitrogen pressure has been relieved. 2. Charging Valve
Guard
Installation
1. Lift accumulator into position on the mounting
bracket. Accumulator should be positioned with
the anti-rotation block positioned between the
two stop blocks on the lower mounting bracket.
2. Secure the accumulator to the mounting
bracket using mounting bands (4, Figure 3-26),
and corresponding hardware. Do not over-
tighten nuts, as this could distort the accumula- FIGURE 3-26. BRAKE ACCUMULATOR
tor. INSTALLATION
3. Reconnect oil line to the bottom of the accumu- 1. Rear Brake Circuit 3. Capscrews, Washers
lator. Accumulator & Nuts
4. Precharge both accumulators with pure dry 2. Front Brake Circuit 4. Mounting Bands
nitrogen as outlined in Frame Mounted Brake Accumulator 5. Oil Line
Accumulator Charging Procedure.
Due to frequent use and wear, retarder control lever Disassembly and Adjustment
(4, Figure 3-30) may occasionally require adjustment
or repair. 1. Remove capscrews (6, Figure 3-30) and lock-
washers (7) from retarder control lever (4).
Removal 2. Remove potentiometer (8).
Adjustment of the retarder control lever or replace- 3. Bend tangs on washer (10) away from slots in
ment of the potentiometer requires removal of the locknut (9).
assembly from the steering column. a. Lever Disassembly:
1. Tilt the steering wheel downward, and tele-
If the retarder control lever is to be com-
scope the wheel towards the operator seat.
pletely disassembled, loosen and remove
Remove the top cover from the steering col-
locknut (9). Remove tang washer (10),
umn.
spring (11), and washer (12).
1. Remove capscrews (1, Figure 3-30) and lock-
Remove set screw (14).
washers (2) from steering column (3).
2. Disconnect the wiring harness from harness Remove the lever and shaft assembly. If nec-
connector (5) on retarder control lever (4). essary, unscrew lever (16) from shaft (15)
and handle (17).
3. Remove the retarder control lever.
Wash the mechanical parts in clean solvent
and inspect for excessive wear, burrs, or
scratches. Replace any defective parts.
Installation b. Lever Adjustments:
1. Connect the wiring harness to harness connec- Rotational Friction Adjustment: The lever
tor (5, Figure 3-30) on retarder control lever (4). assembly should be adjusted such that the
2. Place the retarder control lever into position on frictional forces will hold the lever firmly in
steering column (3). the position selected by the operator. At the
3. Install capscrews (1) and lockwashers (2). same time, the adjustment should not be so
Tighten the capscrews to 36 in. lbs. (4.1 N.m) tight as to cause the operator to use undue
torque. force to move the lever. Loosen or tighten
locknut (9) to attain the proper frictional force
4. Place the cover on the top of the steering col- (2 - 3 in.lbs (0.23 - 0.34 Nm) at the handle.
umn and return the steering wheel to its original
position. The position of the lever should remain sta-
tionary without moving from its own weight or
due to machine vibrations during truck oper-
ation.
When the desired adjustment is obtained,
bend the tang on washer (10) into the slots
on locknut (9).
Detent Adjustment: The detent that holds the
lever in the OFF position can be adjusted, as
well. Loosen or tighten set screw (13) to
adjust the detent. The breakout force of the
detent must be between 17 - 20 in.lbs (1.92
- 2.26 Nm).
INDEX
EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LAP1 Low Accumulator Pressure, Pressure > Three 0-3000 psi (0-20,685 kPa) range.
Tap • One PB6039 female quick disconnect and hose
LAP2 Low Brake Pressure Switch long enough to reach from brake cabinet to the
N.C. - 1850 ± 75 psi (12.95 MPa) inside of the operator's cab for each gauge.
LS1 Low Pressure Shuttle Valve • Accumulator charging kit (EB1759 or equivalent)
with gauges and dry nitrogen.
NVF Front Accumulator Manual Drain Valve
NVR Rear Accumulator Manual Drain Valve
PK1 Park Brake Release Pressure
PK2 Plug Port
PK3 Park Brake Pressure Switch
N.C., 1250 psi (8.75 MPa)
PP3 Brake Lock Pressure Tap
PR Brake Lock Pressure Regulator
2000 psi (13.8 MPa)
PS1 Automatic Apply Valve
1650 psi (11.55 MPa)
SP1 Supply Oil Inlet
SP2 Plug Port
SP3 Supply Oil Pressure Tap
SP4 Plug Port
SV1 Brake Lock Solenoid
SV2 Park Brake Solenoid
T1 Return To Tank
T2 Plug Port
T3 Plug Port
NOTE: Leave rest switch in the ON position and the 1. AR1: Rear Brake Oil Supply to Brake Valve
GF cutout switch in the CUTOUT position throughout 2. AA: Automatic Apply Oil Supply to Brake Valve
brake tests. (See Figure 3-1, page E3-2, Propulsion 3. AF1: Front Brake Oil Supply to Brake Valve
System, for GF switch location.) 4. PK1: Oil Supply to Park Brake
5. T1: Oil Return to Hydraulic Tank
2. Open each brake accumulator bleeddown valve
6. SP1: Brake System Oil Supply from Bleeddown
and precharge both brake manifold accumula-
Manifold and filter
tors (1 & 3, Figure 4-1) to 1400 psi (9,652 kPa).
7. To "B1" Port on Brake Valve
Move the charging kit to the frame mounted
accumulators (behind right front tire) and pre-
charge both accumulators to 1400 psi (9,652 5. Set park brake. Release brake lock.
kPa). Allow gas temperature to approach ambi-
ent temperature before completing precharge 6. Start engine. Observe rising brake pressures as
process. system charges. Brakes should release at
approximately 1650 psi (11,375 kPa) both front
* Record on data sheet. and rear.
NOTE: For best performance, charge accumulators 7. Actuate brake lock. Turn parking brake switch
in the ambient conditions in which the machine will OFF. Rear brake pressure should not exceed
be operating. 2000 ± 100 psi (13,788 ± 690 kPa). Release
3. Close both accumulator bleeddown valves. brake lock.
4. Install pressure gauges at: * Record on data sheet.
a. Front brake test port "BF" (25, Figure 4-1) - 8. Slowly depress brake pedal and note brake
3000 psi (20,685 kPa) gauge. valve pressures. If the rear brake circuit
exceeds 2400 psi (16,545 kPa) at the "BR" test
b. Rear brake test port "BR" (24) - 3000 psi port or front brake circuit exceeds 2400 psi
(20,685 kPa) gauge. (16,545 kPa) at the "BF" test port, correct the
c. Park brake release pressure "PK2" (9) - problem before proceeding. This brake valve
3000 psi (20,685 kPa) gauge. may require adjustment or a dual relay valve
may be malfunctioning. Refer to repair proce-
d. Low accumulator pressure test port "LAP1"
dures, this section.
(18) - 5000 psi (34,475 kPa) gauge.
* Record on data sheet.
NOTE: Unless otherwise specified, perform the Right front brake pressure reads 2400 ± 75
following checks with engine running, rest switch in psi (16,545 ± 517 kPa).
the ON position, park brake on and brake lock Both pressures must remain above their
released. minimum values for a minimum of 20
seconds.
* Record on data sheet.
9. Apply brake lock. Turn the parking brake switch
to the OFF position: 19. Release pedal, assure that each circuit's pres-
sure is zero.
Verify park brake indicator lamp is off.
20. Remove gauges from front brake test ports and
Verify park brake release pressure (gauge
install at the "BR" and "BF" test ports in the
installed in "PK2" port in hydraulic cabinet) is
2700 ± 100 psi (18,615 ± 690 kPa). hydraulic cabinet.
* Record on data sheet. 21. Disconnect circuit #52B wire on the coil of the
brake lock solenoid (SV1) (14, Figure 4-1).
10. Cycle park brake several times to assure crisp Install a jumper wire between circuits #33 and
application and release of oil pressure when #33W at the brake warning delay timer (27, Fig-
switch is OFF. ure 4-1).
11. Place parking brake switch in the ON position 22. Apply the brake lock; the brake lock degradation
and release the brake lock. switch should close:
12. Install a 3000 psi (20,685 kPa) pressure gauge Verify the warning buzzer turns on.
at the "LBP" (9, Figure 4-5) and "RBP" (8) test
ports on the junction block at the left front cor- Verify the low brake pressure warning lamp
ner of the rear axle housing. illuminates.
23. Depress the brake pedal until the warning
13. Very slowly depress brake pedal. Force feed-
stops.
back of pedal on foot should be smooth with no
abnormal noise or mechanical roughness. 24. Very slowly, release the brake pedal while
observing the "BR" pressure gauge:
14. Slowly depress brake pedal:
Verify warning resumes when pressure drops
Verify brake indicator lamp and stop lights
to 1000 ± 25 psi (6,895 ± 172 kPa).
illuminate at 75 ± 5 psi (517 ± 34 kPa) rear
brake pressure. * Record pressure reading when alarm resumes.
* Record on data sheet. 25. Reconnect #52B wire at brake lock solenoid
15. Quickly and completely depress pedal. Verify coil. Remove jumper between circuits #33 and
that within 1 second after brake is applied: #33W.
26. Cycle brake lock several times to assure crisp
Left rear brake pressure ("LBP", 9) reads
2400 ± 75 psi (16,545 ± 517 kPa). shift of solenoid valve and release of oil pres-
sure. Verify stop lights illuminate when brake
Right rear brake pressure ("RBP", 8) reads lock is on.
2400 ± 75 psi (16,545 ± 517 kPa).
27. Apply brake lock and read brake pressure at
Both pressures must remain above their "BR" gauge:
minimum values for a minimum of 20
seconds. Pressure should be 2000 ± 100 psi (13,788 ±
690 kPa).
* Record on data sheet.
* Record on data sheet.
16. Release pedal, assure that each circuit's pres-
sure is zero. 28. If above pressure is not correct, remove plug on
end of PR valve (13, Figure 4-1) and adjust to
17. Move the two 3000 psi (20,685 kPa) gauges to
obtain correct pressure. Reinstall plug after
the test ports on the front brake backplates.
adjustment.
18. Quickly and completely depress pedal. Verify
that within 1 second after brake is applied:
52. Shut down the engine and turn key switch OFF.
Allow steering accumulators to bleed down.
Open both accumulator bleeddown valves and
bleed entire brake system. Close valves after all
pressure is released.
53. Reconnect hose (5, Figure 4-4) to tee at "AR1"
port, bottom of hydraulic cabinet.
54. Remove all test equipment and verify all hoses
have been reconnected.
NOTE: If hoses (4, Figure 4-5) and (10) are switched,
the rear brakes will be slow to apply and slow to
release.
FIGURE 4-5. REAR BRAKE HOSES
TROUBLE: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system. Check wiring.
Brake accumulator bleeding down. Valve open; close valve.
Differential pressure switch defective. Check switch on brake valve and dual relay valves;
replace defective switch assembly or adjust as nec-
essary.
Brake warning relay defective. Replace relay.
TROUBLE: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released
Brake valve out of balance (not tracking). Adjust collars according to instructions.
Differential pressure switch is defective or improp- Check the switch and replace if defective. Check dif-
erly adjusted. ferential pressure switch adjustment.
Accumulator precharge/leak. Check accumulators and recharge if necessary.
Problem in brake valve subassembly. Remove, disassemble, clean, and inspect brake
valve assembly or replace it.
Dual relay valve defective Inspect and repair dual relay valve(s)
Air in one brake circuit. Bleed brakes.
Small leak in one circuit. Inspect brake system and repair leaks.
Brake warning delay timer defective Replace timer.
TROUBLE: A Low Brake Pressure Warning Occurs When Brakes are Applied
Leak or other malfunction in one brake circuit. Inspect brake system and repair leaks.
Brake valve balance is out of adjustment. Adjust collars according to instructions.
Differential pressure switch is defective or improp- Check the switch and replace if defective. Check dif-
erly adjusted. ferential pressure switch adjustment.
A dual relay valve is defective Inspect and repair dual relay valve(s)
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open. Close valve, check precharge.
Accumulator precharge is low. Recharge accumulator
Leak in one circuit. Check plumbing.
Malfunction in brake valve. Remove, disassemble, clean, reassemble; or
replace.
TROUBLE: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected. Check plumbing.
TROUBLE: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in brake valve assembly. Remove, disassemble, clean, reassemble; or
replace.
Damage in brake valve assembly. Repair or replace brake valve assembly.
Dual relay valve malfunctioning Repair or replace dual relay valve assembly.
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component. Check all steering and brake system components.
Steering accumulator precharge too high or too low. Check steering accumulator precharge.
Brake valve plumbed incorrectly. Correct plumbing.
Internal leakage in brake valve assembly. Replace brake valve assembly.
Internal leakage in dual relay valve assembly. Rebuild or replace dual relay valve
Steering/brake pump is worn. Rebuild or replace pump.
Pump unloader or compensator not adjusted cor- Adjust pump pressure controls.
rectly.
STEP 2 __________ All brake accumulators charged to 1400 psi (9.65 MPa).
Refer to appropriate Service Manual procedures and bleed brakes; bleed park brakes.
STEP 15 __________ Left rear brake pressure within one second (LBP).
__________ Right rear brake pressure within one second (RBP).
__________ Brake pressures remain above 2375 psi (16,375 kPa) minimum for 20
seconds.
STEP 45 __________ Front brake pressure at which differential switch actuates low brake
pressure buzzer and lamp.
STEP 51 __________ Rear brake pressure at which differential switch actuates low brake
pressure buzzer and lamp.
INDEX
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION
The ring gear (4, Figure 5-1) is internally splined to
retain the dampers (8) and separator plates (12). The
separator plates are alternately placed between the
friction faced discs (7) which are splined to the inner
gear (6). The inner gear mounts directly to the wheel
hub on the front wheel brakes. On the rear, the inner
gear requires an adapter hub which mounts on the
wheel hub on the wheel motor.
The inboard side of the assembly contains the piston
(9) which is activated by hydraulic pressure supplied
by the dual relay valves (controlled by the brake
valve). As hydraulic pressure is applied, the piston
moves to compress the rotating friction faced discs
against the stationary steel discs. The friction forces
generated resist the rotation of the wheels. As
hydraulic pressure increases, friction forces are
increased and wheel rotation is slowed until maxi-
mum force is reached and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The low pressure cooling circuit is completely iso-
lated from the high pressure, piston apply circuit.
FIGURE 5-1. WET DISC BRAKE ASSEMBLIES
Cooling oil flows from the hydraulic tank to the hoist
pump, through the hoist circuit high pressure filters, 1. Hub Adapter 5. Capscrew & Hardene
through the hoist valve, and into the brake housings. (Rear Only) Washer
A parallel circuit from the hoist valve outlet is con- 2. Capscrew & Lock- 6. Inner Gear
nected to relief valves at the hydraulic tank which washer 7. Friction Disc
limit brake cooling circuit pressure to 35 psi (241 3. Socket Head Screw 8. Damper
kPa). Oil routed to the front brakes passes through (Temporary) 9. Piston Assembly
the oil cooler before entering the front brake hous- 4. Ring Gear 10. Seal Carrier
ings. In addition, the brake cooling oil provides lubri- 11. Back Plate
cation for the front wheel bearings. Oil exiting the
brake housings returns to the hydraulic tank.
Disassembly
Rear Wheel Brake Only: FIGURE 5-4. BRAKE ASSEMBLY
Refer to Wheel Motor Rebuild instructions for rear 1. Ring Gear 4. Shipping/Storage
wheel brake assembly removal. 2. Back Plate Bar
1. Verify socket head capscrews (3, Figure 5-1) 3. Capscrew 5. Inner Gear
are installed at each of the six locations on the
back plate (11). These capscrews are required 6. Remove socket head capscrews (2, Figure 5-
to retain the seal carrier (10) to the back plate 5). Lift seal retainer (1) off brake assembly.
when the brake assembly is not installed on the
NOTE: Socket head capscrews (2) are required to
truck. Shipping bars (4, Figure 5-4) must be
retain and position seal carrier on brake back plate
installed.
when the brake assembly is not installed on the
2. Remove the 12-point capscrews and hardened wheel hub or during brake assembly shipping or
washers (5, Figure 5-1). storage. Shipping bars (4, Figure 5-4) must be
3. Remove capscrews and lockwashers (2) used installed to retain the inner gear inside the brake
to retain the hub to the seal carrier. assembly.
4. Be certain hub and other parts are marked to 7. Remove capscrews (4, Figure 5-5) and hard-
ensure proper orientation during reassembly. ened flatwashers (5) from backplate (3).
Lift the hub adaptor (1) from brake assembly. 8. Insert a 7/8 UNC x 2.0 in. pusher bolt in each of
Be certain to note shim packs installed at six the three tapped holes in the back plate.
locations on between seal carrier and hub. Tighten bolts evenly to lift back plate from ring
Both Front and Rear Wheel Brakes: gear (7). Remove and discard O-ring (6).
9. Noting order of assembly of discs, remove the
Remove the front wheel/brake assembly according to
damper (10) from top of stack. Remove friction
the instructions in Section G, Front Wheel Hub and
discs (11), separator plates (9) and remaining
Spindle.
damper at bottom of stack.
5. Position brake assembly on work surface with
ring gear retainer bars on bottom as shown in 10. Rotate the brake assembly to position shipping
Figure 5-5. bars on top as shown in Figure 5-4.
11. Remove capscrews (3) retaining shipping bars
(4) to housing.
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 top as shown in Figure 5-7.
bars and spacers. 16. Remove capscrews (1, Figure 5-7), spring
13. Remove capscrews (2, Figure 5-6) and hard- guides (2), and piston retract springs (3).
ened washers (3) from piston housing (1).
NOTE: Capscrew (1) threads are coated with
14. Insert a 7/8 UNC x 2.0 in. pusher bolt in each of Loctite® during assembly. A small amount of heat
the three tapped holes in the piston housing. applied to the piston housing may be required for
Tighten bolts evenly to lift housing from ring easier removal.
gear (5). Remove and discard O-ring (4).
17. Loosen or remove plugs installed in piston
housing ports. Carefully lift piston (4) out of
housing (5). Remove seal assemblies (6 & 7).
PARKING BRAKE
INDEX
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Apply the parking brake, put selector switch in 6. Connect a clear plastic hose to the parking
NEUTRAL, place the rest switch in the ON brake bleeder screw. Place the other end of
position, turn the key switch OFF to shut down hose in a container.
the engine, and allow approximately 90 sec- 7. Slowly open bleeder valve and allow hydraulic
onds for the steering accumulators to bleed fluid to run until clear and free of bubbles. Close
down. Confirm the steering pressure is bleeder screw securely.
released by turning the steering wheel - no
movement should occur. Block the truck 8. Repeat Steps 6 & 7 for the other parking brake.
wheels. 9. Shut down engine.
2. Block the truck wheels securely to prevent 10. Remove brake bleed equipment, close axle
movement when the parking brake is released. housing cooling air ducts and reinstall duct tube
3. Open the rear axle housing access door, at door.
remove the cooling air duct tube and open
access covers.
4. Be certain the brake accumulator bleeddown
valves are closed.
5. Start the engine and allow the steering system
to fully charge (pump unloads). Turn the parking
brake to the OFF position.
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The following is a general description of the model 930E hydraulic system. Additional information concerning
individual component description and operation can be found under the different system circuits such as the hoist
circuit, steering circuit, and hydraulic brake circuit.
1. Hoist Valve Tank Return (To 7. Supply From Hoist Pump & Filter 14. Steering Pump Inlet Port
Brake/Hoist Return Manifold) 8. Counterbalance Valve 15. Unloader Valve
2. Supply to Pilot Valve 9. Needle Valve 16. Steering/Brake Pump
3. Hoist Valve 10. Overcenter Manifold 17. Hoist Pump Inlet Hoses
4. From Pilot Valve 11. Hoist Cylinder Supply Tubes 18. Hoist Pump
5. To Brake/Hoist Return Manifold 12. Hoist Quick Disconnects 19. Pump Driveshaft
6. Work Port Outlet 13. Pump Case Drain Line
INDEX
HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1. Drive Gear & Shaft 10. Connector Plate 19. Dowel 28. Snap Ring
2. Seal 11. O-ring 20. Bearing Plate 29. Coupler
3. Idler Gear 12. Bearing Plate 21. Dowel 30. Steel Ring
4. Stud 13. Gear Plate 22. Transition Plate 31. Backup Ring
5. Steel Ball 14. Connector Plate 23. O-ring 32. O-ring
6. Flange 15. Washer 24. (Not Used) 33. Pressure Plate
7. Dowel 16. Nut 25. Coupler 34. Isolation Plate
8. Gear Plate 17. Stud 26. O-ring 35. Plug
9. O-ring 18. Idler Gear 27. Drive Gear (Rear) 36. Snap Ring
NOTE: To aid in shaft seal removal place the flange FIGURE 3-8. SHAFT SEAL REMOVAL
on two small wooden blocks as shown in Figure 3-7.
1. Flange 3. Bearings
2. Punch
NOTE: If trapped air is not bled from steering pump, Inspect and Clean
possible pump damage and no output may result.
NOTE: Inspect the strainers thoroughly for metallic
particles and varnish build up (if oil has been
overheated). The quantity and size of any particles
HYDRAULIC TANK STRAINERS
may be an indication of excessive wear of
Removal components in the hydraulic system.
1. Shut down the engine and the key switch OFF Installation
for at least 90 seconds. 1. Install suction strainers and secure in place with
capscrews and lockwashers. Tighten cap-
screws to standard torque.
2. Using new cover gasket move cover (2, Figure
3-19) into place and install capscrews and lock-
washers (3). Tighten capscrews to standard
torque.
3. Install pump suction hoses.
4. Fill the hydraulic tank; refer to Hydraulic Tank
Filling Instructions. Open both suction line shut-
off valves (4).
5. Loosen suction line connections at both pumps
to bleed any trapped air. Tighten hose connec-
tions.
FIGURE 3-19. STRAINER REMOVAL
6. Bleed trapped air inside steering pump. Refer to
1. Hydraulic Tank 4. Shutoff Valve Section L, Steering Circuit Component Repair -
2. Cover 5. Pump Suction Hoses Steering and Brake Pump Installation.
3. Capscrews, Lock-
NOTE: If trapped air is not bled from steering pump,
washers
possible pump damage and no output may result.
STEERING CIRCUIT
INDEX
STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bleeddown Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
No Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Bleeddown Solenoid
Each time the keyswitch is turned OFF, with the truck
stopped, it energizes the steering system bleed down FIGURE 4-3. BLEEDDOWN MANIFOLD
solenoid (7, Figure 4-3 & 27, Figure 4-4). When the
bleed down solenoid is energized, all hydraulic steer- 1. To Hoist Valve, Power Up
ing pressure, including the accumulators, is bled 2. To Hoist Valve, Power Down
back to the hydraulic tank. Brake pressure however, 3. Spare Pressure Port
will not bleed down due to internal check valves in 4. Test Port
the brake manifold and bleeddown manifold check 5. To Brake System
valve (see schematic). 6. Steering System Pressure Switch
After approximately 90 seconds, the solenoid will de- 7. Steering Accumulator Bleed Solenoid
energize to close the return port to tank. By this time 8. Supply To Flow Amplifier
all the oil in the accumulators should be returned to 9. Return From Flow Amplifier
tank. At start-up, the steering circuit will be charged, 10. To Front Steering Accumulator
including the brake circuit. The low steering pressure 11. To Rear Steering Accumulator
light and buzzer will turn on until steering pressure 12. Relief Valve, 600 psi (4.1 MPa)
reaches 2300 psi (15.9 MPa). This is controlled by 13. Relief Valve, 4000 psi (28.0 MPa)
the steering pressure switch (6, Figure 4-3). 14. Autolube Pump Supply Port
15. Hoist Up Solenoid Valve
During operation, if steering pressure falls below 16. Return From Hoist Pilot Valve
2300 psi (15.9 MPa), the low steering pressure warn- 17. Hoist Pilot Valve, Power Down
ing light will illuminate until pressure returns to nor- 18. Hoist Pilot Valve, Power Up
mal. 19. Return to Tank
20. Feedback Pressure to Unloader valve
21. Supply From Pump
Accumulators
The steering accumulators (5, Figure 4-1) are a float-
ing piston type. The top side of the accumulators are High Pressure Filters
charged to 1400 psi (9.7 MPa) with pure dry nitrogen
The high pressure filter (10, Figure 4-1) filters oil for
with the piston at the bottom.
the steering and brake circuits.
Oil entering the accumulators pushes the piston
If the filter element becomes restricted, a warning
upward compressing the nitrogen on the top side of
indicator is activated at 40 psi (276 kPa) and oil will
the piston. The nitrogen pressure increases directly
bypass the element at 50 psi (345 kPa).
with steering circuit pressure. When steering circuit
pressure reaches 3025 psi (20.9 MPa) the unloader Refer to Section L, Hydraulic System Filters, for fur-
valve will unload the pump. The accumulators will ther information regarding the various system filters
contain a quantity of oil under pressure and held by and maintenance procedures.
check valves in the bleeddown manifold, available for
steering the truck. When system pressure drops to
2750 psi (19.0 MPa) the pump output will again Quick Disconnect Ports
increase, to refill the accumulators and increase
steering system pressure. The accumulators also Ports on the bleeddown manifold allow service per-
provide oil, for a limited period of time, to be used in sonnel to connect an external hydraulic supply to
case the pump becomes inoperative. allow operation of the truck steering and service
brake systems if the steering/brake pump, engine
etc. is not operational.
The external supply is connected to port 13, Figure
4-4 and the return is connected to port 15. This fea-
ture should only be used for emergency use to allow
operation of the truck to return to the shop for service
or move the truck out of haul road traffic.
Neutral Position
Neutral position (Figure 4-13) results when the con-
trol piston (1) centers the swashblock (4). The
swashblock angle is now zero and swashblock face
is now parallel to cylinder face. Therefore, no inward
or outward motion of the pump pistons exists as pis-
ton shoes rotate around the swashblock face. The
lack of inward and outward motion results in no fluid
being displaced from the piston bores to the cres- FIGURE 4-13. PUMP IN NEUTRAL POSITION
cents in the valve plate and subsequently no delivery 1. Control Piston 3. Piston
from pump ports. 2. Housing 4. Swashblock
INDEX
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation
1. Lubricate external splines of stub shaft (11, Fig-
ure 5-1) with a molybdenum disulphide or multi-
purpose NLGI grease.
2. Place steering control unit (9) into position on
the mounting bracket. Install capscrews and
washers (7) and tighten to standard torque. It
may be necessary to loosen capscrews (10) to
ease in the alignment of the stub shaft and the
control unit.
3. With capscrews (3) loosened, allow steering
column to slide downward until stub shaft (11)
splines bottom in steering control unit (9). When
the stub shaft is at rest at the bottom of the input
collar, slide column out to obtain 0.08 to 0.120
FIGURE 5-1. STEERING CONTROL UNIT in. (2 to 3 mm) clearance between end of stub
INSTALLATION shaft and steering control unit. Tighten cap-
screws (3) to standard torque.
1. Steering Column 7. Capscrews & Washers
2. Trim Cover 8. Front Access Cover NOTE: The gap in Step 3 can be measured by
3. Capscrews & Washers 9. Steering Control Unit etching a line across saddle bracket (5) and the
4. Capscrews & Washers 10. Capscrews & Washers bracket mounting face while the stub shaft is at rest
5. Saddle Bracket 11. Stub Shaft in the control unit. Pull the column away from the
6. Capscrew & Nut* control unit until the correct gap exists between the
mark on the bracket and the mark on mounting face.
FIGURE 5-12. CHECK BALL INSTALLATION 19. Tighten cover capscrews in a criss-cross pat-
tern to 2 ± 0.4 ft. lbs. (3 ± 0.5 N.m) torque.
1. Check Ball hole 3. O-Ring
2. Check Ball 4. Housing
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLOW AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal
NOTE: It may not be necessary to remove the
bleeddown manifold from the truck for component
replacement. If the problem area has been isolated,
remove inoperative component and replace with a
new one.
1. Perform normal truck shutdown procedures.
Turn keyswitch OFF and allow 90 seconds for
the accumulators to bleed down. Manually
bleed brake system accumulators located in
hydraulic components cabinet.
2. Disconnect wires at the solenoids (7 & 15, Fig-
ure 6-1) and pressure switch (6).
3. Disconnect, identify and plug each hydraulic
line to prevent contamination. FIGURE 6-1. BLEEDDOWN MANIFOLD
4. Remove mounting capscrews and remove the 1. To Hoist Valve, Power Up
bleed down manifold. Clean exterior of manifold 2. To Hoist Valve, Power Down
before starting disassembly. 3. Spare Pressure Port
4. Test Port
Installation 5. To Brake System
6. Steering System Pressure Switch
1. Install bleeddown manifold. Tighten mounting
7. Steering Accumulator Bleed Solenoid
capscrews to standard torque.
8. Supply To Flow Amp
2. Unplug lines and attach. Tighten connections 9. Return From Flow Amp
securely. Install new O-rings at flange fittings. 10. To Front Steering Accumulator
3. Attach electrical leads to solenoids and pres- 11. To Rear Steering Accumulator
sure switch. If check valves or relief valves were 12. Relief Valve, 600 psi (4.1 MPa)
removed, replace using new O-ring seals. 13. Relief Valve, 4000 psi (28.0 MPa)
4. Start the engine and check for proper operation 14. Autolube Pump Supply Port
and leaks. Check steering and brake function. 15. Hoist Up Solenoid Valve
16. Return From Hoist Pilot Valve
NOTE: Adjustment of the relief valves is not 17. Hoist Pilot Valve, Power Down
necessary or recommended. Relief valves are 18. Hoist Pilot Valve, Power Up
factory preset. Do not attempt to rebuild or repair if 19. Return to Tank
relief valves are defective. Replace as a unit. The 20. Feedback Pressure to Unloader valve
check valves are also replaced only as units. 21. Supply From Pump
Installation
1. Lift accumulator into position on the mounting
bracket. Accumulator should be positioned with
the anti-rotation block positioned between the
two stop blocks on the lower mounting bracket.
2. Secure the accumulator to the mounting
bracket using mounting bands (3, Figure 6-3),
capscrews, lockwashers and nuts. Do not over-
tighten nuts, as this could distort the accumula-
tor.
3. If pressure switches were removed, install at
this time. Connect electrical wiring to pressure
switches and reconnect oil line to the bottom of
the accumulator.
4. Precharge both accumulators with pure dry
nitrogen as outlined in Steering Accumulator FIGURE 6-3. ACCUMULATOR INSTALLATION
Charging Procedure in this section.
1. Accumulator 3. Mounting Band
2. Pressure Switch
1. Capscrew 7. Bearing
2. Cover 8. "T" Ring Seal
3. Charging Valve 9. Housing
4. Gland 10. Plug (or Adaptor)
5. O-ring & Backup Ring 11. Plug FIGURE 6-5. GLAND REMOVAL TOOL
6. Piston (Fabricate Locally)
NOTE: If a loss in nitrogen pressure occurred during 10. Operate truck and check steering.
operation, oil may still be present in the accumulator
b. Remove piston seal from water and assem- After cylinder assembly rebuild, perform the following
ble on piston. Do Not take longer than 5 sec- tests to verify performance is within acceptable limits.
onds to complete as seal will take a
1. Piston leakage must not exceed 1 in3/min. (1.6
permanent set. The piston bearing (4) may
be used to position seal assembly in groove. cm3/min.) at 2500 psi (17.5 MPa), port to port.
Apply pressure evenly to avoid cocking seal. 2. Rod seal leakage must not exceed 1 drop in 8
cycles of operation.
c. If seal has taken a slightly larger set (loose
on piston) a belt type wrench or similar tool 3. Piston break-away force should not exceed 100
can be used to compress O.D. of seal until it psi. (69 kPa).
fits tightly on piston.
Installation
1. Install a new O-ring on pump mounting flange.
2. Make certain the steering pump splined coupler
is in place (inside hoist pump) prior to steering
pump installation.
TROUBLE: Slip - a slow movement of steering wheel fails to steer front wheels
Leakage of steering cylinder piston seals Repair or replace steering cylinder
Worn steering control unit meter Replace steering control unit.
TROUBLE: Free wheeling - steering wheel turns freely with no back pressure. Front wheels do not steer.
Splines of steering column/steering control unit cou- Repair or replace steering column or coupling.
pling may be disengaged or damaged
No flow to steering control unit; can be caused by:
1. Low oil level 1. Add oil and check for leakage.
2. Ruptured hose 2. Replace hose.
3. Broken steering control unit gerotor drive pin 3. Repair or replace steering control unit.
TROUBLE: Steered wheels turn in opposite direction when operator turns steering wheel
Lines connected to wrong cylinder ports Inspect and correct line connections.
(STEERING PUMP)
HOIST CIRCUIT
INDEX
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bleeddown Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overcenter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Up Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hold Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Float Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Pump
The hoist system hydraulic pump is a tandem, gear
type pump driven by a drive shaft on the end of the
traction alternator. The pump has a total output of
246 gpm (931 l/m) at 1900 rpm and 2500 psi (17, 235
kPa).
A smaller, piston type, pressure compensated pump
rated at 66 gpm (250 l/m) @ 1900 rpm, coupled to
the hoist pump, supplies oil to the steering system FIGURE 7-2. HOIST VALVE
and brake apply system.
Hoist pressure is limited to 2500 psi (17,235 kPa) by
internal relief valves located in the hoist control valve 1. Inlet Section 4. Inlet Section
inlet sections. 2. Work Ports Spool 5. Inlet Port
Section 6. Outlet Port
High Pressure Filters 3. Tank Ports Spool 7. Spool Section Cover
Section 8. Separator Plate
Hoist pump output oil is directed to the high pressure
filters, mounted on the inboard side of the fuel tank.
The filter assemblies are equipped with a bypass
valve which permits oil flow if the filter element Inlet Sections - Hoist Valve
becomes excessively restricted. Flow restriction
through the filter element is sensed by an indicator Each of the front and rear inlet sections of the hoist
switch. This switch will turn on a cab mounted red valve contains of the following components:
warning light to indicate filter service is required. The • Flow control valve and main relief valve
indicator light will illuminate when restriction reaches
• Secondary Low pressure relief valve
approximately 40 psi (276 kPa). Actual filter bypass
will result when the filter element restriction reaches • Anti-void check valve
approximately 50 psi (345 kPa). • Load check valve
The flow control portion of the flow control and main
relief valves allow pump flow to the service brake
Hoist Valve
cooling circuit unless the body is being raised or low-
The hoist valve (Figure 7-2) is mounted on a modular ered. The relief portion of the valve is direct acting
assembly containing the hoist valve, overcenter man- and has the capacity to limit the working pressure at
ifold, and both hydraulic pumps. This assembly is full pump flow.
bolted to brackets attached to the frame rails behind
the main alternator. The hoist valve is a split spool
design. (The term “split spool” describes the spool
section of the valve.) The hoist valve precisely fol-
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.)
INDEX
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INLET SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation - Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DUMPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1. Hoist Cylinders
2. Brake/Hoist Return Oil Manifold
3. Overcenter Manifold
4. Hoist valve
5. Bleeddown Manifold
6. Pump Driveshaft
7. Hoist Circuit Filters
8. Hydraulic Tank
9. Hoist Valve Pilot Circuit Hoses
INLET SECTION
Disassembly - Inlet Section
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Disconnect the external tube (7, Figure 8-2) at
the cover end and remove. Remove capscrews
(14, Figure 8-5), remove cover (13). Remove
springs (12), check valves (11) and O-rings
(10).
NOTE: Inlet section shown removed from main valve
body for clarity.
3. Remove capscrews (1) and cover (2). Remove
springs (3 & 5) and flow control/main relief valve
(4). Remove sleeve (6), low pressure relief (7)
and O-rings (8).
NOTE: If restrictor poppet removal in cover (2, Figure
8-5) is required, refer to step 4 and figure 8-6.
NOTE: Pay special attention to poppets (12, 21 and NOTE: Poppets 12, 21 and 22 may be color coded
22 Figure 8-9) during removal to ensure proper and must be installed in their original location.
location during reassembly. Poppets may be
identified with a colored dot (red, green or white). If
3. Repeat Step 2 for the opposite end of spool
poppets are not color coded, use the chart in Figure
(20) to install spring, spring seat, and spool end.
8-10 and the specified drill bit to measure orifice
Make certain spring (16) is blue in color. (A pop-
diameter for identification.
pet and plug are not installed in lower end.)
8. Repeat Step 7 to disassemble opposite end of
4. Lubricate spool assembly and carefully install in
spool (20). Note there is no plug or restrictor
spool housing as shown in Figure 8-11. Make
poppet in opposite end and the spring is blue.
certain the "V" groove (1) in spool assembly (2)
9. Remove spool assembly (14). At top end of is positioned up as noted.
spool, remove plug (3). Remove spring seat (2)
5. Install spring (11, Figure 8-9) in top (grooved)
and spring (11). Remove poppet (12) and spool
end of remaining spool (14). Install spring seat
end (15).
(2). Apply Loctite to the threads of spool end
10. At opposite end, remove plug (3), spring seat (15). Install spool end and tighten to 25 ft. lbs.
(2) and spring (16). Remove restrictor poppet (34 N.m) torque. Install red poppet (12). Apply
(22) and spool end (15). Dri-loc #204 to the threads of plug (3). Install
11. Remove cover (19), remove O-rings (4, 5 & 10). plug and tighten to 15 ft. lbs. (20 N.m) torque.
Remove poppet (18). 6. Repeat step 5 for the bottom end of spool (14).
Install spring (16) which is blue in color, spring
seat (2) and spool end (15). Apply Loctite to
spool end threads. Install spool end (15) and
Cleaning and Inspection - Rear Spool Section
tighten to 25 ft. lbs. (34 N.m) torque. Install
1. Discard all O-rings and backup rings. Clean all White poppet (22). Apply Dri-loc #204 to the
parts in solvent and dry with compressed air. threads of plug (3). Install plug and tighten to 15
2. Inspect all springs for breaks or distortion. ft. lbs. (20 N.m) torque.
Inspect poppet seating surfaces for nicks or 7. Lubricate the assembled spool and install in
excessive wear. All seats must be sharp and spool housing as shown in Figure 8-11. Make
free of nicks. certain the "V" groove is in the up position.
3. Inspect all bores and surfaces of sliding parts
NOTE: Spools (14, Figure 8-9) and (20) are
for nicks, scores or excessive wear.
physically interchangeable. Make sure spool (14) is
4. Inspect all poppets in their respective bore for installed toward the base port of the spool housing.
fit. Poppets should move freely through a com-
plete revolution without binding.
Installation - Quill
1. The plugs (3, Figure 8-22) and the check balls
(4) in the quill should be checked during any
cylinder repair to insure the plugs are tight and
ball seats are not damaged. Refer to Installa-
tion of Check Balls and Plugs in Quill.
2. Secure cap assembly (1) in a sturdy fixture.
Make certain threads in cap and threads on quill
are clean and dry (free of oil and solvent).
3. Using Loctite "LOCQUIC®" Primer "T"
(Komatsu part number TL8753, or equivalent),
spray mating threads of both cap assembly (1)
and quill assembly (2). Allow primer to dry 3 to 5
minutes.
4. Apply Loctite Sealant #277 (Komatsu part num-
ber VJ6863, or equivalent) to mating threads of
both cap assembly and quill assembly.
5. Install quill and use SS1143 tool to tighten quill
to 1000 ft. lbs. (1356 N.m) torque. Allow parts
to cure for 2* hours before exposing threaded
areas to oil.
* Note: If "LOCQUIC®" primer "T" (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
6. Tack weld quill in 2 places as shown in Figure 8-
22.
7. Remove all slag and foreign material from tack
weld area before assembly of cylinder.
Hookup
Be certain there is an adequate, clear area to dump FIGURE 8-25. PUMP MODULE, HOSE HOOKUP
the loaded box. When the good truck is in position,
shut down the engine and allow the hydraulic system 1. Hoist Valve
to bleed down. Be certain pressure has bled off 2. Tubes to LH Hoist Cylinder
before connecting hoses. 3. Power Down Quick Disconnect; Connect to
power up circuit of disabled truck
1. With the good truck parked as close as possi-
4. Power Up Quick Disconnect; Connect to power
ble to the disabled truck, attach a hose from the
down circuit of disabled truck
power up quick disconnect (4, Figure 8-25) to
the power down circuit of the disabled truck.
(Hose must be rated to withstand 2500 psi (17
MPa) or greater pressure.
b. Remove the cap from the hoist pilot valve
NOTE: The power down circuit will use a smaller
relief valve (2, Figure 8-15) located in the
diameter hose (tube) than the power up circuit.
hydraulics components cabinet behind the
2. Connect another hose from the power down cab. While counting the number of turns,
quick disconnect (3) to the power up circuit of slowly screw the relief valve adjustment
the disabled truck. screw clockwise until it bottoms.
NOTE: If both trucks are a model 930E-2, the hoses 5. Repeat step 4 to dump the disabled truck.
will be installed at the quick disconnects shown in
Figure 8-25 and will be crossed when connected. Lowering the Body
6. Place the hoist lever of the good truck in FLOAT
to lower the body. If necessary, momentarily
DUMPING PROCEDURE place the hoist control in POWER UP until the
body is able to descend in FLOAT. Do not accel-
Raising the Body erate the engine.
3. On the disabled truck, move the hoist control 7. After body is lowered, shut down the truck,
lever to power up and then release it to place bleed the hydraulic system and disconnect the
the hoist pilot valve in the HOLD position (leave hoses.
in this position during entire procedure). 8. Reduce power down relief valve pressure to
4. Start the engine on the good truck, place the normal on good truck by turning the adjustment
hoist control in the power down position and counterclockwise the same number of turns as
increase engine rpm to high idle to dump the required in Step 4 b.
disabled truck. If the body of the disabled truck 9. Check power down relief pressure per instruc-
fails to raise, increase the good truck power tions in Section L, Hydraulic Check-Out Proce-
down relief pressure as follows: dure.
a. Shut down engine and allow the hydraulic 10. Check hydraulic tank oil level.
system to bleed down.
INDEX
INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic fluid escaping under pressure can 1. Indicator Switch 6. Filter Element
have sufficient force to enter a person's body by 2. Setscrew 7. Bowl
penetrating the skin and cause serious injury and 3. Head 8. O-Ring
possibly death if proper medical treatment by a 4. Pressure Tap 9. Drain Plug
physician familiar with this injury is not received 5. O-Ring
immediately.
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET . . . . . . . . . . 16
Adjustment
1. If power down relief pressure is not within spec-
ifications, adjust as follows:
a. Remove cap from power down relief valve
(2, Figure 10-6).
1.) To increase power down relief pressure,
turn adjusting screw in (clockwise).
2.) To decrease power down relief pressure,
turn adjusting screw out (counter-clock-
wise).
Operate hydraulic steering system to obtain proper operating temperature. Refer to Check-out
Procedures.
Operate hydraulic system to obtain proper operating temperature. Refer to Check-out Proce-
dures.
INDEX
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recharging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Module
(Figure 2-4):
Provides the electrical connections necessary
between the power lead and the linear detection
wire to the power lead supplying electrical power,
via the squib, to the actuator. Also provides a visual
check of power availability - pressing the switch but-
ton will illuminate the green indicator light if electri-
cal power is available in the system. FIGURE 2-4. CONTROL MODULE
FIGURE 2-11. LINEAR DETECTION WIRE Do Not install squib to power lead at this time
CONNECTOR (Figure 2-13).
! CAUTION !
Remove jumper to prevent fire suppression sys-
FIGURE 2-14. INSTALL JUMPER tem from discharging when squib is installed in
electric detection and actuation system.
2. The Linear Detection Wire
a. Using the furnished text kit, proceed to the
end of the last length of detection wire.
Remove the plugged blank connector (Fig-
ure 2-14) and install the jumper assembly.
NOTE: Retain plugged connector to be reinstalled
after testing is completed.
b. With jumper in place, screw squib connector
into receptacle on test module (Figure 2-15).
Test module light should immediately illumi-
nate. This test confirms that the wire is prop-
erly installed and will function as designed. If
test module light does not illuminate on test
module, refer to the "Troubleshooting" sec- FIGURE 2-16. REMOVE JUMPER ASSEMBLY
tion.
FIGURE 2-19.
Daily
The machine operator should manually test system
power by pushing the button and noting illumination
of indicator light. This confirms battery power is avail-
able. If light is not illuminated, refer to "Troubleshoot-
ing" covered in this section.
FIGURE 2-23. ATTACH INDICATOR LIGHT 14. Install actuation cartridge back into lower actua-
ASSEMBLY (Test Module) tor body and tighten firmly by hand.
TROUBLE: Green Indicator Light on Control Module Does Not Go On When Button is Depressed.
2.00 in.
"D" Plate I.D.
(50.8 mm)
1.37 in.
"E" Plate Thickness
(34.8 mm)
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Haul Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIGHTS, SWITCHES AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIPS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXTERNAL DISPLAY LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Linkage Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gain Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sources of Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Data From Service Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Example Calculation of Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Viewing Payload Calculation Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking the Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting the Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TYPES OF DATA STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine ON/OFF Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Codes and Warning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Total Payload and Total Number of Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Other Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATOR FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Using the Operator Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Viewing the Operator Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clearing the Operator Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dimming the Lights on the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INITIAL SETUP OF PAYLOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Checking the Operator Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checking the Service Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checking the Gt setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking the Inclinometer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibrating a Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DISPLAYS AT START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SETUP AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting The Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting the Option Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting The Machine I.D. Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting The Operator I.D. Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting The Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DOWNLOAD OF INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DISPLAY OF FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Monitoring Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Other Data
This display indicates the status of If the truck engine is started before the preceding
the Inclinometer for the PLM II™, where "Power-up Process" is completed, the display will
shift to normal operation.
"CL : - -" indicates Inclinometer Not Used, and
"CL : oo" indicates Inclinometer Is Used. If the engine is running when the payload meter
starts up, only "o:XXX" and "d:XXX" will display
5. The display will show: before switching to normal operations.
NOTES:
1. The Option Code is set to "0" for trucks not
equipped with Modular Mining System (MMS)
(Except 530M/HD1500).
2. The 530M/HD1500 with Powertrain Manage-
ment Control (PMC) system uses "10" as the
setting for the Option Code.
3. For trucks with Modular Mining System (MMS)
or Scoreboard, the Option Code is "12".
This function will erase all of the cycle data, engine If there are no faults or warnings,
ON/OFF data, and fault/warning data. Total payload the display will show for 6 sec-
and the overall number of cycles will not be cleared. onds.
If there are current faults or warnings, the
IMPORTANT - Before clearing the data, download codes will be displayed in order of their priority,
the data to a personal computer. the highest priority first. Each code will flash for
To begin, the shift lever should be in the "N" position, 6 seconds.
the brake lock set, the hoist control lever should be in 5. After the current codes have been displayed,
the "FLOAT" position and the body in the down posi- past history codes that have been reset will be
tion. displayed. Each code will flash for 3 seconds.
1. Press and hold the MODE If there are no history codes or
switch until "Cd:dP" is displayed. after all history codes have been
2. Press the MODE switch once. shown, the display will show for 3
The display will show: seconds:
3. Press and hold the CAL/CLR The system will then proceed to the following
switch until "A.CLE" is flashing. displays: Refer to Page 25 for details.
4. Press the CAL/CLR switch again
and the memory will be cleared. The meter will
then return to normal operation. • Condition of the shift selector on mechanical
trucks or brake lock on electric trucks.
This does not clear the Operator Load Counter.
The panel will display: "C1:XX" for 3 seconds,
then indicate:
Mechanical trucks
"C1:oo" Shift selector is in "N".
"C1:- -" Shift selector is not in "N'.
Electric trucks
"C1:oo" Brake lock is on.
"C1:- -" Brake lock is off.
• Condition of the Body Up Switch signal.
The panel will display: "C2:XX" for 3 seconds,
then indicate:
"C2:oo" Body up switch is in up position.
"C2:- -" Body up switch is in down position.
INCLINOMETER
As the truck is tilted fore or aft, the weight distribution FIGURE 20-14. INCLINOMETER SIDE
between the front and rear axles changes. To com- CONNECTOR VIEW
pensate for this, the inclinometer measures the
ground angle at which the truck rests. This data is
Pin Number Wire Color Wire Function
then sent to the payload meter so it can calculate the
correct payload weight. The inclinometer is located 1 Black Ground (GND)
below the operator's center console (passenger seat 2 Red + Power
structure).
3 White Signal
Removal
Adjustment
1. Disconnect inclinometer wire lead from har-
ness. 1. Park the truck on a 0% grade.
2. Remove the three capscrews, nuts and lock- 2. Loosen the three inclinometer mounting cap-
washers (4, Figure 20-13) and inclinometer (3). screws (4, Figure 20-13) and rotate the incli-
nometer until a voltage range of 2.6 ± 0.1 volts
can be measured (using a volt-meter) at pins 1
and 2 of the inclinometer harness connector.
3. Tighten all capscrews (4, Figure 20-13) to stan-
dard torque, after the adjustment.
CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins
No. Description Comments White (RS-232C Port)
3 Lamp Relay 2 2 SG
4 Lamp Relay 3 3 RD
5 Lamp Relay 4 4 TX
CN2 - AMP 040 12 Pins Black Connector CN4 - AMP 040 8 Pins Black
No. Description Comments (Optional Input, Reserved)
COMMON PROBLEMS
Suspension Charging
The Payload Meter II™ is a reliable controller and is rarely the source of failure in calculating payloads. The single
most common cause for an inaccurate payload estimate is improper suspension charging. Often maintenance per-
sonnel will not take the time to properly drain a suspension and carefully recharge it with oil and nitrogen. Most
often technicians will simply 'gas up' the suspensions with more nitrogen and send a truck back into service.
Komatsu engineers have conducted tests at customer sites to monitor suspension charging on trucks and found
many trucks to be improperly charged. Trucks with poorly charged suspensions were sent to service bays for main-
tenance by mine personnel. In some cases these trucks were returned to operation in worse condition than when
they were first checked because service personnel did not take the time to carefully charge the suspensions.
The payload meter uses the pressures from the suspensions to calculate payload. As the truck is loaded, a flat
suspension will completely collapse. The top suspension cap will make metal-to-metal contact with the bottom.
This often occurs in the rear suspensions. The pressure in the suspension will not accurately reflect the force
applied to the suspension by the weight of the material in the body and inaccurate payload calculations will result.
In addition to inaccurate payload calculations, improperly charged suspensions increase wear-and-tear on truck
frames and tires, increasing maintenance costs over the life of the truck. Each over-loaded haul cycle with under-
charged suspensions leads to premature failure. Consistently low payload estimates are the first sign that the sus-
pensions are not being properly maintained and the truck is on a path toward increased operating costs and
system failures. Thankfully, the effects of improper suspension charging can be postponed with proper service and
care.
Specific suspension charging procedures for each truck model can be found in the shop manual. In general, the
following items are very important for proper charging:
• Completely discharge the suspension. This may take more than an hour for the nitrogen and oil to completely
discharge. However, to ensure that the proper volume of fresh oil is added, it's necessary to remove as much
of the oil/nitrogen mixture as possible.
• Fill the suspension to the proper height with fresh oil, this is critical to keeping the suspensions from bottoming
out.
• Charge the suspension to the proper height with nitrogen.
Refer to Section “H” for the proper charging procedures.
This module contains an example of how to use the Scope program from Komatsu to monitor suspension pressure
data.
410
Voutput = 1 + 4 × = 1.576vdc
2845
Don’t forget to add the 1v since the output of the pressure sensor at 0 psi is 1 volt
The generic version is:
Suspension _ pressure
Voutput = 1 + 4 ×
2845
Connector 7821915320
Terminal 7821915010
Connector 7830115260 Connector 7845253670
Terminal 7821912020 Terminal 7827101440
Plate 7821912510 Plate 7821912450
A:A:
PLM RTS
PLM RTS
B:B:
PLM SGND
PLM SGND
C:C:
PLM Rxd
PLM Rxd
D:D:
PLM Txd
PLM Txd
E:E:
PLM CTS
PLM CTS
MATING FACE OF
BRAKE LOCK DOWNLOAD
CONNECTOR CONNECTOR
Originally, this program was designed for engineering testing purposes only. It was not designed for general distri-
bution or use. This program sets the Komatsu Mining Systems Payload Meter II™ into real-time data transfer
mode. This allows the technician to monitor all inputs into the system. Scope also allows for the logging of this
real-time data. These files can be used to analyze the inputs over a period of time.
Scope is used to record suspension pressures during a haul cycle. These pressures can be imported into Microsoft
Excel or other spreadsheet programs to graph each suspension. Visually, a service technician can look for flat or
undercharged suspensions. In addition, all the input to the payload meter can be checked using the PC instead of
the switches on the front panel of the payload meter
System Requirements - Microsoft Windows 95, access to serial communications port 1, EF9159 & EF9160 har-
nesses to connect the Payload Meter II™ to the serial port of the PC. Payload Meter II™ must also be set up to use
MMS Communications Mode. This is indicated on power up of the Payload Meter by OP12. Changing this setting is
described in “Setting the Option Code”.
Downloading Scope – Scope is available on the internet. It can be found at the following address:
http://www.kms-peoria.com/payload
The program, Scopezipped.exe, is a self-extracting executable. Save it into its own directory on your hard drive
and run it. The program will unzip and be ready to run.
NOTE: This program has not been tested on all versions of Windows and may not work on all operating systems.
Using Scope
1. Start Scope Payload Meter II™.
2. Power the Payload Meter II™ System.
3. StartRTM - Start real time communications soon after the payload meter finishes it’s initial display of internal
settings. This display cycle is described in “Displays at Start-Up”.
4. The Scope window should now indicate real-time conditions. The RTM D I/O conditions show the inputs into
the Payload Meter II™. The suspension pressures, inclinometer, speed, and truck status displayed are the
current readings from all sensors. This display will remain live as long as the communications connection is
maintained.
5. To create a record of the data being transmitted by the Payload Meter II™, press StartLog. The program will
prompt for a file name. Once entered, Scope will begin to save data to this file.
6. Use the StopLog command to stop logging data to the file.
7. Use the StopRTM command to stop real time communications. After a period of time, the payload meter
should indicate a communications error.
In the sample data shown, the column marked "Type" refers to the type of data being transmitted; “R” is used for
Real-Time, “F” is used for Final Load and “S” is used for Swing Load.
For the swing load data line the format is Time, S, Swing Load, Predicted Load, FL, FR, RL, RR.
For a final load transmission the format is Time, F, Final Load, FL, FR, RL, RR.
The Payload Meter requires 5 wire RS232 communications. Payload Meter communications connections are :
1 - RTS 2 - Signal Ground 3 - RxD 4 - TxD 5 - CTS
·As shown in the previous examples, Scope can be used to create log files of the suspension pressure data.
Graphs of this data can give be used to determine the relative health of the suspensions.
CAB COMPONENTS
INDEX
TRUCK CAB
INDEX
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-17
Removal - Cab
NOTE: The following procedure describes removal of
After the truck is parked in position for the repairs, the cab as a complete module with the hydraulic
the truck must be shut down properly to ensure the brake cabinet attached. All hoses and wire
safety of those working in the areas of the deck, elec- harnesses should be marked prior to removal for
trical cabinet and retarding grids. The following pro- identification to ensure correct reinstallation:
cedures will ensure the electrical system is properly
discharged before repairs are started. 1. Disconnect hydraulic hoses routed to frame
from fittings at rear of cab under brake cabinet
(3, Figure 2-2). (It is not necessary to discon-
nect hoses attached to, and routed under the
cab.) Cap all lines to prevent contamination.
2. Disconnect wire harnesses (4) at connectors
located under hydraulic cabinet.
3. Remove cable and hose clamps as needed for
cab removal
4. Close heater shutoff valves located at the water 7. Evacuate air conditioning system:
pump inlet housing on the right side of the
a. Attach a recycle/recovery station at the air
engine and at the water manifold. Disconnect
conditioning compressor service valves.
heater hoses at each valve and drain coolant
(Refer to Section N, Operator Comfort for
into a container.
detailed instructions.)
5. Remove clamps and heater hoses from fittings
b. Evacuate air conditioning system refrigerant.
underside of deck, below heater. Cap fittings
and plug hoses. c. Remove the air conditioner system hoses
6. Remove air cleaner restriction indicator hoses which are routed to the bottom of the cab
near front, inside corner under cab. from the receiver/drier and compressor. Cap
hoses and fittings to prevent contamination.
8. Attach a lifting device to the lifting eyes pro-
vided on top of the cab.
FIGURE 2-8.
FIGURE 2-7.
FIGURE 2-9.
FIGURE 2-10.
1. Screws 2. Rubber Felt Insert
Installation
1. Install the seal material around the door open-
ing in the cab. Start at the bottom center of the
cab opening and work the seal lip over the
edge of the opening. Go all the way around the
opening. Be sure that the seal fits tight in the
corners. A soft face tool may be used to work
the seal up into the corners.
2. Continue going all the way around the opening.
When the ends of the seal meet at the starting
bottom center of the cab opening, it may be
necessary to trim off some of the seal.
NOTE: The ends of the seal material need to be
square-cut to assure a proper fit.
FIGURE 2-17.
3. Fit both ends so that they meet squarely, then
1. Door Opening Seal 2. Door Hinge Seal
while holding ends together, push them firmly
into the center of the opening.
CAB COMPONENTS
INDEX
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WINDSHIELD WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WINDSHIELD WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation
1. Place the linkage into position in the wiper com-
FIGURE 3-3. PARK POSITION partment.
1. Wiper Motor 2. Linkage Retainer 2. If equipped, place spacer blocks (1, Figure 3-4)
into position under pillow blocks (3). Install cap-
screws (2), the washers, and the nuts that
secure the pillow blocks.
3. Install nut (3, Figure 3-2) on each wiper shaft
and tighten finger-tight. Torque the nuts to 160-
177 in. lbs. (18-20 Nm). Do not overtighten.
Wiper Linkage Replacement The threads on the shafts are easily stripped
when improperly tightened.
Removal
4. Align the linkage and attach to the wiper motor
1. Remove the wiper arms. Refer to Wiper Arm drive arm using retainer (2, Figure 3-3).
Replacement in this section.
NOTE: When the motor is parked, the drive arm will
2. Remove wiper retainer (2, Figure 3-3) and dis- be in the 3 o’clock position as shown in Figure 3-3.
connect the wiper linkage from the wiper motor
5. Install the wiper arms. Refer to Wiper Arm
drive arm.
Installation. Ensure the wipers arms operate
3. Remove nut (3, Figure 3-2) and the washer properly and park in the proper position after
from each wiper shaft. installation is complete.
Service
If windshield washer maintenance is required, check
the strainer opening for obstructions and inspect the
hoses for damage. Check the voltage to the pump
from the control switch. If the pump is inoperable,
replace it with a new pump assembly.
Note: The pump is only available as an assembly
and cannot be repaired.
Operation
Heat for the cab is provided by passing coolant from
the engine cooling system through a heater coil.
Blowers move air across the heating coil which
warms the air for heating or defrosting.
An engine driven freon compressor passes refriger-
ant through an evaporator coil mounted in the same
enclosure. The same blowers used for heating move
air across the evaporator to provide cooled air
through the outlet vents.
All heater and air conditioner controls are mounted
on a pod on the face of the enclosure. Refer to Fig-
ure 4-1 for the following:
• Defroster switch (1): This is a 2-position toggle
switch; "down " is OFF. "Up" provides air flow
through the defroster vents.
• Outside/Inside air control switch (2): This is a 2-
position toggle switch; "down" recirculates cab
air. "Up" allows outside air to flow through heater
or air conditioner coils.
• Heat vent control switch (3): This is a 2-position
toggle switch; "down " is OFF. "Up" provides
heated air flow to the cab floor.
• Temperature control knob (4): This is a variable
rotary control. Rotating the knob
counterclockwise (blue arrow) will select
increasingly cooler temperatures. Rotating the
knob clockwise (red arrow) selects increasingly FIGURE 4-1. HEATER / AIR CONDITIONER
warmer temperatures. CONTROLS
• Fan control (5); This is a 3-position rotary switch; 1. Defroster Control 5. Fan Control
rotate knob to select low, medium, or high fan 2. Outside/Inside Air 6. Heater/Air Condi-
speed. Control tioner Selector
• Heater/Air conditioner selector switch (6): This is 3. Heat Control 7. Outlet Vents
a three position switch; the right position 4. Temperature Control
activates the heater, the left position activates the
air conditioner, and the center position is OFF.
Actuators
Three linear actuators (22, Figure 4-3) are installed
inside the heater housing and are used to actuate the
flappers for the following:
• Defroster outlet FIGURE 4-3. CAB FILTER LOCATION
Test
Visually inspect the flapper and linkage for the func-
tion being diagnosed. Make certain the flapper is not
binding or obstructed, preventing movement from
one mode to the other.
Verify voltage is present at the actuator when the tog-
gle switch is closed or absent when the toggle switch
is opened.
If voltage is proper, disconnect actuator from flapper
and verify actuator force is comparable to a known
(new) actuator. If not, replace with a new actuator.
Reclaimed Refrigerant
Reclaimed refrigerant has been filtered through a
R-134a Refrigerant Containers
more thorough filtering process and has been pro-
cessed to the same standards of purity as virgin Two basic, readily available containers are used to
refrigerant. Because of this, reclaimed refrigerant is store R-134a: the 30 or 60 pound bulk canisters (Fig-
acceptable for use in all systems, not just mobile. ure 4-5).
The reclaiming equipment used for this process is
Always read the container label to verify the contents
expensive, and therefore, not common among nor-
are correct for the system being serviced. Note the
mal maintenance shops. Equipment such as this is
containers for R-134a are painted light blue.
more commonly found in air conditioning specialty
shops.
Refrigerant Quantity
If not enough refrigerant is charged into the system,
cooling ability will be diminished. If too much refriger- FIGURE 4-6. R-134a CONTAINERS
ant is charged into the system, the system will oper-
ate at higher pressures, and in some cases, may 1. 30 lb. Cylinder 2. 60 lb. Cylinder
damage system components. Exceeding the speci-
fied refrigerant charge will not provide better cooling.
If an incorrect charge is suspected, recover the
refrigerant from the system, and charge the system
with the correct operating weight (6.9 lb, 3.13 kg).
This is not only the recommended procedure, but it is
also the best way to ensure that the system is operat-
ing with the proper charge and providing optimum
cooling. Using the sight glass to determine the
charge is not an accurate method.
8 24 - 29 ft.lbs. 33 - 39 Nm
10 26 - 31 ft.lbs. 36 - 42 Nm
12 30 - 35 ft.lbs. 41 - 47 Nm
Only SAE and/or Mobile Air Conditioning Society
(MACS) approved flushing methods with the Installation torque for the single M10 or 3/8 in. cap-
appropriate refrigerants are to be performed screws securing the inlet and outlet fittings onto the
when removing debris from the system. Other compressor ports is 11 - 25 ft.lbs. (15 - 34 Nm).
methods may be harmful to the environment, as
well as air conditioning components.
Expansion Valve
When removing the expansion valve from the sys-
tem, remove the insulation, clean the area and dis-
connect the line from the receiver-drier. Detach the
capillary (bulb) and external equalizer tube (if
present) from their mounting locations. Remove the
expansion valve from the evaporator inlet. Expansion
valve service is limited to cleaning or replacing the fil-
ter screen. If this is not the problem, replace the
valve. Secure the capillary and equalizer, if used, to
clean surfaces and replace or attach any insulating
material.
Compressor
NOTE: Some compressors may be discarded
The compressor can fail due to shaft seal leaks (no because it is suspected that internal components
refrigerant in the system), defective valve plates, within the compressor have seized. Ensure that
bearings, or other internal parts or problems associ- the compressor clutch is working properly before
ated with high or low pressure, heat, or lack of lubri- discarding a compressor for internal seizure. The
cation. Be sure the compressor is securely mounted normal compressor life span should be about
and the clutch pulley is properly aligned with the twice as long as the normal life span of the com-
drive pulley. pressor clutch.
Use a mechanic's stethoscope to listen for noises It is important to note that often times a weak clutch
inside the compressor. coil may be mistaken for a seized compressor. When
a coil’s resistance has increased over time and the
magnetic field weakens, the coil may not be able to
pull the load of the compressor. Failure of the coil to
allow the compressor shaft to be turned, may appear
as though the compressor is locked up.
FIGURE 4-14.
Servicing the Compressor Clutch 1. Belt Pulley 3. Shaft
2. Clutch Hub/Drive 4. Locknut
* RECOMMENDED TOOLS FOR COMPRESSOR Plate
CLUTCH REMOVAL AND INSTALLATION
**J-9403 Spanner Wrench 2. Remove the drive belt from compressor belt
pulley (1, Figure 4-13).
**J-25030 Clutch Hub Holding Tool
FIGURE 4-15.
Use the proper tools to remove and replace 1. Thin Wall Socket 3. Clutch Hub
clutch components. Using the recommended 2. Clutch Hub Holding
tooling helps prevent damage to compressor Tool
components during maintenance.
Do not drive or pound on the clutch plate, hub
assembly, or shaft. Internal damage to the com-
pressor may result.
FIGURE 4-18.
FIGURE 4-17.
FIGURE 4-19. If the resistance of the coil is not within the specifica-
tions, the clutch will not operate properly. Remove
1. Pulley Assembly 3. Retaining Ring Pliers the retaining ring and replace the coil.
2. Pulley Retainer Ring
FIGURE 4-21.
1. Bearing Installer 2. Universal Handle
The most important factor is the ability for the The proper method for charging refrigerant into a R-
system to hold the deepest vacuum the pump 134a system is to first, recover all of the refrigerant
can pull, and hold it for 15 minutes after the from the system. The charging refrigerant should
pump has stopped. This may take several tries then be weighed on a scale to ensure the proper
depending on how long the system was held in a amount is charged into the system. Most recovery
vacuum. units include a scale within the apparatus, thus mak-
ing it very easy to charge the correct amount every
time. If equipment such as this is not available, a
common scale can be used to determine the weight
of charge. Simply weigh the charging tank, subtract
the weight of the proper charge, and charge the sys-
tem until the difference is shown on the scale. On
certain types of equipment, it is also possible to add
any necessary lubricant when charging the system.
Indications:
Low side pressure - VERY LOW
High side pressure - VERY LOW
Discharge air is warm.
No bubbles observed in sight glass, may show oil
streaks.
- Pressure sensing switch may have compressor Add refrigerant (make sure system has at least
clutch disengaged. 50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
-
enable the compressor to operate, if the com-
- Refrigerant excessively low; leak in system. pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is warm.
The low pressure switch may have
shut off the compressor clutch.
Leaks Found:
Add refrigerant (make sure system has at least
50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable the compressor to operate, if the com-
pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
Indications:
Low side pressure - Normal
High side pressure - Normal
Discharge air is only slightly cool.
(In a cycling type system with a
thermostatic switch, the switch may not cycle
the clutch on and off, so the low pressure
gauge will not fluctuate.)
Indications:
Low side pressure - HIGH
High side pressure - HIGH
Discharge air is only slightly cool.
Indications:
Low side pressure - VERY LOW or in a Vacuum
High side pressure - HIGH
Discharge air only slightly cool.
Expansion valve body is frosted or sweaty.
Indications:
Low side pressure - HIGH
High side pressure - Normal
Air from vents in the cab seems warm
or only slightly cool.
Indications:
Low side pressure - LOW
High side pressure - Normal to HIGH
Discharge air is only slightly cool.
Look for sweat or frost on high side hoses
and tubing. The line will be cool to the touch
near the restriction.
Indications:
Low side pressure - HIGH
High side pressure - LOW
Compressor operates noisily.
Indications:
Low side pressure - Normal
High side pressure - Normal
Low side pressure may cycle within a smaller
range as the compressor clutch cycles
more frequently than normal. This may indicate
the thermostat is set too high.
Indications:
Low Side High
High Side High
Discharge air may be warm.
High pressure hoses and lines are very hot.
Date:____________Hour Meter:________________
NOTE: Compressor should be run at least 5 minutes
(40°F minimum ambient temperature) every month,
Maintenance Interval in order to circulate oil and lubricate components.
COMPONENT (months)
Maintenance Interval
3 6 12 Done
COMPONENT (months)
1. Compressor
3 6 12 Done
Check noise level
4. Expansion Valve X
Check clutch pulley
Inspect capillary tube (if
Check oil level used) for leakage, damage,
Run system 5 minutes looseness
Check belt tension 5. Evaporator
(80-100) lbs; V-belt
Clean dirt, bugs, leaves, etc.
Inspect shaft seal for leakage from fins (w/ compressed air)
Check mounting bracket Check solder joints on inlet/
(tighten bolts) outlet tubes (leakage)
Check clutch alignment w/ Inspect condensation drain
crankshaft pulley (within
6. Other Components
0.06 in.)
Check discharge lines
Perform manifold gauge
(hot to touch)
check
Check suction lines
Verify clutch is engaging
(cold to touch)
2. Condenser
Inspect fittings/clamps/hoses
Clean dirt, bugs, leaves, etc.
Check thermostatic switch for
from coils (w/compressed air)
proper operation
Verify engine fan clutch is
Outlets in cab: 40°F to 50° F
engaging (if installed)
Inspect all wiring connections
Check inlet/outlet for
obstructions or damage Operate all manual controls
through full functions
3. Receiver-Drier
Check inlet line from
condenser (should be hot to
touch)
Replace, if system is opened
Installation
1. Install stub shaft (11, Figure 5-1) on steering
column splines. Leave a 0.125 in. (3.2 mm) gap
between end of stub shaft and end of steering
column housing. Tighten clamp capscrew (6) to
standard torque.
2. Apply molybdenum disulphide or multi-purpose
NLGI grease to external splines of stub shaft.
3. With the steering column tilted at approximately
30°, insert the lower end of the column into the
opening in the instrument panel. Attach saddle
bracket (5) with capscrews and washers (4).
Tighten to standard torque.
4. Position saddle bracket over tapped mounting
holes and install capscrews and washers (3).
Tighten capscrews just enough to secure col-
FIGURE 3-1. STEERING COLUMN umn in position.
INSTALLATION 5. With capscrews (3) loosened, allow steering
1. Steering Column 7. Capscrews & Washers column to slide downward until stub shaft (11)
2. Trim Cover 8. Front Access Cover splines bottom in steering control unit (9). When
3. Capscrews & Washers 9. Steering Control Unit the stub shaft is at rest at the bottom of the input
4. Capscrews & Washers 10. Capscrews & Washers collar, slide column out to obtain 0.08 to 0.120
5. Saddle Bracket 11. Splined Stub Shaft in. (2 to 3 mm) clearance between end of stub
6. Capscrew & Nut* shaft and steering control unit. Tighten cap-
screws (3) to standard torque.
NOTE: The gap in Step 5 can be measured by
Removal etching a line across saddle bracket (5) and the
1. Shut down the engine by turning the key switch bracket mounting face while the stub shaft is at rest
"Off" and allow the steering accumulators to in the control unit. Pull the column away from the
bleed down. Allow at least 90 seconds for bleed control unit until the correct gap exists between the
down. Turn the steering wheel to ensure no mark on the bracket and the mark on mounting face.
pressure remains. 6. Carefully tighten capscrews (7 & 10). It is impor-
2. Open the battery disconnect switches. tant to use care when tightening to be certain no
binding occurs between stub shaft and steering
3. Remove access cover (8, Figure 5-1) from the
unit splines.
front of the cab.
4. Loosen capscrews (7 & 10) on control unit (9). Note: Be certain clearance adjusted in Step 5
remains between 0.08 and 0.120 inches (2 to 3 mm)
5. Disconnect wire harness from the steering col-
when capscrews are tightened.
umn at the connector.
Horn Button
The horn (2, Figure 5-3) is actuated by pushing the
button in the center of the steering wheel. Operation
of the horn should be verified before moving the
truck. Observe all local safety rules regarding the use
of the horn as a warning signal device before starting
engine and moving the vehicle.
The lever and foot-operated Retarder/Service Brake Starting on a Grade With a Loaded Truck
pedal can be used simultaneously or independently.
Initial propulsion with a loaded truck should begin
The Propulsion System Controller (PSC) will deter-
from a level surface whenever possible, but when
mine which device is requesting the most retarding
there are circumstances where starting on a hill or
effort and apply that amount.
grade cannot be avoided, use the following proce-
dure:
1. Fully depress the foot-operated retarder/service
Dynamic Retarder /Service Brake Pedal
brake pedal (DO NOT use retarder lever) to
The Dynamic Retarder/Service Brake Pedal (3, Fig- hold the truck on the grade. With service brakes
ure 5-2) is a single, foot-operated pedal which con- fully applied, move the selector switch to a drive
trols both retarding and service brake functions. The position (Forward/Reverse) and increase
first portion of pedal travel commands retarding effort engine RPM with throttle pedal.
through a rotary potentiometer. The second portion 2. As engine RPM approaches maximum, and
of pedal travel modulates service brake pressure operator senses propulsion effort working
directly through a hydraulic valve. Thus, the operator against the brakes, release the brakes and let
must first apply, and maintain, full dynamic retarding truck movement start. Be sure to completely
in order to apply the service brakes. Releasing the release the foot-operated retarder/service brake
pedal returns the brake and retarder to the "off" posi- pedal. As truck speed increases above 3-5
tion. MPH (5-8 KPH) the Propulsion System Control
When the pedal is partially depressed, the dynamic (PSC) will drop propulsion if the retarder is still
retarding is actuated. As the pedal is further applied.Releasing and reapplying dynamic
depressed, to where dynamic retarding is fully retarding during a hill start operation will result
applied; the service brakes (while maintaining full in loss of propulsion and, if truck speed is above
retarding) are actuated through a hydraulic valve 1-2 MPH, application of retarding effort.
which modulates pressure to the service brakes.
Completely depressing the pedal causes full
application of both dynamic retarding AND the
service brakes. An indicator light in the overhead
panel (B3, Figure 5-7) will illuminate), and an
increase in pedal resistance will be felt when the Ser-
vice Brakes are applied.
Lighter
The LIGHTER (5, Figure 5-5) may be used for light-
ing cigars/cigarettes. Always use CAUTION with
smoking materials!
This socket may also be used for a 12 VDC power
supply.
WIRE NUMBERS
1. 712/21PB/11S 11. 71/79M/SPR55/79H/72F/ 21. 712D/31TS/710/49
2. 11S/11TD/11R SPR54 22. 712D/38G/710/49
3. 712/47S/47L/710 12. 712BL/52B/39H/710/SPR59 23. 15V/72MT/49/710
4. 11L/48A/48B 13. 71/52C/21PB/21 24. 11L/36
5. 11L/48F 14. 41TS/74X/74Z/710 25. 15V/34BT/710/49
6. 49/710 15. 45R/710 26. 710/72RQ
7. N/A 16. 41H/710 27. 11D/41L/41TS
8. 712/28E 17. 45L/710 28. High 66S/Low 66L/710/66P
9. 11L/11RB 18. 41TS/77/77A/710 Park/712W / Washer 66
10. 712/69M/SPR56/SPR57/ 19. 712D/710/49 29. 49/41TS
SPR58 20. 712D/31PS/710/49
Operation
1. Stop the truck, and reduce engine rpm to low
idle. Place the selector switch in "NEUTRAL"
and apply the parking brake switch. Place the Fog Lights (Optional)
rest switch in "ON" position (put drive system in
"REST" mode of operation). Refer to the discus- Fog Lights (5, Figure 5-6) are
sion of the rest switch later in this chapter. optional equipment that are use-
ful in foggy conditions and heavy
2. Press the top of the engine shutdown switch to
rain. Pressing the top of the
select the “ON” (center) position. Press the top
rocker switch turns the lights
of the switch again to activate the timer delay
"On". Pressing the bottom of the
(momentary position). Release the switch and
switch turns the lights "Off".
allow it to return to the “ON” position.
When the engine shutdown timer has been acti-
vated, the timer delay indicator light (C4, Figure Ladder Light Switch
5-7) in the overhead status panel will illuminate
to indicate that the shutdown timing sequence The switch (4, Figure 5-6) turns
has started. The engine will continue to idle for the ladder lights "On" or "Off"
approximately 5 minutes to allow for proper after or before using ladder.
engine cool-down before stopping. Pressing the top of the rocker
switch turns the lights "On".
3. Turn the keyswitch counterclockwise to the
Pressing the bottom of the
"OFF" position to cause the engine to shutdown
switch turns the lights "Off".
when the timing sequence is complete. When
Another switch is mounted at the
the engine stops, this will activate the hydraulic
front left of truck near the base of ladder.
bleeddown timer and turn off the 24 VDC elec-
tric circuits controlled by the keyswitch.
NOTE: To cancel the 5 minute idle timer sequence, Manual Backup Switch
press the timer delay shutdown switch to the "OFF"
(lower) position. If the keyswitch is in the "OFF" The Manual Backup Switch (3,
position, the engine will stop. If the keyswitch is in the Figure 5-6) allows backup lights
"ON" position, the engine will continue to run. to be turned "On" providing
added visibility and safety when
the Selector Switch (see Opera-
4. With keyswitch "OFF", and engine stopped, tor Controls) is not in "REV"
wait at least 90 seconds. Ensure the steering position. When the SWITCH is
circuit is completely bled down by turning the pressed toward the "on" position, the MANUAL
steering wheel back and forth several times. No BACK UP LIGHT indicator (B4, Overhead Panel, Fig-
front wheel movement will occur when hydraulic ure 5-7) will be illuminated.
pressure is relieved.
Row / Indicator Indicator Color Wire Row / Indicator Indicator Color Wire
Column Description Index Column Description Index
A1* NOT USED 12FD/34TL A5 NO POWER Red-12M/75-6PI
B1* Low Steering Pressure Red-12FD/33A B5 PROPULSION SYSTEM Amber-12F/79WI
C1 Low Accumulator Pr. Red-12F/33K WARNING
When the keyswitch is turned "ON", the low steering Not currently used. Reserved for future use or
pressure warning light will illuminate until the steering options.
system hydraulic pressure reaches 2100 psi (14.7
E1. LOW BRAKE PRESSURE
MPa). The warning horn will also turn on, and both
will remain on, until the accumulator has been This red indicator light indicates a malfunction within
charged. the hydraulic brake circuit. If this light comes on and
buzzer sounds, shut down truck operation and
During truck operation, the low steering pressure
notify maintenance personnel.
warning light and warning horn will turn sound if
steering system hydraulic pressure drops below NOTE: Adequate hydraulic fluid is stored to allow the
2100 psi (14.7 MPa). operator to safely stop the truck.
• If the light illuminates momentarily ("flickers")
while turning the steering wheel at low truck
speed and low engine RPM, this may be
This warning light indicates the oil level in the This amber parking brake indicator will illuminate
hydraulic tank is below recommended level. Damage when the parking brake is applied. Do not attempt to
to hydraulic pumps may occur if operation continues. drive truck with parking brake applied.
Shut truck down and notify maintenance personnel
B3. SERVICE BRAKE
immediately.
This amber service brake indicator will illuminate
B2. NOT USED when the service brake pedal is applied or when
Not currently used. Reserved for future use/options. wheel brake lock or emergency brake is applied. Do
not attempt to drive the truck from stopped position
C2. CIRCUIT BREAKER TRIPPED with service brakes applied, except as noted in
“Operating Instructions, Starting On a Grade With a
This light will illuminate if any of the circuit breakers Loaded Truck”, Section 3.
in the relay circuit control boards are tripped. The
relay circuit boards are located in the Electrical Inter- C3. BODY UP
face Cabinet.
This amber indicator, when illuminated, shows that
NOTE: Additional circuit breakers are in the operator the body is not resting on the frame. The truck should
cab behind the center console, however tripping of not be driven until body is down and light is off.
these circuit breakers should not activate this light.
D3. DYNAMIC RETARDING
D2. HYDRAULIC OIL FILTER MONITOR
This amber indicator illuminates whenever the
This light indicates a restriction in the high pressure retarder pedal or lever is operated, RSC (Retard
filter assembly for either the steering or hoist circuit. Speed Control) is activated, or the automatic over-
This light will come on before filters start to bypass. speed retarding circuit is energized, indicating the
Notify maintenance personnel at earliest opportunity dynamic retarding function of the truck is operating.
after light comes on.
E3. STOP ENGINE
NOTE: The filter monitor warning light may also
illuminate after the engine is initially started if the oil This RED warning light will illuminate if a serious
is cold. If the light turns off after the oil is warmed, engine malfunction is detected in the electronic
filter maintenance is not required. engine control system. (Continued on next page.)
C5. PROPULSION SYSTEM TEMPERATURE Stop the truck as soon as possible in a safe area
and apply the parking brake.
This amber AC Drive System "Temperature Warning" SHUT DOWN THE ENGINE immediately. Addi-
light indicates the drive system temperature is above tional engine damage is likely to occur if opera-
a certain level. When this condition occurs, the oper- tion is continued.
ator should consider modifying truck operation in
order to reduce system temperature. The operator is An example of a condition that could cause the Stop
not required to stop the truck at this time. Engine light to illuminate:
• If the governor senses an overspeed condition,
D5. HIGH HYDRAULIC OIL TEMPERATURE the ECM will close the fuel solenoid and stop the
This red warning light indicates high oil temperature flow of fuel to the engine until engine speed is
in the hydraulic tank. Several things occur before the back within normal operating range.
red light illuminates:
A6. NO PROPEL
The red "No Propel" light indicates a fault has
occurred which has eliminated the propulsion capa-
bility.
If this condition occurs, the operator should
safely stop the truck, move Selector Switch to
Neutral, apply the Park Brake, shutdown engine,
and notify maintenance personnel immediately.
INDEX
INDEX
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. ENGINE -
a. Check the oil level on the dipstick. Refer to
the engine manual for oil recommendations.
(Lube Key “A”).
*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation).
*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:
*This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:
FIGURE 2-6.
1. Magnetic Plug 2. Cover
FIGURE 2-7.
INDEX
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANT REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Injector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PUMP REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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. L.H. Suspension, Bottom Bearing 14. R.H. Hoist Cylinder, Bottom Bearing
3. L.H. Body Pivot Pin 15. R.H. Anti-Sway Bar Bearing
4. L.H. Hoist Cylinder, Top Bearing 16. Vent Hose
5. L.H. Hoist Cylinder, Bottom Bearing 17. Junction Box
6. L.H. Anti-Sway Bar Bearing 18. Pressure Switch, N.O., 2500 psi (17 237 kPa)
7. Rear Axle Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. Pressure Switch, N.O., 2000 psi (13 790 kPa) 21. Filter
10. R.H. Suspension, Top Bearing 22. Grease Supply to Injectors
11. R.H. Suspension, Bottom Bearing 23. Truck Frame
12. R.H. Body Pivot Pin 24. Injector
Grease Reservoir (12, Figure 4-3) Pump Cutoff Pressure Switch (N.O. 2500 psi [17
237 kPa]) (10, Figure 4-3)
The reservoir has an approximate capacity of 60 lbs.
(27 kg) of grease. When the grease supply is replen- This pressure switch de-energizes the pump sole-
ished by filling the system at the service center, the noid relay when the grease line pressure reaches the
grease is passed through the filter to remove con- switch pressure setting, turning off the motor and
taminants before it flows into the reservoir. pump.
Pressure Reducing Valve (4, Figure 4-3) Grease Pressure Failure Switch (N.O. 2000 psi
[13 789 kPa]) (9, Figure 4-4)
The pressure reducing valve, located on the manifold
reduces the hydraulic supply pressure (from the truck This pressure switch monitors grease pressure in the
steering circuit) to a suitable operating pressure, injector bank on the rear axle housing. If the proper
[325-350 psi (2 240 to 2 415 kPa)] for the hydraulic pressure is not sensed within 60 seconds (switch
motor used to drive the lubricant pump. contacts do not close), several relays energize, actu-
ating a warning lamp circuit to notify the operator a
Flow Control Valve (9, Figure 4-3) problem exists in the lube system.
The flow control valve mounted on the manifold, con- Pressure Gauge (7, Figure 4-3)
trols the amount of oil flow to the hydraulic motor.
The flow control valve has been factory adjusted The pressure gauge monitors hydraulic oil pressure
and the setting should not be disturbed. to the inlet of the hydraulic motor.
The solenoid valve, when energized, allows oil to Each injector delivers a controlled amount of pres-
flow to the hydraulic motor. surized lubricant to a designated lube point. Refer to
Figure 4-4 for locations.
STAGE 1.
The injector piston (2) is in its normal or
“rest” position. The discharge chamber (3) is
filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant (6),
the slide valve (5) is about to open the pas-
sage (4) leading to the measuring chamber
(1) above the injector piston (2).
STAGE 2.
When the slide valve (5) uncovers the pas-
sage (4), lubricant (6) is admitted to the mea-
suring chamber (1) above the injector piston
(2) which forces lubricant from the discharge
chamber (3) through the outlet port (7) to the
bearing.
STAGE 3.
As the injector piston (2) completes its
stroke, it pushes the slide valve (5) past the
passage (4), cutting off further admission of
lubricant (6) to the passage (4) and measur-
ing chamber (1). The injector piston (2) and
slide valve (5) remain in this position until
lubricant pressure in the supply line (6) is
vented.
STAGE 4.
After venting, the injector spring expands,
causing the slide valve (5) to move, so that
the passage (4) and discharge chamber (3)
are connected by a valve port (8). Further
expansion of the spring causes the piston to
move upward, forcing the lubricant in the
measuring chamber (1) through the passage
(4) and valve port (8) to refill the discharge
chamber (3).
LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Oil level should be
checked at 1000 hour intervals. To add oil, remove
pipe plug (3, Figure 3-5) and fill housing to bottom of
plug hole.
FIGURE 3-5. PUMP CONTROLS
Injector Adjustment
FIGURE 3-6. TYPE SL-1 INJECTOR
The injectors may be adjusted to supply from 0.008
in3 to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per 1. Adjusting Screw 11. Spring Seat
injection cycle. The injector piston travel distance 2. Locknut 12. Plunger
determines the amount of lubricant supplied. This 3. Piston Stop Plug 13. Viton Packing
travel is in turn controlled by an adjusting screw in 4. Gasket 14. Inlet Disc
the top of the injector housing. 5. Washer 15. Viton Packing
6. Viton O-Ring 16. Washer
Turn the adjusting screw (1, Figure 4-9) counter- 7. Injector Body Assy. 17. Gasket
clockwise to increase lubricant amount delivered and 8. Piston Assembly 18. Adapter Bolt
clockwise to decrease the lubricant amount. 9. Fitting Assembly 19. Adapter
When the injector is not pressurized, maximum injec- 10. Plunger Spring 20. Viton Packing
tor delivery volume is attained by turning the adjust-
ing screw (1) fully counterclockwise until the
indicating pin (8) just touches the adjusting screw. At
the maximum delivery point, about 0.38 inch (9.7 SYSTEM CHECKOUT
mm) adjusting screw threads should be showing. To check system operation (not including timer), pro-
Decrease the delivered lubricant amount by turning ceed as follows:
the adjusting screw clockwise to limit injector piston
1. Turn keyswitch ON and start the engine.
travel. If only half the lubricant is needed, turn the
adjusting screw to the point where about 0.19 inch 2. Actuate the lube system test switch at the reser-
(4.8 mm) threads are showing. The injector will be voir/pump assembly on the front bumper.
set at minimum delivery point with about 0.009 inch 3. The motor and pump should operate until the
(0.22 mm) thread showing. system attains 2500 psi (17 237 kPa).
NOTE: The above information concerns adjustment 4. Once the required pressure is achieved, the
of injector delivery volume. The timer adjustment pump motor should turn off and the system
should also be changed, if overall lubricant delivery is should vent.
too little or too much. Injector output should NOT be 5. Check for pump, hose or injector damage or
adjusted to less than one-fourth capacity. leakage with the system under pressure.
NOTE: The piston assembly (8) has a visible indica- 6. After checking system, shutdown engine,
tor pin at the top of the assembly to verify the injector observing normal precautions regarding high
operation. voltage present in the propulsion system before
attempting to repair lube system.
If the following procedures do not correct the problem, contact a factory authorized service center.
NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing
cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as
specified.
Low lubricant supply. Dirt in reservoir, pump inlet clogged, filter clogged.
Air trapped in lubricant supply line. Prime system to remove trapped air.
Lubricant supply line leaking. Check lines and connections to repair leakage.
Vent valve leaking. Clean or replace vent valve.
Pump worn or scored. Repair or replace pump assembly.
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.
Relay (RB7K5) may be defective. Replace relay.
Timer BAT (-) connection is not on grounded mem- Connect to good ground.
ber.
Timer BAT (+) connection not on circuit continu- Establish direct connection between Timer BAT (+)
ously connected to BAT (+) terminal during opera- connection and 24 V BAT (+) terminal.
tion of vehicle.
Loose wire connections at any of the timer termi- Secure wire connections.
nals.
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 capaci- may be generated into vehicle electrical system
tor causing uncontrolled turn-on of its output relay. which may cause timer to turn on at random
intervals, independent of timer setting.
If this occurs, a 250 to 1,000 MFD capacitor rated
150 to 350 VDC should be added across BAT (+)
and BAT (-) terminals to suppress this noise and
improve timer performance.
Timer out of adjustment or damaged component. Refer to Timer Adjustment and re-adjust timer or
replace timer.
Daily Lubrication System Inspection It is good practice to manually lube each bearing
point at the grease fitting provided on each Injector.
1. Check grease reservoir level. This will indicate if there are any frozen or plugged
Inspect grease level height after each shift of opera- bearings, and will help flush the bearings of contami-
tion. Grease usage should be consistent from day-to- nants.
day operations. 5. System Checkout
• Lack of lubricant usage would indicate an a. Remove all SL-1 injector cover caps to allow
inoperative system. Excessive usage would visual inspection of the injector cycle indica-
indicate a broken supply line. tor pins during system operation.
2. Check filter bypass indicator when filling reser- b. Start truck engine.
voir. Replace element if bypassing.
c. Actuate the lube system test switch. The
3. Check all grease feed line hoses from the SL-1
hydraulic motor and grease pump should
Injectors to the lubrication points.
operate.
a. Repair or replace all damaged feed line
d. With the grease under pressure, check each
hoses.
SL-1 injector assembly. The cycle indicator
b. Make sure that all air is purged and all new pin should be retracted inside the injector
feed line hoses are filled with grease before body.
sending the truck back into service.
e. When the system attains 2500 psi (17 237
4. Inspect key lubrication points for a bead of lubri- kPa), the pump should shut off and the pres-
cant around seal. If a lubrication point appears sure in the system should drop to zero, vent-
dry, troubleshoot and repair problem. ing back to the grease reservoir.
250 Hour Inspection f. With the system vented, check all of the SL-1
injector indicator pins; all of the pins should
1. Check all grease feed line hoses from the SL-1 be visible. Replace or repair injectors, if
Injectors to the lubrication points (see, Figure 4- defective.
3).
g. Reinstall all injector cover caps.
a. Repair or replace all worn / broken feed line
hoses. h. Check timer operation.
b. Make sure that all air is purged and all new
feed line hoses are filled with grease before Note: With engine running, lube system should
sending the truck back into service. activate within 5 minutes. The system should build
2. Check all grease supply line hoses from the 2000 to 2500 psi within 25-40 seconds.
pump to the SL-1 injectors.
a. Repair or replace all worn / broken supply
lines. a. If the system is working properly, the truck is
ready for operation.
b. Make sure that all air is purged and all new
supply line hoses are filled with grease b. If the system is malfunctioning, refer to the
before sending the truck back into service. troubleshooting chart.
3. Check grease reservoir level.
a. Fill reservoir if low. 1000 Hour Inspection
b. Check reservoir for contaminants. Clean, if 1. Check pump housing oil level and correct if
required. necessary.
c. Check that all filler plugs, covers and
breather vents on the reservoir are intact and
free of contaminants.
L
G
Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-32
Lubrication and Service . . . . . . . . . . . . . . . . . . . . P2-3
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Lubrication System, Automatic . . . . . . . . . . . . . . . P3-3
O S
Oiling and Charging Procedure, Suspension . . . . H4-3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Operator Cab Controls . . . . . . . . . . . . . . . . . . . . . N5-3 Software Functions, PSC . . . . . . . . . . . . . . . . . . E2-32
Optional Equipment Starter, 24VDC (Refer to Engine Manual)
Fire Control System . . . . . . . . . . . . . . . . . . . . . .M2-3
Seal Assemblies, Gap Adjustment
Payload Meter II . . . . . . . . . . . . . . . . . . . . . . . .M20-1
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-11
Overhead Display Panel . . . . . . . . . . . . . . . . . . . N5-23 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-12
Seat, Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
P Solenoid
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3 Bleeddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-5
Pedal Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M8-1
Accelerator, Electronic . . . . . . . . . . . . . . . . . . . E2-54 Specifications
Retarder, Electronic . . . . . . . . . . . . . . . . . . . . . E2-54 HYDRAIR® II Oil . . . . . . . . . . . . . . . . . . . . . . . H4-10
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5 HYDRAIR® II Nitrogen . . . . . . . . . . . . . . . . . . . H4-10
Plates, Warning and Caution . . . . . . . . . . . . . . . . . A4-1 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
Portable Test Unit (PTU) . . . . . . . . . . . . . . . . . . . . E3-6 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3 Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3 Spindle, Front Wheel Hub . . . . . . . . . . . . . . . . . . .G3-3
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8 Starter Disconnect Relay . . . . . . . . . . . . . . . . . . . . D2-5
Engine/Alternator Mating . . . . . . . . . . . . . . . . . . C4-5 Status/Warning Indicator Lights. . . . . . . . . . . . . . N5-24
Pressure Control Adjustment, Pump . . . . . . . . . . L10-4 Steering
Propulsion System Controller (PSC) . . . . . . . . . . . E2-5 Accumulator Charging Procedure . . . . . . . . . . . . L6-7
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . E3-22 Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
Pump, Hoist System . . . . . . . . . . . . . . . . . . . . . . . L3-3 Hydraulic Check-Out Procedure . . . . . . . . . . . . L10-3
Pump, Steering/Brake System . . . . . . . . . . . . . . L6-14 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-3
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . L6-25
Strainer, Hydraulic Tank. . . . . . . . . . . . . . . . . . . . L3-17
Suspension, HYDRAIR® II
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
U
Unloader Valve, adjustment . . . . . . . . . . . . . . . . .L10-4