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CEBM017908

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Manual

DUMP TRUCK

SERIAL NUMBERS A30462 - A30600

®
This material is proprietary to Komatsu America
Corp (KAC), and is not to be reproduced, used, or
disclosed except in accordance with written autho-
rization from KAC.
It is the policy of the Company to improve prod-
ucts 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 dis-
tributor for information on the latest revision.

Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel
must read and understand this manual before operating or maintaining this machine.

This manual should be kept in or near the machine for reference, and periodically reviewed by all per-
sonnel who will come into contact with it.

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.

CALIFORNIA
Proposition 65 Warning
Mercury and mercury compounds are known to the State of California to cause developmental prob-
lems. This machine may be equipped with optional HID lamps which contain mercury. There is no risk
of exposure unless the lamps are broken. However, the lamps must be reused, recycled or properly
disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.
NON-OEM PARTS IN CRITICAL SYSTEMS

For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.

Replacement parts manufactured and supplied by unauthorized sources may not be


designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.

Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.

Use of non-OEM parts places full responsibility for the safe performance of the Kom-
atsu product on the supplier and user. Komatsu will not in any case accept responsi-
bility for the failure or performance of non-OEM parts in its products, including any
damages or personal injury resulting from such use.
FOREWORD

This manual is written for use by the operator and/or the service technician. It is designed to help these persons to
become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All
operators and maintenance personnel should read and understand the information in this manual before operating
the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and
cautions should be understood and followed when operating the truck or performing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other
general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major
serviceable 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 typical of the component shown and may not be an exact reproduction of
what is found on the truck.

This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,”
“front,” or “rear” are made with respect to the operator's normal seated position unless specifically stated otherwise.
When assembly instructions are provided without references to specific torque values, standard torque values
should be used. Standard torque values are shown in torque charts in the General Information section of this
manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque
specifications have ±10% tolerance unless otherwise specified.
A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck
Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (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 “E” designates an Electrical wheel motor drive system.
The Product Identification Number (vehicle serial number) contains information which identifies several
characteristics of this unit. For a more detailed explanation, see the end of Section A4.

The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other
components. The vehicle design and application guidelines are sensitive to the maximum GVW.
GVW is total weight: empty vehicle weight + fuel & lubricants + payload.

To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck
(which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and
subtract it from the GVW. The result is the allowable payload.

NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload.
To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be
removed as often as practical.

Exceeding the allowable payload will reduce the expected life of truck components.

A00041 8/10 Introduction A-1


This “ALERT” symbol is used with the signal words,
“DANGER”, “WARNING”, and “CAUTION” in this
manual to alert the reader to hazards arising from
improper operating and maintenance practices.

“DANGER” identifies a specific potential hazard WHICH WILL


RESULT IN EITHER INJURY OR DEATH if proper precautions
are not taken.

“WARNING” identifies a specific potential hazard WHICH


MAY RESULT IN EITHER INJURY OR DEATH if proper
precautions are not taken.

“CAUTION” is used for general reminders of proper safety


practices OR to direct the reader’s attention to avoid unsafe
or improper practices which may result in damage to the
equipment.

A-2 Introduction 8/10 A00041


TABLE OF CONTENTS

SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

ELECTRICAL SYSTEM (24VDC NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D

ELECTRIC PROPULSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E

REAR AXLE, SPINDLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G

HYDRAIR® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H

BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L

OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

OPERATOR CAB AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q

SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R

A00041 8/10 Introduction A-3


KOMATSU MODEL 930E-4 DUMP TRUCK

A-4 Introduction 8/10 A00041


SECTION A
GENERAL INFORMATION
INDEX

MAJOR COMPONENTS & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

SAFETY AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

TORQUE TABLES AND CONVERSION CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

STORAGE AND IDLE MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7

A01001 8/10 Index A1-1


NOTES

A1-2 Index 8/10 A01001


MAJOR COMPONENTS & SPECIFICATIONS
TRUCK AND ENGINE OPERATOR’S CAB
The 930E-4 Dump Truck is an off-highway, rear The operator cab has been engineered for operator
dump truck with AC Electric Drive. The gross vehicle comfort and to allow for efficient and safe operation
weight is 1,100,000 lbs (498,960 kg). The engine is a of the truck. The cab provides wide visibility with an
Komatsu SSDA16V160 rated @ 2700 HP (2014 kW). integral 4-post ROPS/FOPS structure and an
advanced analog operator environment. It includes a
MAIN ALTERNATOR tinted safety-glass windshield and power-operated
side windows, a deluxe interior with a fully adjustable
The diesel engine drives an in-line alternator at
seat with lumbar support, a fully adjustable/tilt
engine speed. The alternator produces AC current
steering wheel, controls mounted within easy reach
which is rectified to DC within the main control
of the operator, and an analog instrument panel
cabinet. The rectified DC power is converted back to
which provides the operator with all instruments and
AC by groups of devices called "inverters", which are
gauges which are necessary to control and/or
also within the main control cabinet. Each inverter
monitor the truck's operating systems.
consists of six phase modules under the control of a
gate driver power converter (GDPC). The two
GDPCs control the operation of each phase module.
POWER STEERING
Each phase module contains paired positive and The truck is equipped with a full time power steering
negative semiconductor switches referred to as system which provides positive steering control with
insulated gate bipolar transistors (IGBT). The IGBTs minimum operator effort. The system includes
cycle on and off at varying frequencies to create an nitrogen-charged accumulators which automatically
AC power signal from the DC supply. provide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
The AC power signal produced by each inverter is a
variable-voltage, variable-frequency (VVVF) signal.
DYNAMIC RETARDING
Frequency and voltage are changed to suit the
operating conditions. The dynamic retarding is used to slow the truck
Cooling air for the control/power group and wheel during normal operation or control speed coming
motors, as well as the alternator itself, is provided by down a grade. The dynamic retarding ability of the
dual fans mounted on the alternator shaft. electric system is controlled by the operator through
the activation of the retarder pedal (or by operating a
AC INDUCTION TRACTION MOTORIZED lever on the steering wheel) in the operators cab and
by setting the RSC (Retarder Speed Control).
WHEELS
Dynamic retarding is automatically activated, if the
The alternator output supplies electrical energy to the truck speed goes to a preset overspeed setting.
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction BRAKE SYSTEM
motors with full-wave AC power.
Service brakes at each wheel are oil-cooled multiple
The two wheel motors convert electrical energy back disc brakes applied by an all-hydraulic actuation
to mechanical energy through built-in gear trains system. Depressing the brake pedal actuates both
within the wheel motor assembly. The direction of the front and rear brakes after first applying the retarder.
wheel motors is controlled by a directional control All wheel brakes will be applied automatically if the
lever located on the center console. brake system pressure decreases below a preset
minimum.
SUSPENSION
The parking brake is a dry disc type, mounted
® inboard on each rear wheel motor, and is spring-
Hydrair II suspension cylinders located at each
wheel provide a smooth and comfortable ride for the applied and hydraulically-released with wheel speed
operator and dampens shock loads to the chassis application protection (will not apply with truck
during loading and operation. moving).

A02074 9/09 Major Components & Specifications A2-1


A2-2 Major Components & Specifications 9/09 A02074
SPECIFICATIONS
These specifications are for the standard Komatsu 930E-4 Truck. Customer options may change this listing.

ENGINE

Komatsu SSDA16V160
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake HP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2700 HP (2014 kW) @ 1900 RPM
Flywheel HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2550 HP (1902 kW) @ 1900 RPM
Weight (Wet)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9608 kg (21,182 lbs)
* Weight does not include Radiator, Sub-frame, or Alternator.

AC ELECTRIC DRIVE SYSTEM

(AC/DC Current)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Electric GTA-41
Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340 m³/ min (12,000 cfm)
Motorized Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GDY106 AC Induction Traction Motors
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.62:1
Maximum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5 km/h (40 mph)
* Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.
Komatsu and GE must analyze each job condition to ensure proper application.

DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard
Maximum Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5400 HP (4026 kW)
Continuous* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 HP (2460 kW)
* Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.

BATTERY ELECTRIC SYSTEM


Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four 8D, 12 volt wet batteries with disconnect switch
Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 CCA
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 260 Amp Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts

SERVICE CAPACITIES
Crankcase (including lube oil filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 liters (74 gallons)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594 liters (157 gallons)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4542 liters (1200 gallons)
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325 liters (350 gallons)
Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 liters (25 gallons) per wheel

A02074 9/09 Major Components & Specifications A2-3


HYDRAULIC SYSTEMS
Hoist and Brake Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem Gear
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931 L/min (246 gpm) @ 1900 RPM and 17,237 kPa (2500 psi)
Steering/Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Compensated Piston
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L/min (65 gpm) @ 1900 RPM and 18,961 kPa (2750 psi)
Relief Pressure - Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17,237 kPa (2500 psi)
Relief Pressure - Steering/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27,579 kPa (4000 psi)
Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947 liters (250 gallons)
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 Rating =200

SERVICE BRAKES
All Hydraulic Actuation with Traction System Wheel Slip/Slide Control
Front and Rear Oil-Cooled Multiple Discs on each wheel
Total Friction Area / Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97,019 cm² (15,038 in²)
Maximum Apply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17,238 kPa (2500 psi)

STEERING
Twin hydraulic cylinders with accumulator assist to provide constant rate steering
Emergency power steering automatically provided by accumulators
Turning Circle (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.7 m (97 ft. 7 in.)

TIRES
Radial Tires (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53/80 R63
Rock Service, Deep Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless
Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . patented Phase I New Generation™ rims

STANDARD DUMP BODY CAPACITIES AND DIMENSIONS


Capacity
Heaped @ 2:1 (SAE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211 m3 (276 yd3)
Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171 m3 (224 yd3)
Width (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 m (26 ft. 9 in.)
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 m (10 ft. 7 in.)
Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.06 m (23 ft. 2 in.)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

NOTE: Optional capacity dump bodies are available.

A2-4 Major Components & Specifications 9/09 A02074


WEIGHT DISTRIBUTION

Empty Vehicle Loaded Vehicle


Front Axle (49.3%). . . . . . . 103,301 kg (227,738 lbs) Front Axle (33.0%) . . . . . 165,554 kg (364,980 lbs)
Rear Axle (50.7 %) . . . . . . 107,518 kg (237,034 lbs) Rear Axle (67.0%) . . . . . 336,124 kg (741,020 lbs)
Total (with 50% fuel) . . . . . 210,819 kg (464,772 lbs) Total . . . . . . . . . . . . . . . 501,678 kg (1,106,000 lbs)

Standard Komatsu body . . . . 30,362 kg (66,936 lbs) Nominal Payload*. . . . . . . . 290,859 kg (641,228 lbs)
Standard tire weight. . . . . . . . 26,127 kg (57,600 lbs)
* Nominal payload is defined within Komatsu
America Corporation’s payload policy
documentation. Nominal payload must be adjusted if
the weight of any customized body or tires vary from
that of the standard Komatsu body and tires. Nominal
payload must also be adjusted to take into account
the additional weight of any custom/optional extras
fitted to the truck which are not stated within the
Standard Features list of the applicable specification
sheet.

A02074 9/09 Major Components & Specifications A2-5


NOTES

A2-6 Major Components & Specifications 9/09 A02074


SAFETY
GENERAL Fire Extinguisher And First Aid Kit
Safety records from most organizations will show that • Make sure that fire extinguishers are accessible
the greatest percentage of accidents are caused by and proper usage techniques are known.
unsafe acts performed by people. The remainder are • Provide a first aid kit at the storage point.
caused by unsafe mechanical or physical conditions.
Report all unsafe conditions to the proper authority. • Know what to do in the event of a fire.
• Keep the phone numbers of persons you should
The following safety rules are provided as a guide for
contact in case of an emergency on hand.
the operator. However, local conditions and
regulations may add many more to this list.

Read and follow all safety precautions. Failure to


do so may result in serious injury or death.

Safety Rules
• Only trained and authorized personnel may Clothing And Personal Items
operate and maintain the truck.
• Avoid loose clothing, jewelry, and loose long hair.
• Follow all safety rules, precautions and They can catch on controls or in moving parts
instructions when operating or performing and cause serious injury or death. Also, never
maintenance on the truck. wear oily clothes as they are flammable.
• When working with another operator or a person • Wear a hard hat, safety glasses, safety shoes,
on work site traffic duty, make sure that all mask and gloves when operating or maintaining
personnel understand all hand signals that are to a truck. Always wear safety goggles, hard hat
be used. and heavy gloves if your job involves scattering
metal chips or minute materials--particularly
Safety Features when driving pins with a hammer or when
• Make sure that all guards and covers are in their cleaning air cleaner elements with compressed
proper position. Have any damaged guards and air. Also, ensure that the work area is free from
covers repaired. (See Operating Instructions - other personnel during such tasks.
“Preparing For Operation”.)
• Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. 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.
• Check the seat belt fabric, buckle and hardware
for damage or wear. Replace any worn or
damaged parts immediately.
• The seat belts must be replaced 5 years after
seat belt manufacture, or after every 3 years of
use, whichever comes first.

A03039 12/11 General Safety & Operating Instructions A3-1


Leaving The Operator’s Seat Fire Prevention For Fuel And Oil
When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a
touch any control lever that is not locked. To prevent flame. Fuel is extremely flammable and can be
accidental operations from occurring, always perform hazardous. Keep flames away from flammable
the following: fluids.

• Move the directional control lever to PARK. Do • Keep oil and fuel in a designated location and do
not use the wheel brake lock when the engine not allow unauthorized persons to enter.
will be turned off. • When refueling, stop the engine and do not
• Lower the dump body to the frame. smoke.

• Stop the engine. When exiting the truck, always • Refueling and oiling should be done in well
lock compartments and take the keys with you. If ventilated areas.
the truck should suddenly move or move in an • Tighten all fuel and oil tank caps securely.
unexpected way, this may result in serious bodily
injury or death.

Mounting And Dismounting


• Use the handrails and steps when getting on or
off the truck.
• Never jump on or off the truck. Never climb on or
off a truck while it is moving.
• When climbing on or off a truck, face the truck
and use the hand-hold and steps.
• Never hold any control levers when getting on or
off a truck.
• Always maintain three-point contact with the
hand-holds and steps to ensure that you support
yourself.
• When bringing tools into the operator's
compartment, always pass them by hand or pull
them up by rope.
• If there is any oil, grease, or mud on the hand-
holds or steps, wipe them clean immediately.
Always keep these components clean. Repair
any damage and tighten any loose bolts.

A3-2 General Safety & Operating Instructions 12/11 A03039


Precautions With High Temperature Fluids Prevention Of Injury By Work Equipment
Immediately after truck operation, engine coolant, Never enter or put your hand, arm or any other part of
engine oil, and hydraulic oil are at high temperatures your body between movable parts such as the dump
and are pressurized. If the cap is removed, the fluids body, chassis or cylinders. If the work equipment is
are drained, the filters are replaced, etc., there is operated, clearances will change and may lead to
danger of serious burns. Allow heat and pressure to serious bodily injury or death.
dissipate before performing such tasks and follow
proper procedures as outlined in the service manual.
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
To prevent hot coolant from spraying: modification.
1. Stop the engine.
2. Wait for the coolant temperature to decrease.
Precautions When Using ROPS
3. Depress the pressure release button on the cap
to vent cooling system pressure. The ROPS is intended to protect the operator if the
truck should roll over. It is designed not only to
4. Turn the radiator cap slowly to release the support the load of the truck, but also to absorb the
pressure before removing. energy of the impact.
To prevent hot engine oil spray: • The Rollover Protection Structure (ROPS) must
1. Stop the engine. be properly installed before the truck is operated.

2. Wait for the oil temperature to cool down. • ROPS installed on equipment manufactured and
designed by Komatsu America Corp. fulfills all of
3. Turn the cap slowly to release the pressure the regulations and standards for all countries. If
before removing the cap. it is modified or repaired without authorization
from Komatsu, or if it is damaged when the truck
rolls over, the strength of the structure will be
compromised and will not be able to fulfill its
Asbestos Dust Hazard Prevention
intended purpose. Optimum strength of the
Asbestos dust is hazardous to your health when structure can only be achieved if it is repaired or
inhaled. If you handle materials containing asbestos modified as specified by Komatsu.
fibers, follow the guidelines below: • When modifying or repairing the ROPS, always
consult your nearest Komatsu distributor.
• Never use compressed air for cleaning.
• Even with the ROPS installed, the operator must
• Use water for cleaning to control dust.
always use the seat belt when operating the
• Operate the truck or perform tasks with the wind truck.
to your back whenever possible.
• Use an approved respirator when necessary.

A03039 12/11 General Safety & Operating Instructions A3-3


Precautions For Attachments PRECAUTIONS BEFORE OPERATION
• When installing and using optional equipment, Safety is thinking ahead. Prevention is the best safety
read the instruction manual for the attachment program. Prevent a potential accident by knowing the
and the information related to attachments in this employer's safety requirements and all necessary job
manual. site regulations. In addition, know the proper use and
• Do not use attachments that are not authorized care of all the safety equipment on the truck. Only
by Komatsu America Corp. or the authorized qualified operators or technicians should attempt to
regional Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.
attachments could create a safety problem and
adversely affect the proper operation and useful Safe practices start before the operator gets to the
life of the truck. equipment.
• Any injuries, accidents, and product failures Safety At The Worksite
resulting from the use of unauthorized
attachments will not be the responsibility of • When walking to and from a truck, maintain a
Komatsu America Corp. or the authorized safe distance from all machines even when the
regional Komatsu distributor. operator is visible.
• Before starting the engine, thoroughly check the
area for any unusual conditions that could be
Precautions For Starting The Truck dangerous.
Start the engine from the operator’s seat only. Never • Examine the road surface at the job site and
attempt to start the engine by shorting across determine the best and safest method of
cranking motor terminals. This may cause a fire, or operation.
serious injury or death to anyone in truck’s path. • Choose an area where the ground is as
horizontal and firm as possible before performing
the operation.
• If you need to operate on or near a public road,
protect pedestrians and cars by designating a
person for work site traffic duty or by installing
fences around the work site.
• The operator must personally check the work
area, the roads to be used, and the existence of
obstacles before starting operations.
• Always determine the travel roads at the work
site and maintain them so that it is always safe
for the machines to travel.
• If travel through wet areas is necessary, check
the depth and flow of water before crossing the
shallow parts. Never drive through water that
exceeds the permissible water depth.

A3-4 General Safety & Operating Instructions 12/11 A03039


Fire Prevention Mirrors, Windows And Lights
• Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the
flammable items that have accumulated in the windshield, cab windows, mirrors and lights.
engine compartment. Failure to do so could result Good visibility may prevent an accident.
in a fire.
• Adjust the rear view mirror to a position where
• Check the fuel, lubrication, and hydraulic the operator can see best from the operator's
systems for leaks. Repair any leaks. Clean any seat. If any glass or light is broken, replace it with
excess oil, fuel or other flammable fluids, and a new part.
dispose of them properly.
• Make sure that the headlights, work lights, and
• Make sure that a fire extinguisher is present and taillights are in proper working order. Make sure
in proper working condition. that the truck is equipped with the proper work
lamps that are needed for the operating
• Do not operate the truck near open flames.
conditions.

In The Operator Cab (Before Starting The Engine)


• Do not leave tools or spare parts lying around. Do
not allow trash to accumulate in the cab of the
truck. Keep all unauthorized reading material out
of the truck cab.
• Keep the cab floor, controls, steps and handrails
free of oil, grease, snow and excess dirt.
Ventilation In Enclosed Areas
• Read and understand the contents of this
If it is necessary to start the engine within an manual. Pay special attention to Section A3
enclosed area, provide adequate ventilation. Inhaling pertaining to safety and operating instructions.
exhaust fumes from the engine can kill. Become thoroughly acquainted with all gauges,
instruments and controls before attempting
operation of the truck.
• Read and understand the WARNING and
CAUTION decals in the operator's cab.
• Make sure that the steering wheel, horn, controls
and pedals are free of any oil, grease or mud.
• Check the operation of the windshield wiper,
condition of wiper blades, and the washer fluid
reservoir level.
Preparing For Operation • Be familiar with all steering and brake system
controls, warning devices, road speeds and
• Always mount and dismount while facing the loading capabilities before operating the truck.
truck. Never attempt to mount or dismount the
truck while it is in motion. Always use handrails Seat Belts
and ladders when mounting or dismounting the
truck. • On both driver and passenger seats, check the
seat belt fabric, buckle, all belt retractors and
• Check the deck areas for debris, loose hardware hardware for damage or wear. Replace any worn
and tools. Check for people and objects that or damaged parts immediately.
might be in the area.
• Even if there are no signs of damage, replace
• Become familiar with and use all protective both driver and passenger seat belts 5 years after
equipment devices on the truck and ensure that seat belt manufacture, or every 3 years after start
these items (anti-skid material, grab bars, seat of use, whichever comes first. The passenger
belts, etc.) are securely in place. seat belt date of manufacture label is sewn into
the seat belt near the buckle. The driver seat belt
date of manufacture label is sewn into the
shoulder harness belt, near the retractor end.

A03039 12/11 General Safety & Operating Instructions A3-5


OPERATING THE TRUCK
When Starting The Engine
• Never attempt to start the engine by shorting
across cranking motor terminals. This may cause
a fire, or serious injury or death to anyone in
The tire and rim assembly may explode if
truck’s path.
subjected to excessive heat. Personnel should
• Never start the engine if a warning tag has been move to a remote or protected location if sensing
attached to the controls. excessively hot brakes, smelling burning rubber
• When starting the engine, sound the horn as an or observing evidence of fire near the tire and
alert. wheel area.
• Start and operate the truck only while seated in If the truck must be approached to extinguish a
the operator’s seat. fire, those personnel should do so only while
facing the tread area of the tire (front or back)
• Do not allow any unauthorized persons in the
operator's compartment or any other place on the unless protected by using large heavy equipment
truck. as a shield. Stay at least 50 ft. (15 m) from the
tread of the tire.
General Truck Operation
In the event of fire in the tire and wheel area
• Wear the seat belt at all times. (including brake fires), stay away from the truck
for at least 8 hours or until the tire and wheel are
• Only authorized persons are allowed to ride in
cool.
the truck. Riders must be in the cab and belted in
the passenger seat. • Keep serviceable fire fighting equipment on
• Do not allow anyone to ride on the decks or steps hand. Report empty extinguishers for
of the truck. replacement or refilling.

• Do not allow anyone to get on or off the truck • Always place the directional control lever in the
while it is in motion. PARK when the truck is parked and unattended.
Do not leave the truck unattended while the
• Do not move the truck in or out of a building engine is running.
without a signal person present.
• Park the truck a safe distance away from other
• Know and obey the hand signal communications vehicles as determined by the supervisor.
between operator and spotter. When other
machines and personnel are present, the • Stay alert at all times! In the event of an
operator should move in and out of buildings, emergency, be prepared to react quickly and
loading areas, and through traffic under the avoid accidents. If an emergency arises, know
direction of a signal person. Courtesy at all times where to get prompt assistance.
is a safety precaution!
• Immediately report any adverse conditions at the
haul road, pit or dump area that may cause an Ensuring Good Visibility
operating hazard. • When working in dark places, install work lamps
• Check for flat tires periodically during a shift. If and head lamps. Set up extra lighting in the work
the truck has been operating on a “flat”, do not area if necessary.
park the truck inside a building until the tire cools. • Discontinue operations if visibility is poor, such as
If the tire must be changed, do not stand in front in mist, snow, or rain. Wait for the weather to
of the rim and locking ring when inflating a tire improve to allow the operation to be performed
mounted on the truck. Observers should not be safely.
permitted in the area and should be kept away
from the side of such tires.

A3-6 General Safety & Operating Instructions 12/11 A03039


Traveling Traveling On Slopes
• When traveling on rough ground, travel at low • Traveling on slopes could result in the truck
speeds. When changing direction, avoid turning tipping over or slipping.
suddenly.
• Do not change direction on slopes. To ensure
• Lower the dump body and set the dump lever to safety, drive to level ground before turning.
the FLOAT position before traveling.
• Do not travel up and down on grass, fallen
• If the engine stops while the truck is in motion, leaves, or wet steel plates. These materials may
secondary steering and braking enable the truck make the truck slip on even the slightest slope.
to be steered and stopped. A fixed amount of Avoid traveling sideways, and always keep travel
reserve oil provides temporary steering and speed low.
braking to briefly allow the truck to travel to a safe
• When traveling downhill, use the retarder to
area. Apply the brakes immediately and stop the
reduce speed. Do not turn the steering wheel
truck as quickly and safely as possible off of the
suddenly. Do not use the foot brake except in an
haul road, if possible.
emergency.
• If the engine should stop on a slope, apply the
service brakes fully and stop the truck. Move the
Traveling In Reverse
directional control lever to PARK after the truck
Before operating the truck: has stopped.
• Sound the horn to warn people in the area. Make
sure that the back-up horn also works properly.
Operating On Snow Or Ice
• Check for personnel near the truck. Be
particularly careful to check behind the truck. • When working on snowy or icy roads, there is
danger that the truck may slip to the side on even
• When necessary, designate a person to watch the slightest slope. Always travel slowly and
the area near the truck and signal the operator. avoid sudden starting, turning, or stopping in
This is particularly necessary when traveling in these conditions.
reverse.
• Be extremely careful when clearing snow. The
• When operating in areas that may be hazardous road shoulder and other objects are buried in the
or have poor visibility, designate a person to snow and cannot be seen.
direct work site traffic.
• Do not allow any one to enter the line of travel of
the truck. This rule must be strictly observed Avoid Damage To Dump Body
even with machines equipped with a back-up
horn or rear view mirror. Always be extremely cautious when working in
tunnels, on bridges, under electric cables, or when
entering a parking place or any other place where
there are height limits. The dump body must be
completely lowered before driving the truck.

A03039 12/11 General Safety & Operating Instructions A3-7


Driving Near High Voltage Cables When Loading
Driving near high-voltage cables can cause electric • Make sure that the surrounding area is safe. Stop
shock. Always maintain safe distances between the the truck in the correct loading position, then load
truck and the electric cable as listed below. the body uniformly.
Voltage Minimum Safety Distance • Do not leave the operator's seat during the
6.6 kV 3m 10 ft. loading operation.
33.0 kV 4m 14 ft.
Parking The Truck
66.0 kV 5m 17 ft.
• Choose a flat, level surface to park the truck. If
154.0 kV 8m 27 ft. the truck has to be parked on a slope, put blocks
275.0 kV 10 m 33 ft. behind all the wheels to prevent truck movement.
• When parking on public roads, provide fences
The following actions are effective in preventing and signs, such as flags or lights, on the truck to
accidents while working near high voltages: warn pedestrians and other vehicles. Make sure
that the truck, flags or lights do not obstruct
• Wear shoes with rubber or leather soles. traffic.
• Use a signalman to give warning if the truck • Before leaving the truck, lower the dump body
approaches an electric cable. fully, move the directional control lever to PARK,
• If the work equipment touches an electric cable, stop the engine and lock everything. Always take
the operator should not leave the cab. the key with you.
• When performing operations near high voltage
cables, do not allow anyone to approach the
truck.
• Check with the electrical maintenance
department about the voltage of the cables Do not activate the wheel brake lock when the
before starting operations. parking brake is activated. Bleed down of
hydraulic pressure may occur, causing the truck
Working On Loose Ground
to roll away.
• Avoid operating the truck near cliffs, overhangs
and deep ditches. If these areas collapse, the Towing
truck could fall or tip over and result in serious
injury or death. Remember that ground surfaces • Improper towing methods may lead to serious
in these areas may be weakened after heavy rain personal injury and/or damage.
or blasting. • Use a towing device with ample strength for the
• Freshly laid soil and the soil near ditches is loose. weight of this truck.
It can collapse under the weight or vibration of • Never tow a truck on a slope.
the truck. Avoid these areas whenever possible.
• Inspect towing components, such as tow bars
When Dumping and couplings, for any signs of damage. Never
use damaged or worn components to tow a
• Before starting the dumping operation, make disabled vehicle.
sure that there are no persons or objects behind
the truck. • Keep a safe distance from the trucks and towing
apparatus while towing a vehicle.
• Stop the truck in the desired location. Check
again for persons or objects behind the truck. • When connecting a truck that is to be towed, do
Give the determined signal, then slowly operate not allow anyone to go between the tow vehicle
the dump body. If necessary, use blocks for the and the disabled vehicle.
wheels or position a flagman. • Set the coupling of the truck being towed in a
• When dumping on slopes, truck stability is poor straight line with the towing portion of the tow
and there is danger of tipping over. Always use truck, and secure it in position.
extreme care when performing such operations. • For towing methods, refer to Operating
• Never travel with the dump body raised. Instructions, Towing.

A3-8 General Safety & Operating Instructions 12/11 A03039


WORKING NEAR BATTERIES • Batteries generate hydrogen gas. Hydrogen gas
is very explosive and can easily be ignited with a
Battery Hazard Prevention small spark or flame.
• Battery electrolyte contains sulfuric acid, which • Before working with batteries, stop the engine
can quickly burn the skin and eat holes in and turn the key switch to the OFF position.
clothing. If you spill acid on yourself, immediately • Avoid short-circuiting the battery terminals
flush the area with water. through accidental contact with metallic objects,
• Battery acid can cause blindness if splashed into such as tools, across the terminals.
your eyes. If acid gets into your eyes, flush them • When removing or installing batteries, check
immediately with large quantities of water and which is the positive (+) terminal and the negative
see a doctor at once. (-) terminal.
• If you accidentally drink acid, drink a large • Tighten the battery terminals securely. Loose
quantity of water, milk, beaten eggs or vegetable terminals can generate sparks and lead to an
oil. Call a doctor or poison prevention center explosion.
immediately.
• Tighten battery caps securely.
• Always wear safety glasses or goggles when
working with batteries.

A03039 12/11 General Safety & Operating Instructions A3-9


Jump Starting With Booster Cables Jump Starting With Receptacles
• Always wear safety glasses or goggles when • Always wear safety glasses or goggles when
starting the truck with booster cables. starting the machine with booster cables.
• When starting from another truck, do not allow • While jump starting with another machine, DO
the two trucks to touch. NOT allow the two machines to touch.
• Perform the operation with two people: one • Perform the operation with two people: one
person in the cab of the disabled machine, the person in the cab of the disabled machine, the
other person working with the jumper cables. other person working with the jumper cables.
• Ensure the parking brake is applied on both • Ensure the parking brake is applied on both
machines. machines.
• Ensure the size of the booster cables and clips • Inspect the cables and connectors for any
are suitable for the battery size. Inspect the damage or corrosion.
cables and connectors for any damage or
• Ensure the key switch and both battery
corrosion.
disconnect switches on the disabled machine are
• Ensure the key switch and both battery in the OFF position.
disconnect switches on the disabled machine are
• Connect the jumper cable to the receptacle on
in the OFF position.
the good machine to the receptacle on the
• Connect the batteries in parallel: positive to disabled machine.
positive and negative to negative.
• Allow time for the batteries to charge.
• Connect the positive (+) cable from the good
NOTE: The batteries will charge even with the
machine to the (+) on the disabled machine first.
Then connect the ground cable from the negative battery disconnect switches are in the OFF position.
(-) battery terminal on the good machine to the • If the batteries are low, DO NOT attempt starting
frame of the disabled machine, as far away as the machine with only one set of jumper cables
possible from the batteries. This will prevent a installed. Install the second set of jumper cables
spark from possibly starting a battery fire. in the same way as already described.
• If the batteries are low, DO NOT attempt starting • Turn the battery disconnect switches to the ON
the machine with only one set of jumper cables position and attempt starting.
installed. Install the second set of jumper cables
in the same way as already described. • For booster cable removal, disconnect the cables
from each machine.
• For booster cable removal, disconnect the
ground or negative (-) cable first, then the • If any tool touches between the positive (+)
(24VDC +) cable last. terminal and the chassis, it will cause sparks.
Always use caution when using tools near the
• If any tool touches between the positive (+) battery.
terminal and the chassis, it will cause sparks.
Always be cautious when using tools near the
battery.

A3-10 General Safety & Operating Instructions 12/11 A03039


BEFORE PERFORMING MAINTENANCE Proper Tools
Only use tools that are suited to the task. Using
Stopping The Engine Before Service
damaged, low quality, faulty or makeshift tools could
• Before performing inspections or maintenance, cause personal injury.
stop the truck on firm flat ground, lower the dump
body, move the directional control lever to PARK,
and stop the engine.
• If the engine must be run during service, such as
when cleaning the radiator, the directional control
lever must be in PARK. Always perform this work
with two people. One person must sit in the
operator's seat to stop the engine if necessary.
During these situations, never move any controls
that are not related to the task at hand. Use of Tie-Off Anchor During Maintenance and
Repair
• When servicing the truck, do not to touch any
moving parts. Never wear loose clothing or While working at heights
jewelry. during assembly, mainte-
• Put wheel blocks under the wheels to prevent nance or repair of the
truck movement. haul truck, workers
should wear an appropri-
• When performing service with the dump body ate fall protection har-
raised, place the dump lever in the HOLD ness and attach it to a
position and apply the lock (if equipped). Install
tie-off anchor or tie-off
the body-up safety pins or cable securely.
point.
Warning Tag Komatsu anchor (58B-98-75190) is available for use
Starting the engine or operating the controls while with fall protection harnesses. Carefully read and
other personnel are performing maintenance on the understand the harness maker’s instructions before
truck can lead to serious injury and/or death. Always using any fall protection harness.
attach the warning tag to the control lever in the NOTE: The anchor must not be used for lifting.
operator's cab to alert others that you are working on
the truck. Attach additional warning tags around the
truck, if necessary.
These tags are available from your Komatsu
distributor. Warning tag part number: 09963-03001

A03039 12/11 General Safety & Operating Instructions A3-11


Securing The Dump Body

To avoid serious personal injury or death, the


body retention sling must be installed whenever
personnel are required to perform maintenance
on the truck while the dump body in the raised
position.
The Komatsu body-up safety sling can only be
used with a Komatsu body. Non-OEM body may
not accommodate the Komatsu body-up safety
sling. The end user must ensure that a proper
cable/sling is used.
1. Raise the body to its maximum height.
2. Install two shackles (2, Figure 3-1) and body
retention sling (3) between rear body ear (1)
and the axle housing.
3. Secure the shackle pins with cotter pins.
4. Move the hoist lever to the FLOAT position to
slowly lower the body until the sling is
supporting the full weight of the body. Then FIGURE 3-1. BODY RETENTION SLING
move the hoist lever to the HOLD position. INSTALLATION
5. After service work is completed, reverse the 1. Rear Body Ear 3. Body Retention
installation steps to remove the sling. 2. Shackle & Pin Sling

A3-12 General Safety & Operating Instructions 12/11 A03039


WHILE PERFORMING MAINTENANCE Working Under The Truck
NOTE: Only authorized personnel should service • Always lower all movable work equipment to the
and repair the truck. ground or to their lowest position before
performing service or repairs under the truck.
Keep The Truck Clean • Always block the tires of the truck securely.
• Spilled oil, grease, scattered tools, etc., can • Never work under the truck if the truck is poorly
cause you to slip or trip. Always keep your truck supported.
clean and tidy.
• If water gets into the electrical system, there is
danger that the truck may move unexpectedly
and/or damage to components may occur. Do not
use water or steam to clean any sensors,
connectors or the inside of the operator's
compartment.
• Use extreme care when washing the electrical
control cabinet. Do not allow water to enter the Rotating Fan And Belts
control cabinet around the doors or vents. Do not Stay away from all rotating parts such as the radiator
allow any water to enter the cooling air inlet duct
fan and fan belts. Serious bodily injury may result
above the electrical control cabinet. If water
enters the control cabinet through any opening or from direct or indirect contact with rotating parts and
crevice, major damage to the electrical flying objects.
components is possible.
• Never spray water into the rear wheel electric
motor covers. Damage to the wheel motor
armatures may occur.
• Do not spray water into the retarding grids.
Excess water in the retarding grids can cause a
ground fault, which will prevent propulsion.

Waste Materials
• Never dump oil into a sewer system, river, etc.
• Always put oil drained from your truck in
appropriate containers. Never drain oil directly
onto the ground.
• Obey appropriate laws and regulations when
Attachments disposing of harmful objects such as oil, fuel,
coolant, solvent, filters and batteries.
Place attachments that have been removed from the
truck in a safe place and manner to prevent them • The machine may be equipped with optional High
from falling. Intensity Discharge (HID) lighting lamps which
contain mercury. These lamps must be reused,
recycled or properly disposed of in accordance
with applicable local, state and federal laws.

A03039 12/11 General Safety & Operating Instructions A3-13


Adding Fuel Or Oil Handling High Pressure Hoses
• Spilled fuel and oil may cause slipping. Always • Do not bend high pressure hoses or hit them with
clean up spills immediately. hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during
• Always add fuel and oil in a well-ventilated area. use.
• When refueling, stop the engine and do not • Always repair any loose or broken hoses. If fuel
smoke.
or oil leaks, it may result in a fire.
• Tighten the cap of the fuel and oil fillers securely.
Precautions With High Pressure Oil
• Never use fuel to wash parts.
• Work equipment circuits are always under
Radiator Coolant Level pressure. Do not add oil, drain oil or perform
maintenance or inspections before completely
If it is necessary to add coolant to the radiator, stop releasing the internal pressure.
the engine and allow the engine and radiator to cool
down before adding the coolant. Depress the • Small, high-pressure pin hole leaks are extremely
pressure release button on the cap to vent cooling dangerous. The jet of high-pressure oil can
pierce the skin and eyes. Always wear safety
system pressure. Slowly loosen the cap to relieve
glasses and thick gloves. Use a piece of
any remaining pressure. cardboard or a sheet of wood to check for oil
leakage.
• If you are hit by a jet of high-pressure oil, consult
a doctor immediately for medical attention.

Use Of Lighting
When checking fuel, oil, coolant or battery electrolyte, Performing Maintenance Near High Temperature
always use lighting with anti-explosion specifications. Or High Pressure
If such lighting equipment is not used, there is danger
of an explosion. Immediately after stopping operation, engine coolant
and operating oils are at high temperature and under
high pressure. If the cap is removed, the oil or water
is drained, or the filters are replaced under these
conditions, 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
as outlined in the shop manual.

Precautions With The Battery


When repairing the electrical system or performing
electrical welding, remove the negative (-) terminal of
the battery to stop the flow of current.

A3-14 General Safety & Operating Instructions 12/11 A03039


TIRES Tire Maintenance
If the proper procedure for performing maintenance
Handling Tires
or replacement of the wheel or tire is not used, the
Rim and tire maintenance can be hazardous unless the wheel or tire may burst, causing damage, serious
correct procedures are followed by trained personnel. injury, or even death. When performing such mainte-
Improperly maintained or inflated tires can overheat nance, consult your authorized regional Komatsu dis-
and burst due to excessive pressure. Improper inflation tributor, or the tire manufacturer.
can also result in cuts in the tire caused by sharp
Refer to the Society of Automotive Engineers (SAE),
stones. Both of these conditions can lead to tire dam-
SAE J1337, Off-Road Rim Maintenance Procedures
age, serious personal injury, or even death. To safely
and Service Precautions, Section 4.2 for additional
maintain a tire, adhere to the following conditions:
information on demounting the tires and rim assem-
• Before a tire is removed from a vehicle for tire blies. Also, refer to Section 4.4 of SAE J1337 for
repair, the valve core must be partially removed assembly and inflation recommendations.
to allow deflation, and then the tire/rim assembly
can be removed. During deflation, persons must The U.S. Department of Labor Mine Safety and Health
stand outside of the potential trajectory of the Administration (MSHA) addresses tire repairs in its Title
locking ring of a multi-piece wheel rim. 30 Code of Federal Regulations, 30 CFR 57.14104.
• After the tire/rim assembly is installed on the
vehicle, inflate the tires to their specified
pressure. Abnormal heat is generated,
particularly when the inflation pressure is too low.
DO NOT stand in front of a rim and locking ring
NOTE: To prevent injury from the wheel rims during when inflating a tire mounted on the machine.
tire inflation, use one of the following: Observers must not be permitted in the area.
• A wheel cage or other restraining device that will DO NOT weld or heat the rim assembly with the tire
constrain all wheel rim components during an mounted on the rim. Resulting gases inside the tire
explosive separation of a multi-piece wheel rim, may ignite, causing explosion of the tire and rim.
or during the sudden release of air.
• A stand-off inflation device which permits a Storing Tires After Removal
person to stand outside of the potential trajectory
• As a basic rule, store the tires in a warehouse in
of the wheel components.
which unauthorized persons cannot enter. If the
• Use the specified tires. tires are stored outside, always erect a fence
around the tires and put up “No Entry” signs and
The tire inflation pressure and permissible speeds, other warning signs that even young children can
given in this manual, are general values. The actual understand.
values may differ, depending on the type of tire and
the specific operating conditions. For details, please • Stand the tire on level ground and block it
consult the tire manufacturer. securely so that it cannot roll or fall over.
• If the tire falls over, flee the area quickly. The tires
When the tires become overheated, a flammable gas
for dump trucks are extremely heavy. Never
is produced inside the tire which can ignite. It is par- attempt to hold or support the tire. Attempting to
ticularly dangerous if the tires become overheated hold or support a tire may lead to serious injury.
while the tires are pressurized. If the gas generated
inside the tire ignites, the internal pressure will sud-
denly rise, and the tire will explode, resulting in dan-
ger and/or death to personnel in the area. Explosions
differ from punctures or tire bursts because the
destructive force of the explosion is extremely large.
Therefore, the following operations are strictly pro-
hibited when the tire is pressurized:
• Welding the rim • Mounted tires stored as spares must be inflated
• Welding near the wheel or tire. to the minimum inflation pressure necessary to
keep the tire beads properly seated. Maximum
• Smoking or creating open inflation pressure of the stored tire must not
flames exceed 15% of the tire’s cold inflation pressure.

A03039 12/11 General Safety & Operating Instructions A3-15


WHEN REPAIRS ARE NECESSARY
NOTE: Only qualified maintenance personnel who • Always fasten the welding machine ground (-)
understand the systems being repaired should lead to the piece being welded. The grounding
attempt repairs. clamp must be attached as near as possible to
the weld area. Never allow welding current to
• Many components on the Komatsu truck are pass through ball bearings, roller bearings,
large and heavy. Ensure that lifting equipment - suspensions or hydraulic cylinders. Always avoid
hoists, slings, chains, and lifting eyes - are of laying welding cables over or near the vehicle
adequate capacity to handle the lift. electrical harnesses. Welding voltage could be
• Do not work under a suspended load. Do not induced into the electrical harness and possibly
work under a raised body unless body safety cause damage to components.
cables, props or pins are in place to hold the • If the truck must be towed, use a rigid tow bar.
body in up position. Check the truck frame for a decal recommending
• Do not repair or service the truck while the engine special towing precautions. Also refer to
is running, except when adjustments can only be Operating Instructions - Section 30, Towing.
made under such conditions. Keep a safe • Drain, clean, and ventilate fuel tanks and
distance from moving parts. hydraulic tanks before making any welding
• When servicing any air conditioning system with repairs.
refrigerant, wear a face shield and cold resistant
gloves for protection against freezing. Follow all
current regulations for handling and recycling
refrigerants.
• Follow package directions carefully when using
cleaning solvents. Any operating fluid, such as hydraulic oil,
escaping under pressure can have sufficient
• If an auxiliary battery assist is needed, first use
force to enter a person's body by penetrating the
one cable to connect the 24V positive (+) post of
the disabled truck batteries to the 24V positive skin. Serious injury and possibly death may
(+) post of the auxiliary assist. Use a second result if proper medical treatment by a physician
cable to connect the 24V negative (-) post of the familiar with this injury is not received
auxiliary assist battery to a frame ground (-) on immediately.
the disabled truck away from the battery.
• Relieve pressure in lines or hoses before making
• Always disconnect the positive and negative any disconnects.
battery cables of the vehicle before doing any
• After adjustments or repairs, replace all shields,
welding on the unit. Failure to do so may
screens and clamps.
seriously damage the battery and electrical
equipment. Disconnect the battery charging • Only a qualified operator or maintenance
alternator lead wire and isolate the electronic personnel who are also qualified in truck
control components before making welding operation should move the truck under its own
repairs. (It is not necessary to disconnect or power in the repair facility or during road testing
remove any control circuit cards on electric drive after repairs are complete.
dump trucks or any of the AID circuit control
cards.)

A3-16 General Safety & Operating Instructions 12/11 A03039


SPECIAL PRECAUTIONS FOR WORKING Engine Shutdown Procedure Before Welding or
ON AC DRIVE TRUCKS Performing Maintenance
Normal operation of the AC drive system at shutdown
Preliminary Procedures Before Welding
should leave the system safe to service. However, in
or Performing Maintenance
the event of a system failure, performing the following
Before welding or repairing an AC drive truck, procedure before any maintenance activities will
maintenance personnel should notify a Komatsu ensure that no hazardous voltages are present in the
service representative. Only qualified personnel, AC drive system.
specifically trained for servicing the AC drive system,
1. Before shutting down the engine, verify the
should perform this service.
status of all the drive system warning lights on
If it is necessary to perform welding or repair to the the overhead display panel. Use the lamp test
truck without the field engineer present, the following switch to verify that all lamps are functioning
procedures must be followed to ensure that the truck properly.
is safe for maintenance personnel to work on and to If any of the red drive system warning lights
reduce the chance for damage to equipment. remain on, do not attempt to open any cabinets,
disconnect any cables, or reach inside the
retarding grid cabinet without a trained drive
system technician present, even if the engine is
off. Only qualified personnel, specifically trained
for servicing the AC drive system, should
perform this service.
Anytime the engine is running, do not open any
of the cabinet doors or remove any covers. Do 2. If all red drive system warning lights are off,
not use any of the power cables for hand holds or follow the “Normal Engine Shutdown
foot steps. Do not touch the retarding grid Procedure” later in this chapter.
elements. 3. After the engine has been stopped for at least
five minutes, inspect the link voltage lights on
the exterior of the main control cabinet and
back wall of the operator's cab (DID panel). If all
lights are off, it is safe to work on the retarding
grids, wheel motors, alternator and related
power cables.
Before opening any cabinets or touching a
retarding grid element or a power cable, the 4. Locate the GF cut-out switch in the access
engine must be shutdown and the red drive panel on the left side of the main control
system warning lights must not be illuminated. cabinet. Place the switch in the “alternator
cutout” position. This will prevent the alternator
from re-energizing and creating system voltage
until the switch is returned to its former position.

A03039 12/11 General Safety & Operating Instructions A3-17


5. Before welding on the truck, disconnect all 11. If the red lights on the exterior of the control
electrical harnesses from the Engine Control cabinet and/or the back wall of the operator's
System (ECS) inside the electrical cabinet cab continue to be illuminated after following
behind the operator's cab. Also, disconnect the the above procedure, a fault has occurred.
ground strap from the ECS. Leave all cabinet doors in place. Do not touch
6. Do not weld on the rear of the control the retarding grid elements. Do not disconnect
cabinet! The metal panels on the back of the any power cables or use them as hand or foot
cabinet are part of capacitors and cannot be holds.
heated. Notify your Komatsu service representative
immediately. Only qualified personnel,
7. Do not weld on the retarding grid exhaust
specifically trained for servicing the AC drive
louvers! They are made of stainless steel.
system, should perform this service.
Some power cable panels throughout the truck
are also made of aluminum or stainless steel. 12. Replace all covers and doors. Place the GF
They must be repaired with the same material cutout switch and battery disconnect switches
or the power cables may be damaged. in their original positions. Reconnect all
8. Power cables must be cleated in wood or other harnesses prior to starting the truck.
non-ferrous materials. Do not repair cable Leave the drive system in the rest mode until
cleats by encircling the power cables with metal the truck is to be moved.
clamps or hardware. Always inspect power
cable insulation before servicing the cables and
returning the truck to service. Discard cables
with broken insulation.
10. Power cables and wiring harnesses should be
protected from weld spatter and heat.
Always fasten the welding machine ground (-)
lead to the piece being welded. The grounding
clamp must be attached as near as possible
to the weld area.
Always avoid laying welding cables over or near
the vehicle electrical harnesses. Welding volt-
age could be induced into the electrical harness
and cause damage to components.
Before doing any welding on the truck, discon-
nect the battery charging alternator lead wire
and isolate electronic control components.
Also, always disconnect the negative and posi-
tive battery cables of the vehicle. Failure to do
so may seriously damage the battery and elec-
trical equipment.
Never allow welding current to pass through ball
bearings, roller bearings, suspensions or
hydraulic cylinders.

A3-18 General Safety & Operating Instructions 12/11 A03039


CAPACITOR DISCHARGE SYSTEM
The control cabinets are equipped with two capacitor • Personal Protective Equipment (PPE) for working
charge lights, one on the exterior of the cabinet and with 2000 VDC meter
one in the interior. The capacitor charge lights, when (safety shoes, high voltage gloves, and safety
off, indicate to service personnel that the drive sys- glasses)
tem is safe to work on. Certain drive system failures, • Multimeter for ground resistance measurement
however, can result in a condition where one or more
• Grounding stick pair (Figure 3-3)
capacitors can remain in a charged state even (Komatsu p/n PC3299)
though the capacitor charge lights are off. (HVR Advanced Power Components MAS-
Because a danger can still exist with the capacitor 000039 Ground Stick Pair or equivalent)
charge lights off, it is necessary to adhere to the fol-
lowing instructions before touching or servicing drive
system components. Only authorized service person-
nel are allowed to service the drive system.
Refer to the shop manual for rules when servicing
the drive system. Adhere to the proper procedures
for disabling the drive system.

Necessary Tools

• 2000 VDC meter (Figure 3-2)


(Komatsu p/n PC3186)
(Bierer RCDC 1000 or equivalent)

FIGURE 3-3. GROUNDING STICKS (PC3299)

FIGURE 3-2. VOLT METER (PC3186)

A03039 12/11 General Safety & Operating Instructions A3-19


Warnings And Cautions
All applicable local mine, government, and industry
rules for working with high voltage must be followed.
Required personal protective equipment, including
but not limited to safety shoes, high voltage gloves,
Hazardous voltages are present in this equip-
and safety glasses must be worn.
ment. Avoid touching any energized equipment
Safety cautions and warnings appear throughout the when the door to the low voltage area is open.
instructions. WARNING indicates the potential for
personal injury and CAUTION indicates the potential Failure to do so may result in personal injury and
for equipment damage. Read the following warnings equipment damage.
prior to working on this drive system.

Hazardous voltages are present in this equip-


ment. Ensure that the Control Power Switch Hazardous voltages may be present in this equip-
(CPS) is in the OFF position and that the Genera- ment even if the engine and capacitor charge
tor Field Contactor (GFCO) switch is in the CUT- lights are off.
OUT position before attempting any work on the
drive system components. Check that Capacitor Use measurement and protective equipment
Charge Lights (CCL’s) are not illuminated. rated for 2000 VDC minimum to verify that no
voltage is present before touching any terminal.
Use measurement and protective equipment
rated for 2000 VDC minimum to verify that no Verify functionality of the measurement equip-
voltage is present before touching any terminal. ment using site-approved procedures both
before and after performing control group mea-
Verify functionality of the measurement equip- surements.
ment using site-approved procedures both
before and after performing control group mea- Failure to observe these precautions may result
surements. in death or serious personal injury.
Failure to observe these precautions may result
in death or serious personal injury.

Verify that the Capacitor Charge Light (CCL) Voltages in excess of 1500 VDC may be present.
above the high voltage contactor area is not illu- Any measurement and/or protective equipment
minated before opening the doors to the high used must be rated at 2000 VDC minimum.
voltage area or the high voltage contactor area.
Verify functionality of the measurement equip-
Use measurement and protective equipment ment using site-approved procedures both
rated for 2000 VDC minimum to verify that no before and after performing control group mea-
voltage is present before touching any terminal. surements.

Verify functionality of the measurement equip- Failure to observe these precautions may result
ment using site-approved procedures both in death or serious personal injury.
before and after performing control group mea-
surements.

Failure to observe these precautions may result


in death or serious personal injury.

A3-20 General Safety & Operating Instructions 12/11 A03039


Manual DC Link Capacitor Discharge Procedure
Follow any and all local and site specific procedures
and requirements for working on off-highway mining
equipment.

Verify that:
• The engine is off and the parking brake is on.
FIGURE 3-4. INFORMATION DISPLAY PANEL
• The generator field is cut out via GF cutout switch
(2, Figure 3-4) in the low voltage area of the 1. Control Power Switch 3. Capacitor Charge
control cabinet. 2. GF Cutout Switch Light

1. Apply control power for a minimum of 30 sec-


onds. Then, turn off control power using control
power switch (1) on the switch panel.
In most control cabinets, RP2 is the normal dis-
charge path. In groups containing an RP3 contactor,
With control power on, an RP contactor closes
RP2 and RP3 are alternated as the normal discharge
and discharges the DC link through the
path. Refer to Figure 3-5.
retarding grids in less than 10 seconds.

FIGURE 3-5. DISCHARGE PATHS

A03039 12/11 General Safety & Operating Instructions A3-21


2. Observe both capacitor charge lights (CCL1,
CCL2). CCL1 is on the outside of the contactor
box. CCL2 is on the switch panel inside the low
voltage area. The lights will stay illuminated as
long as the voltage on the DC link is greater
than 50 VDC. Refer to Figure 3-6. Verify functionality of the measurement equip-
ment using site-approved procedures both
before and after performing control group mea-
surements.

Failure to observe these precautions may result


Hazardous voltages may be present in this equip- in death or serious personal injury.
ment even if the engine and capacitor charge
lights are off.

Use measurement and protective equipment


rated for 2000 VDC minimum to verify that no
voltage is present before touching any terminal.

FIGURE 3-6. CAPACITOR CHARGE LIGHTS


1. Exterior Capacitor Charge Light (CCL2) 3. Information Display Panel
2. Interior Capacitor Charge Light (CCL1) 4. DC Link Capacitors

A3-22 General Safety & Operating Instructions 12/11 A03039


Failure of the Discharge System 1. Open the high voltage area doors.
If the capacitor charge lights remain illuminated, a 2. With a suitable high voltage meter rated for at
failure of the normal (fast) capacitor discharge sys- least 2000 VDC, such as PC3186 or equivalent,
tem (RP discharge path) has likely occurred. The plus suitable protective equipment, measure the
slow discharge resistors that are hard wired across voltage across each of the DC link capacitors.
the DC link should then discharge the capacitors. Place one meter lead on the positive (+) capaci-
The slow discharge resistors will discharge the DC tor terminal, and the other meter lead on the
link to less than 1 VDC in under 7.5 minutes. If after negative (-) capacitor terminal, and observe the
7.5 minutes, the capacitor charge lights are still illu- voltage. See Figure 3-7 and Figure 3-8. If the
minated, it must be assumed that the automatic dis- voltage is less than 1.0 V the capacitor is suffi-
charge system is not working and that high voltage is ciently discharged. Repeat on all DC Link
present in the high voltage area. capacitors. If the voltage of any capacitor is
above 1.0 V, manually discharge the capacitor
as described in “Manual Discharge of Capaci-
tors”.

FIGURE 3-7. DC METER ON CAPACITOR

FIGURE 3-8. CAPACITOR TERMINAL POLARITY

A03039 12/11 General Safety & Operating Instructions A3-23


Manual Discharge of Capacitors 3. Discharge the relevant capacitors. Open the
door(s) and place one grounding stick on one of
If the voltage is greater than 1V on any of the capaci-
the positive (+) capacitor terminals and the
tors, the capacitor must be manually discharged.
other on the diagonally located negative (-) ter-
With a suitable capacitor discharge device, such as
minal. Refer to Figure 3-8 and Figure 3-10.
ground stick pair (PC3299), discharge the capacitors
Attempt to minimize the time between applica-
where needed per the following instructions:
tion of the positive stick and the negative stick
1. With the control cabinet high voltage compart- so that the current flow will be positive to nega-
ment doors closed, connect the ground stick tive rather than either to ground. Leave sticks in
pair ground lead to ground. The most conve- place until capacitors are discharged. Refer to
nient location is the middle top bolt that Figure 3-10.
attaches the door center post to the control cab-
NOTE: On the capacitors located behind the door
inet frame.
post, it is difficult to access diagonal terminals on the
2. Verify the ground connection and ground stick same capacitor. If using adjacent terminals, use care
resistance levels. Measure the resistance to keep the tips separated while discharging or else
between each individual ground stick tip to use a positive terminal on one capacitor and negative
either the GND1 or GND2 ground block in the terminal of the adjacent capacitor on the same bus
low voltage compartment of the control cabinet bar.
using a multimeter (Figure 3-9). Ensure that the
resistance is within the manufacturer’s specifi- For PC3299 grounding sticks, the discharge times
cations for the ground sticks. from 2000 volts are:
• 15 seconds (maximum) for 2 capacitors
For PC3299 grounding sticks, the valid range is
80 to 125 ohms per stick. • 75 seconds (maximum) for 10 capacitors

Hazardous voltages are present in this equip-


ment. Avoid touching any energized equipment
when the door to the low voltage area is open.
Failure to do so may result in personal injury and
equipment damage.

FIGURE 3-9. GROUNDING STICK LEAD CONNECTION AND CHECK

A3-24 General Safety & Operating Instructions 12/11 A03039


4. Measure voltage on all capacitors as described
in “Failure of the Discharge System”. Discharge
any capacitors that show voltage.
5. If all capacitors read discharged, verify that the
meter is functioning correctly using site-
Voltages in excess of 1500 VDC may be present.
approved procedures. If so, proceed to “Short
Any measurement and/or protective equipment
Isolated Capacitor Terminals”.
used must be rated at 2000 VDC minimum.

Verify functionality of the measurement equip-


ment using site-approved procedures both
before and after performing control group mea-
surements.

Failure to observe these precautions may result


in death or serious personal injury.

FIGURE 3-10. APPLICATION OF GROUNDING STICKS TO


CAPACITOR TERMINALS

A03039 12/11 General Safety & Operating Instructions A3-25


Short Isolated Capacitor Terminals Any capacitor that is isolated from the DC link and
confirmed discharged must have its terminals electri-
cally shorted together to prevent static charge build
up. Use bare wire to jumper all four terminals on the
capacitor. See Figure 3-11. Proceed to troubleshoot
and repair the control group to restore it to original
Hazardous voltages may be present in this equip- functionality.
ment even if the engine and capacitor charge
lights are off.

Use measurement and protective equipment


rated for 2000 VDC minimum to verify that no
voltage is present before touching any terminal.

Verify functionality of the measurement equip-


ment using site-approved procedures both
before and after performing control group mea-
surements.

Failure to observe these precautions may result


in death or serious personal injury.

FIGURE 3-11. JUMPER ALL TERMINALS ON


ISOLATED CAPACITOR

A3-26 General Safety & Operating Instructions 12/11 A03039


OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
The safest trucks are those which have been properly
prepared for operation. At the beginning of each shift,
a careful check of the truck should be made before
attempting to start the engine.
High voltage may be present on this truck! DO
Safety is thinking ahead. Prevention is the best safety NOT open any electrical cabinet doors on this
program. Prevent a potential accident by knowing the truck while the engine is running. Never climb on
employer's safety requirements, all necessary job site any power cables or use power cables for
regulations, and use and care of the safety handholds or footholds unless the engine has
equipment on the truck. Only qualified operators or been shut down and the system has been verified
technicians should attempt to operate or maintain a to be at “rest”.
Komatsu truck.
1. Start at left front of truck. Visually inspect all
Safe practices start before the operator gets to the lights and safety equipment for damage. Make
equipment. sure that the lenses are clean and unbroken.
• Wear the proper clothing. Loose fitting clothing, 2. Move in front of the left front tire. Inspect the
unbuttoned sleeves and jackets, jewelry, etc., hub and brake assemblies for leaks and any
can catch on a protrusion and cause a potential abnormal conditions.
hazard. 3. Make sure that all suspension mounting hard-
• Always use the personal safety equipment ware is secure. Inspect the mounting key area
provided for the operator such as hard hats, for evidence of wear. Make sure that the sus-
safety shoes, safety glasses or goggles. There pension extension (exposed piston rod) is cor-
are some conditions when protective hearing rect and that there are no leaks.
devices should also be worn for operator safety. 4. Make sure that the anchor end of the steering
• When walking to and from the truck, maintain a cylinder is secure and properly greased.
safe distance from all machines, even if the 5. With the engine stopped, check the engine oil
operator is visible. level. Use the service light, if necessary.
6. Inspect the air conditioner belts for correct ten-
WALK AROUND INSPECTION
sion, obvious wear, and tracking. Make sure
At the beginning of each shift, a careful walk around that the fan guard is secure and in good condi-
inspection should be performed before attempting to tion. When leaving this point, turn off the service
start the engine. A walk around inspection is a light if used.
systematic ground level inspection of the truck and its
7. Move outside of the front wheel. Make sure that
components to ensure that the truck is safe to
all of the mounting nuts/studs are in place and
operate before entering the operator's cab.
tight. Check the tires for cuts, damage, or
Start at the left front corner of the truck (see the bubbles. Check for evidence of incorrect tire
illustration on the next page) and move in a inflation.
counterclockwise direction. Move front-to-rear,
8. Move in behind the front wheel. Make sure that
across the rear, and continue forward up the opposite
the steering cylinder is properly greased and
side of the truck to the original starting point.
the mounting hardware is tight. Check the
If these steps are performed in sequence and are suspension mounting hardware and suspension
repeated from the same point and in the same extension. Make sure that the suspension
direction before every shift, many potential problems protective boot is in good condition. Inspect the
may be avoided or scheduled for maintenance. hub and brakes for any unusual conditions.
Unscheduled downtime and loss of production can be Check the entire area for leaks.
reduced as a result.
Local work practices may prevent an operator from
performing all tasks suggested here. To the extent
permitted, the operator should follow this routine.

A03039 12/11 General Safety & Operating Instructions A3-27


START HERE

A3-28 General Safety & Operating Instructions 12/11 A03039


13. Move around the left side dual tires. Make sure
FIGURE 3-12. TOP VIEW that all wheel nuts/studs are in place and tight.
Inspect the wheel for any oil that would indicate
1. Operator Cab brake leakage or wheel motor leakage.
2. Auto Lubrication
3. Radiator Check the dual tires for cuts, damage, and bub-
4. Reserve Oil System bles. Verify that tire inflation is correct. If the
5. Engine truck has been run on a “flat”, the tire must be
6. Fuel Filters cooled before moving the truck inside. Check
7. Suspension for any rocks that might be lodged between the
8. Wet Disc Brake dual tires.
9. Brake Accumulators 14. Inspect the left rear suspension for damage,
10. Hoist Filters correct rod exposure, and leaks. Ensure that
11. Steering Filter the covers over the chrome piston rod are in
12. Fuel Tank good condition.
13. Hoist Cylinder
15. Open the rear axle hatch. Inspect for leaks
14. Rear Axle Housing
around the parking brakes. Make sure the
15. Wet Disc Brake
cooling air exhaust ductwork is intact and there
16. Wheel Motor Transmission
are no obstructions.
17. Rear Tires
18. Rear Suspension 16. While standing at the rear axle hatch, look up to
19. Rear Axle Hatch check that the rear lights and backup alarms are
20. AC Electric Motor in good condition. Look up at the panhard rod to
21. Hydraulic Tank check that it is properly greased. Also check
22. Steering Pump both body hinge pins for proper greasing and
23. Hoist Pump any abnormal condition. Check the hoist limit
24. Steering Accumulators switch and clear any mud or debris from the
25. Alternator contacts.
17. Perform the same inspections on the right rear
suspension.
18. Move around the right side dual tires. Inspect
between the tires for rocks. Inspect the tires for
9. Inspect the sight glass on the hydraulic tank. cuts, damage and proper inflation.
With the engine stopped and the body down, 19. Make sure that all wheel nuts/studs are in place
the hydraulic oil level must be visible in the cen- and tight. Inspect the wheel for any oil that
ter of the upper sight glass. would indicate brake leakage or wheel motor
10. Verify that all hydraulic tank shut-off valves are leakage.
locked in their fully open positions. 20. Move in front of right dual tires. Inspect the hoist
11. Move around the hydraulic tank and in front of cylinder in the same manner as the left side.
the rear dual tires. Inspect the hoist cylinder for Make sure the body-up limit switch is secure
any damage and leaks. Make sure that both and in good condition. Remove any mud or dirt
upper and lower hoist cylinder pins are secure accumulation from the switch.
and properly greased. 21. Move around the fuel tank. Make sure that the
12. Look under the lower edge of the chassis to fuel gauge agrees with the fuel gauge in the
make sure that the flexible duct that carries the cab. Inspect the mounting hardware for the fuel
air from the main blower to the final drive tank at the upper saddles and at the lower back
housing is in good condition. Also, look up at side of the tank. Check the hoist filters for leaks.
the main hydraulic pumps to see if there is any
leakage or any other unusual condition with the
pumps or pump drive shafts.

A03039 12/11 General Safety & Operating Instructions A3-29


22. Move in behind the right front wheel. Make sure
that the steering cylinder is properly greased
and the mounting hardware is secure. Check
the suspension mounting hardware and
suspension extension. Make sure that the
suspension protective boot is in good condition. If the engine has been running, allow the coolant
Inspect the hub and brakes for any unusual to cool before removing the fill cap or draining
conditions. Check the entire area for leaks. the radiator. Serious burns may result if skin
comes in contact with hot coolant.
23. Move out and around the right front wheel.
Make sure that all wheel nuts/studs are in place 29. Use the coolant level sight gauge to check the
and tight. coolant level in the radiator. If it is necessary to
remove the radiator cap, make sure that the
24. Move behind the front of the right front wheel. engine is off, then relieve the coolant pressure
Check the hub and brakes for leaks and any by slowly removing the radiator cap.
unusual conditions. Make sure that the steering
cylinder is secure and properly greased. Inspect 30. Inspect the retarding grid covers. Make sure
the engine compartment for any leaks and that the latches are in place and secure. Inspect
unusual conditions. Inspect the fan guard and the main air inlet to ensure that it is clear. Make
belts. Check for any debris behind the radiator. sure that all cabinet door latches are secure.

25. Inspect the auto lube system. See Section P3, 31. Move around to the rear of the cab. Open the
Automatic Lubrication System, for more doors of the brake cabinet and check inside the
information about the auto lube system. cabinet for leaks.

26. As you move in front of the radiator, remove any 32. Clean the cab windows and mirrors. Clean out
debris that is stuck in front of the radiator. the cab floor, if necessary. Make sure that the
Check for any coolant leaks. Inspect the steering wheel, operator controls, and pedals
headlights and fog lights. are free of any grease or mud.

27. Before climbing the ladder to the first level, 33. Stow any personal gear in the cab so that it
make sure that the ground level engine does not interfere with any operation of the
shutdown switch is ON. Inspect the fire control truck. Dirt or trash buildup, specifically in the
actuator. Make sure that the safety pin and the operator's cab, should be cleared. Do not carry
plastic tie that prevents accidental actuation are tools or supplies in the cab or on the deck.
in place and in good condition. Make sure that 34. Adjust the seat and the steering wheel for the
the battery disconnect switches are activated. most operator comfort.
28. Always use handrails and ladders when 35. Before operating the truck, read about and
mounting or dismounting the truck. Clean any understand the locations and functions of all
foreign material such as ice, snow, oil or mud operator controls listed in Section N5, Operator
from the ladders and handrails. Cab Controls.

A3-30 General Safety & Operating Instructions 12/11 A03039


ENGINE START-UP

Do not crank an electric starter for more than 30


Never attempt to start the engine by shorting seconds. Allow two minutes for cooling before
across the starter terminals. This may cause fire, attempting to start the engine again. Severe
or serious injury or death to anyone in the damage to the starter motors can result from
machine’s path. Start the engine from the overheating.
operator’s seat only. 5. The key switch is a four-position switch (ACC,
If the truck is equipped with an auxiliary cold OFF, RUN, START). The ACC position is not
weather heater system, do not attempt to start currently used.
the engine while the heaters are in operation. a. Turn the key switch one position clockwise to
Damage to the coolant heaters will result! the RUN (not START) position. All electrical
circuits except the start circuit are activated.
b. Turn the key switch fully clockwise to the
START position and hold this position until
the engine starts. The START position is
spring-loaded and will return the switch to
the RUN position when the key is released.
NOTE: This truck is equipped with an engine prelube
system. With this feature, a noticeable time delay
may occur before engine cranking begins as the
engine lube oil passages are being filled and
pressurized.
6. After the engine has started, place the rest
switch in the OFF position to deactivate the rest
mode. Refer to Section N5, Operator Cab And
Controls for more information on the rest switch.

1. Make sure that all personnel are clear of the


truck before starting the engine. Always sound
the horn as a warning before moving any
controls.
2. If the truck is in an enclosure, make sure that
there is adequate ventilation before start-up.
Exhaust fumes are dangerous!
3. Make sure that the directional control lever is in
PARK before starting.
4. Place the rest switch in the ON position to put
drive system in rest mode. For more
information, refer to Section N5, Operator Cab
And Controls.

A03039 12/11 General Safety & Operating Instructions A3-31


AFTER ENGINE HAS STARTED PRE-SHIFT BRAKE CHECK
(if equipped)
NOTE: Komatsu recommends that operators perform
static brake tests to verify that the braking systems
are adequate at the beginning of each shift before
operating the truck.
Do not leave the truck unattended while the The static brake test allows the operator to check the
engine is running. Move the directional control service brake, parking brake and the dynamic
lever to PARK and turn off the engine before retarder. The purpose of these tests is to verify the
leaving the truck. functionality of the service brake, parking brake and
Become thoroughly familiar with the steering, braking retarder systems at the time they are tested.
and emergency controls. After performing each test, it is the operator’s respon-
1. After the engine has been started and the low sibility to determine if the truck passed each test and
pressure warning systems are normal, test the if the truck is safe for operation.
steering by turning the steering wheel fully to The order of performing the brake tests, (service
the left and right. brake, parking brake or retard system) does not mat-
If the steering system is not operating properly, ter. Each brake test is a separate test, where one
turn the engine immediately. Determine the brake system or all three can be tested at any time.
steering system problem and have it repaired
before resuming operation. If an operator has questions during brake testing,
refer to the drive system Diagnostic Information Dis-
2. Operate each of the truck's brake circuits at play (DID) panel, located on the back wall of the cab
least twice before operating and moving the for guidance.
truck. These circuits include the service brake,
parking brake, and brake lock. With the engine
running and the hydraulic circuit fully charged,
activate each circuit individually from the
operator's cab.
If any application or release of any brake circuit If the truck fails any brake test, notify mainte-
appears sluggish or improper, or if warning nance personnel immediately. Do not resume
alarms are activated, turn off the engine and operation unless the truck passes all brake tests.
notify maintenance personnel immediately. Do
not operate the truck until the faulty brake circuit
is fully operational.
3. Check the gauges, warning lights, and Events
instruments before moving the truck to ensure The following events have been added to the drive
proper system operation and proper instrument system software to support the brake test feature.
functioning. Pay special attention to the braking
and steering hydraulic circuit warning lights. If • 645-1 Service Brake test Performed
warning lights come on, turn off the engine • 645-2 Parking Brake Test Performed
immediately and determine the cause.
• 645-3 Retard Test Performed
4. Make sure that the headlights, work lights, and
• 645-4 Brake Test Switch stuck closed
taillights are in proper working order. Check the
operation of windshield wiper. Good visibility
may help prevent an accident.
The Events Log will record when and which brake
tests have been performed.

A3-32 General Safety & Operating Instructions 12/11 A03039


OPERATION If the brake check light does not illuminate immedi-
ately after pressing the brake test switch, there is
The static brake test utilizes a momentary switch and
most likely a problem with the setup. Refer to the
a check light located in the overhead display panel.
setup conditions and take action to prepare the truck
for a brake test.

Brake Test Switch


The brake test switch is used to If there is a problem with the truck setup, the DID
initiate a brake test. Press on the panel will display the problem.
momentary switch to enter the For example if the engine is off:
brake test mode. If certain condi-
tions are met, the operator can ERROR Entering Brake Test
enter a brake test sequence. Engine not running

If the Truck is loaded:


ERROR Entering Brake Test
Truck is NOT Empty

Brake Check Light If all of the conditions are correct, except the brakes
The amber light is used to indi- are not set correctly, an error message will be dis-
cate when the truck is in the played. For example, if the service brake and parking
brake test mode. When illumi- brake are both applied together:
nated, a brake test is ready. ERROR Entering Brake Test
When flashing, the brake test is Set Brakes for Test
at the validation point, or the
retard system test is finished.
Brake Test Exit Criteria

Description Numerous conditions can occur which may interrupt


a brake test, including the following:
The operator can choose which brake test to per-
form, and will set the truck controls based on the set- • Any of the setup conditions becoming false
tings in Table 1. The drive system will detect the • Drive system fault which restricts the LINK or
position of the directional control lever, and will pre- Propel mode
pare for the appropriate test. The operator will then
• Truck Speed greater than 3.2 kph (2.0 mph)
press the brake test switch.
• Drive system at torque level for more than 30
If the brake check light is illuminated solid after seconds
pressing the brake test switch, the system is in brake
test mode and is ready for the chosen test to be initi- • Brake test requested, but not initiated by the
ated by the operator. After testing, the operator will operator within 60 seconds after pressing the
brake test switch
then determine if the truck passed the brake tests,
and if it is safe for operation.

Table 1: BRAKE TEST SETTINGS


Wheel Brake Service Brake Directional
Test Type Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF RELEASED PARK
Retard Test OFF RELEASED PARK

A03039 12/11 General Safety & Operating Instructions A3-33


PERFORMING THE BRAKE TESTS Service Brake Test

Setup 1. Firmly depress the service brake pedal.


2. Place the directional control lever in the NEU-
Before performing any brake test, the following con- TRAL position. Ensure the wheel brake lock
ditions must be met: switch is OFF.
• Dump body empty 3. Press the brake test switch and wait for the
brake check light to be on solid.
NOTE: The drive system will not enter any brake test
if the truck is loaded. 4. Fully depress the service brake pedal. Ensure
full brake application is reached. Failure to
• Truck located outside on a flat area, where truck reach full brake application will affect the ser-
movement is allowed. vice brake test results.
5. The DID panel will display:
Service Brake Test READY
Press Accel Pedal to Start

6. With the service brake pedal still fully applied,


Ensure the area around the truck is free of per- fully depress the accelerator pedal. The drive
sonnel and objects. Some truck movement could system controller will enter propel mode and
occur during brake testing. generate torque up to the service brake limit.
Maintain full service brake pressure during the
The drive system is unable to determine if the test.
truck is on a hill or in a parking ditch. Testing
during these conditions will affect test results. NOTE: The drive system can only detect if the
service brakes are applied. It can not detect the
percentage of application. It is up to the operator to
Before performing any brake test, the truck must be press hard enough on the service brake pedal to
in the following state: achieve a full brake application.

• Engine on (low idle)


• Drive system ready (Ready Mode) 7. The DID panel will display:

• Dump body down Service Brake Test ACTIVE


Check Truck Movement when Light Flashes
• No drive system warning lights ON
(Can not be in LIMP mode.) 8. Once torque has reached the limit for the ser-
• Zero ground speed vice brake test, the brake check light will begin
to flash. This is the indication for the operator to
make a determination as to the status of the
service brake system.
• If the truck did not move:
The service brake system passed the test.
• If the truck moved during the test:
The service brake system failed the test.

A3-34 General Safety & Operating Instructions 12/11 A03039


9. Release the accelerator pedal and the torque Parking Brake Test
will be reduced, the test will stop and the brake 1. Place the directional control lever in the PARK
check light will turn off. position.
10. Place the directional control lever in the PARK 2. Press the brake test switch and wait for the
position. Release the service brake pedal. brake check light to be on solid.
11. If the truck failed the service brake test, notify 3. The DID panel will display:
maintenance personnel immediately.
Parking Brake or Retard Test READY
Press Accel or Retard Pedal to Start

4. Fully depress the accelerator pedal. The drive


system controller will enter propel mode and
generate torque up to the park brake limit.
If the truck fails the service brake test, notify 5. The DID panel will display:
maintenance personnel immediately. Do not
Park Brake Test ACTIVE
resume operation unless the truck passes all
Check Truck Movement when Light Flashes
brake tests.
6. Once the torque has reached the limit for the
parking brake test, the brake check light will
NOTE: If the operator partially or fully releases the
begin to flash. This is the indication for the oper-
accelerator pedal during the test, torque will be
ator to make a determination as to the status of
reduced and the brake check light will go back on
the parking brake system.
solid when torque falls below the test set point. The
operator can re-apply the accelerator pedal to • If the truck did not move:
increase torque and the brake check light will again The park brake system passed the test.
flash when the torque is at the test limit. • If the truck moved during the test:
The park brake test has failed. Release the
accelerator pedal. If the truck starts to roll, apply
If the test exits abnormally, or if the operator simply the service brakes to hold the truck stationary.
does not press the accelerator pedal far enough to Notify maintenance personnel immediately.
achieve the torque level for the service brake test,
the DID panel will display:
Brake Test ERROR
Test did NOT complete

If the truck fails the parking brake test, notify


maintenance personnel immediately. Do not
resume operation unless the truck passes all
brake tests.

7. When the operator releases the accelerator


pedal, torque will be reduced, the test will stop
and the brake check light will turn off.

A03039 12/11 General Safety & Operating Instructions A3-35


Retard System Test EMERGENCY STEERING SYSTEM
1. Place the directional control lever in the PARK
Operation
position.
2. Press the brake test switch and wait for the This truck is equipped with an emergency steering
brake check light to be on solid. system. This system is a backup in the event of loss
of oil supply to the main steering system. The
3. The DID panel will display:
emergency steering system was designed to meet or
Parking Brake or Retard Test READY exceed SAE J1511 and ISO 5010 standards.
Press Accel or Retard Pedal to Start
If the low steering system pressure indicator light and
alarm are activated, a failure in the hydraulic oil
4. Fully depress the retard pedal. The drive sys-
supply to the steering and brake system exists. When
tem controller will ramp up the engine speed,
the alarm is activated, typically there is enough
close RP1, close RP2, close RP3 (if present),
hydraulic pressure stored in the brake and steering
turn on the choppers, and test the retarding sys-
accumulators to allow brief operation of the steering
tem. The system will verify current flow through
and brake functions. However, this oil supply is
each grid leg and the grid blower motor.
limited. Therefore, it is important to stop the truck as
5. The DID panel will display the current status of quickly and safely as possible after the alarm is first
the test. activated.
Retard System Test ACTIVE If the oil supply pressure drops to a predetermined
RP1 RP2 RP3 CHOP level, the low brake pressure warning light will also
(Elements are added as the test progresses.)
illuminate. If the oil pressure continues to decrease,
the brake auto-apply feature will activate the service
6. Upon successful completion of the test, the light brakes to stop the truck.
will flash for 10 seconds indicating a successful
test. The DID panel will display: Pre-Operation Testing
Retard System Test PASSED NOTE: Komatsu recommends that operators perform
or this test to verify that the steering accumulator
precharge pressure is adequate at the beginning of
Retard System Test FAILED or Incomplete each shift before operating the truck.
NOTE: If the brake check light never flashes, but 1. Park the empty truck on flat, level ground.
turns off, the test has failed. Lower the dump body onto the frame and stop
the engine. Make sure that the key switch is in
the OFF position.
2. Wait at least 90 seconds to verify that all
hydraulic pressure has been relieved from the
steering accumulators. Turn the steering wheel
If the truck fails the retard system test, notify
from stop to stop. If the front wheels do not
maintenance personnel immediately. Do not
move, there is no hydraulic pressure.
resume operation unless the truck passes all
brake tests. 3. Check the hydraulic tank oil level. The oil level
must be visible in the center of the upper sight
glass and must not cover the entire upper sight
7. When the operator releases the retard pedal, glass. Add oil if necessary. Do not overfill.
the test will stop and the brake check light will
turn off.
8. If the retard system failed the test, notify main-
tenance personnel immediately. Do not resume
operation unless the truck passes all brake
tests.

A3-36 General Safety & Operating Instructions 12/11 A03039


4. Turn the key switch to the ON position, but do MACHINE OPERATION SAFETY
not start the engine. PRECAUTIONS
a. Steering system pressure: Verify that the low
After the engine is started and all systems are
steering pressure warning light is
functioning properly, the operator must follow all local
illuminated. If it is not illuminated,
safety rules to ensure safe machine operation.
immediately notify maintenance personnel.
Do not operate the truck until the problem is
corrected.
b. Steering accumulator precharge: Verify that
the low accumulator precharge warning light
is not illuminated and the warning buzzer is
not sounding. If the warning light is If any of the red warning lights come on or if any
illuminated and the buzzer is sounding, gauge reads in the red area during truck
immediately notify maintenance personnel. operation, a malfunction is indicated. Stop the
Do not operate the truck until the problem is truck as soon as possible and turn off the engine.
corrected. Have the problem corrected before resuming
truck operation.
5. Start the engine and allow the steering
accumulators to fully charge. Turn the steering
wheel so that the front wheels are straight.
6. Check the hydraulic tank oil level while the
engine is on.
a. If the oil level is visible in center of the lower The truck is equipped with “slip/slide” control. If
sight glass and does not cover the entire this function becomes inoperative, operating the
lower sight glass, the steering accumulators truck with stalled or free spinning wheel motors
are adequately charged. Proceed to Step 7. may cause serious damage to the wheel motors.
b. If the oil level is below the lower sight glass, If the truck does not begin to move within 10
the steering accumulators are not seconds after depressing the throttle pedal with
adequately charged. Stop the engine and the directional control lever in a F or R position,
turn the key switch to the OFF position. release the throttle pedal and allow the wheels to
Immediately notify maintenance personnel. regain traction before accelerating again.
Do not operate the truck until the problem is • Always look to the rear before backing the truck.
corrected. Watch for and obey the ground spotter's hand
signals before making any reverse movements.
7. If the steering accumulators are adequately
Sound the warning horn (three blasts). The
charged, stop the engine by using the spotter should have a clear view of the entire
emergency shutdown switch. Leave the key area at the rear of the truck.
switch in the ON position. This allows the
steering accumulators to retain their hydraulic • Operate the truck only while properly seated with
seat belt fastened. Keep hands and feet inside
charge. The low steering pressure warning light
the cab while the truck is in operation.
and the low accumulator precharge warning
light should not illuminate. • Do not allow unauthorized personnel to ride in or
on the truck. Do not allow anyone to ride on the
8. Turn the steering wheel from stop to stop. The ladder of the truck.
front wheels should turn fully to the left and to
the right. Also, the low steering pressure • Check the gauges and instruments frequently
warning light should illuminate and the warning during operation for proper readings.
buzzer should sound. • Observe all regulations pertaining to the job site's
If the front wheels cannot be turned fully to the traffic pattern. Be alert to any unusual traffic
left and right, or if the warning light and buzzer pattern. Obey the spotter's signals.
do not activate, immediately notify maintenance
personnel. Do not operate the truck until the
problem is corrected.
If the truck passes this test, the emergency steering
system is functioning properly.

A03039 12/11 General Safety & Operating Instructions A3-37


• Match the truck speed to haul road conditions. 4. When backing up the truck, give a back-up
Slow down the truck in congested areas. Keep a signal of three blasts on the horn. When starting
firm grip on the steering wheel at all times. forward, give two blasts on the horn. These
• Do not allow the engine to run at idle for signals must be given each time the truck is
extended periods of time. moved forward or backward.
• When the truck body is in the dump position, do 5. Use extreme caution when approaching a haul
not allow anyone beneath it unless the body-up road intersection. Maintain a safe distance from
retaining pin or cable is in place. oncoming vehicles.
6. Maintain a safe distance when following
another vehicle. Never follow another vehicle in
the same lane closer than 15 m (50 ft). When
driving on a downgrade, this distance should be
at least 30 m (100 ft).
Do not use the brake lock or the emergency
brake (if equipped) for parking. With the engine 7. Do not stop or park on a haul road unless it is
stopped, hydraulic pressure will bleed down, unavoidable. If you must stop, move the truck to
allowing the brakes to release. a safe place, move the directional control lever
to PARK and turn off the engine before leaving
• Check the brake lock performance periodically the cab. Chock the wheels securely and notify
for safe loading and dump operation. maintenance personnel for assistance.
• Proceed slowly on rough terrain to avoid deep 8. Before driving up or down a grade, maintain a
ruts or large obstacles. Avoid traveling close to speed that will ensure safe driving and provide
soft edges or the edge of a fill area.
effective retarding under all conditions. Refer to
• Do not drive over unprotected power cables. Dynamic Retarding in Section N5, Operator
• Truck operation requires concentrated effort by Cab And Controls. Refer to the grade/speed
the driver. Avoid distractions of any kind while chart in the operator's cab to determine the
operating the truck. maximum safe truck speeds for descending
various grades with a loaded truck.
9. When operating the truck in darkness, or when
OPERATING ON THE HAUL ROAD visibility is poor, do not move the truck unless all
headlights, clearance lights, and tail lights are
1. Always stay alert! If you are unfamiliar with the on. Do not back up the truck if the back-up horn
road, drive with extreme caution. The cab doors or lights are inoperative. Always dim the
should remain closed at all times if the truck is headlights when meeting oncoming vehicles.
in motion or unattended.
10. If the emergency steering light and/or low brake
2. Obey all road signs. Operate the truck so it is pressure warning light illuminate during
under control at all times. Govern the truck operation, steer the truck immediately to a safe
speed by the road conditions, weather, and area away from other traffic, if possible, and
visibility. Report poor haul road conditions stop the truck. Refer to Step 7.
immediately. Muddy or icy roads, pot holes, or
other obstructions can present hazards. 11. Check the tires for proper inflation periodically
during your shift. If the truck has been run on a
3. Initial propulsion with a loaded truck should “flat”, or under-inflated tire, it must not be
begin from a level surface whenever possible. If parked in a building until the tire cools.
there are circumstances where starting on a hill
or grade cannot be avoided, refer to Starting On
a Grade With a Loaded Truck.

A3-38 General Safety & Operating Instructions 12/11 A03039


STARTING ON A GRADE WITH A Overload Speed Limit Function
LOADED TRUCK NOTE: This feature can be enabled or disabled at
Initial propulsion with a loaded truck should begin the discretion of site management. The setting for
from a level surface whenever possible. If the truck payload trigger and speed limits are also adjustable
must be started on a hill or grade, use the following by local site preference.
procedure: The overload speed limit function limits the speed of
1. Fully depress the service brake pedal. Do not the truck if a payload limit setting has been exceeded.
use the retarder lever to hold the truck on the The overload signal becomes true (24 volts) when the
grade. With the service brakes fully applied, PLMIII early estimate of payload exceeds the preset
move the directional control lever to a drive payload ton threshold.
position (FORWARD or REVERSE) and The PLMIII early estimate of payload calculation
increase the engine rpm with the throttle pedal. occurs after 12 seconds of travel above 5 kph (3
2. As the engine rpm approaches the maximum, mph) after being loaded. Once the overload signal
and the operator senses the propulsion effort becomes true, it stays true until the payload is
working against the brakes, release the brakes dumped.
and let truck movement start. Completely
By default, the overload speed limit is disabled
release the service brake pedal. As the truck
(option 0 in the configuration file). The configuration
speed increases above 5-8 kph (3-5 mph), the
file can be set to:
propulsion system controller (PSC) will drop the
propulsion if the retarder is still applied. Option 1 - Overload speed limit is imposed.
NOTE: Releasing and re-applying dynamic retarding or
during a hill start operation will result in loss of
Option 2 - No propel restriction is imposed and
propulsion.
logged. The truck cannot move under its own power
when the overload signal becomes true.
PASSING
1. Do not pass another truck on a hill or blind
curve. Only use areas designated for passing. The overload speed limit can be adjusted by
modifying the configuration file. Use the Payload
2. Before passing, make sure that the road ahead
Service Software Lite Version (available for download
is clear. If a disabled truck is blocking your lane,
at www.KomatsuAmerica.net) to set the overload
slow down and pass with extreme caution.
threshold.
LOADING When option 1 is selected, and the overload signal is
true, tractive effort is reduced to attempt to respect
1. Pull into the loading area with caution. Remain
the speed limit setting. The retard effort will not be
at a safe distance while the truck ahead is being
engaged to lower the speed of the truck. Once the
loaded.
truck speed matches that of the overload speed limit
2. When approaching or leaving a loading area, setting, limited propel efforts and retarding efforts will
watch out for other vehicles and personnel be used as necessary. This feature maintains the
working in the area. truck speed at the maximum of the overload speed
3. When pulling in under a loader or shovel, follow limit setting.
the spotter or shovel operator’s signals. The
truck operator may speed up loading operations
by observing the location and loading cycle of
the truck being loaded ahead, then follow a
similar pattern.
4. During loading, the operator must stay in the
cab with the engine running. Place the
directional control lever in NEUTRAL and apply
the brake lock.
5. When loaded, pull away from shovel as quickly
as possible but with extreme caution.

A03039 12/11 General Safety & Operating Instructions A3-39


DUMPING
Raising The Dump Body
1. Pull into the dump area with extreme caution.
Make sure the area is clear of persons and
obstructions, including overhead utility lines.
Obey signals directed by the spotter, if present.
2. Avoid unstable areas. Stay a safe distance from
the edge of the dump area.

To prevent tipping or rolling, position the truck 5. Pull the lever to the rear to actuate the hoist
on a solid, level surface before dumping. As the circuit. Releasing the lever anywhere during
body raises, the truck center of gravity will move. “hoist up” will hold the body at that position.

3. Carefully maneuver the truck into the dump 6. Raise the engine rpm to accelerate the hoist
position. When backing the truck into the dump speed. If dumping very large rocks or sticky
position, use only the foot-operated brake pedal material as described in the WARNING above,
to stop and hold the truck. Do not rely on the slowly accelerate the engine to raise the body.
wheel brake lock to stop the truck. This control When the material starts to move, release the
is not modulated and applies the rear service hoist lever to the HOLD position. If the material
brakes only. does not continue moving and clear the body,
repeat this procedure until the material has
4. When the truck is stopped and in the dump cleared the body.
position, apply the brake lock and move the
directional control lever to NEUTRAL. 7. Reduce the engine rpm as the last stage of the
hoist cylinder begins to extend. Let the engine
go to low idle as the last stage reaches half-
extension.
8. Release the hoist lever as the last stage of the
Dumping very large rocks (10% of payload or hoist cylinder reaches full extension.
greater) or sticky material (loads that do not flow
9. After the material being dumped clears the
freely from the body) may allow the material to
body, lower the body to the frame.
move too fast and cause the body to move
rapidly and suddenly. This sudden movement NOTE: If the directional control lever is in REVERSE
may jolt the truck violently and cause possible when the dump body is raised, reverse propel is
injury to the operator and/or damage to the hoist inhibited. To deactivate, lower the dump body and
cylinders, frame, and/or body hinge pins. move the directional control lever out of REVERSE.

A3-40 General Safety & Operating Instructions 12/11 A03039


Lowering The Dump Body Lowering The Dump Body
(When dumping on flat ground): (When dumping over a berm or into a crusher):
It is very likely when dumping on flat ground that the 1. Move the hoist lever forward to the DOWN
dumped material will build up enough to prevent the position. Release the lever to place the hoist
body from lowering. In this case, the truck will have to control valve in the FLOAT position, which
be driven forward a short distance (just enough to allows the body to return to the frame.
clear the material) before the body can be lowered.
1. Move the directional control lever to If dumped material builds up at the rear of the
FORWARD, release the brake lock, depress the body and the body cannot be lowered, perform
override button, and drive just far enough the following steps:
forward for the body to clear the material. a. Move hoist lever back to the HOIST position
2. Stop, move the directional control lever to to fully raise the dump body. Release the
NEUTRAL, and apply the brake lock. hoist lever so it returns to the HOLD position.
3. Move the hoist lever forward to the DOWN NOTE: Do not drive forward if the tail of body will not
position. Release the lever to place the hoist clear the crusher wall in the fully raised position.
control valve in the FLOAT position, which b. Move the directional control lever to
allows the body to return to the frame. FORWARD, release the brake lock, depress
If dumped material builds up at the rear of the the Override button, and drive forward to
body and the body cannot be lowered, then clear the material.
perform the following steps:
c. Stop, move the directional control lever to
a. Move the hoist lever back to the RAISE NEUTRAL, apply the brake lock and lower
position to fully raise the dump body. Then the body.
release the hoist lever so it returns to the
NOTE: Failure to hoist the body after making an
HOLD position.
unsuccessful attempt at lowering the body may result
b. Move the directional control lever to in the dump body suddenly lowering after the truck
FORWARD, release the brake lock, depress has pulled ahead of the material that was previously
the override button, and drive forward to preventing the body from lowering.
clear the material.
c. Stop, move the directional control lever to
NEUTRAL, apply the brake lock, and lower
the body.
NOTE: Failure to hoist the body after making an
unsuccessful attempt at lowering the body may result
in the dump body suddenly lowering after the truck
has pulled ahead of the material that was previously
preventing the body from lowering. Do not move the truck with the dump body raised
except in an emergency. Failure to lower the
body before moving the truck may cause damage
to the hoist cylinders, frame and/or body hinge
pins.

2. With the body returned to the frame, move the


Do not move the truck with the dump body raised directional control lever to FORWARD, release
except in an emergency. Failure to lower body the brake lock, and leave the dump area
before moving truck may cause damage to hoist carefully.
cylinders, frame and/or body hinge pins.
4. With the body returned to frame, move the
directional control lever to FORWARD, release
the brake lock, and leave the dump area
carefully.

A03039 12/11 General Safety & Operating Instructions A3-41


TOWING SAFE PARKING PROCEDURES
Before towing a truck, many factors must be carefully Continue to use safety precautions when preparing
considered. Serious personal injury and/or significant for parking and engine shutdown.
property damage may result if important safety
If the equipment is being used in consecutive shifts,
practices, procedures and preparation for moving
any questionable truck performance the operator
heavy equipment are not observed. Do not tow the
may have noticed must be checked by maintenance
truck any faster than 8 kph (5 mph).
personnel before the truck is released to another
Information about the towing attachments listed operator.
below is available from your Komatsu service
1. Park the truck on level ground, if possible. If the
representative:
truck must be parked on a grade, position the
Front Bumper Modification Kit - MK3941: This kit truck at a right angle to the grade.
contains the parts necessary to modify the front 2. The directional control lever must be in PARK
bumper for installation of towing bosses. One and chocks must be placed in front of and
MK3941 kit is required for each truck in the fleet. behind the wheels so the truck cannot roll. Each
Tow Adaptor Structure - MK3945: This structure truck should be parked at a reasonable distance
must be ordered (or designed) to mate with the from one another.
intended towing vehicle and is intended for towing an
unloaded vehicle only.
A disabled machine may be towed after the following
precautions have been taken.
1. Turn off the engine. Do not activate the wheel lock feature when the
2. If the truck is equipped, install hydraulic parking brake is activated. Bleed down of
connections for steering and dumping between hydraulic pressure may occur, causing the truck
towing and towed vehicles. Check the towed to roll away.
vehicle braking system. 3. Haul roads are not safe parking areas. In an
3. If the truck is loaded, dump the entire load. emergency, pick the safest spot that is most
Never pull or tow a loaded truck. Refer to visible to other machines in the area. If the truck
Disabled Truck Dumping Procedure. becomes disabled where traffic is heavy, mark
the truck with warning flags in daylight or flares
4. Make sure that the tow bar has adequate
at night.
strength (approximately 1.5 times the gross
vehicle weight of truck being towed).
5. Make sure that the towing vehicle has adequate
capacity to both move and stop the towed truck
under all conditions.
6. Chock the disabled truck’s wheels to prevent
movement while attaching the tow bar.
7. Release the disabled truck’s brakes and
remove the blocking.

Sudden movement may cause tow bar failure.


Smooth, gradual truck movement is preferred.
8. Minimize the tow angle at all times. Never
exceed 30 degrees. The towed truck must be
steered in the direction of the tow bar.

A3-42 General Safety & Operating Instructions 12/11 A03039


NORMAL ENGINE SHUTDOWN DELAYED ENGINE SHUTDOWN
PROCEDURE PROCEDURE
Follow this procedure at each engine shutdown. 1. Stop the truck out of the way of other traffic on a
level surface and free of overhead power lines
1. Stop the truck out of the way of other traffic on a
or other obstructions in case dump body needs
level surface. Make sure that there are no
to be raised.
overhead power lines or other obstructions in
case the dump body must be raised. a. Reduce the engine speed to low idle.
a. Reduce the engine speed to idle. b. Place the directional control lever in PARK.
Make sure that the parking brake applied
b. Place the directional control lever in PARK.
indicator light in the overhead display panel
Make sure that the parking brake applied
is illuminated.
indicator light is illuminated.
2. Place the rest switch in the ON position to put
c. Allow the engine to cool gradually by running
the AC drive system in the rest mode. Make
at low idle for 3 to 5 minutes, or activate the
sure that the rest mode indicator light in the
5 minute shutdown delay timer as described
overhead panel is illuminated.
in “Delayed Engine Shutdown Procedure”.
3. Press the top of the engine
2. Place the rest switch in the ON position to put
shutdown timer switch to select
the AC drive system in the rest mode. Make
the ON (center) position. Press
sure that the rest mode indicator light in the
the top of the switch again to
overhead panel is illuminated.
activate the timer delay
3. With the engine cooled down, turn the key (MOMENTARY position). Release the switch
switch to the OFF position for normal engine and allow it to return to the ON position.
shutdown.
If the engine does not shutdown with the key When the engine shutdown timer
switch, use the engine shutdown switch on the has been activated, the timer
operator cab center console. Pull this switch up delay indicator light in the
until the engine stops. overhead panel will illuminate to
4. With the key switch OFF and engine stopped, indicate that the shutdown timing
wait at least 90 seconds. Make sure that the sequence has started. The engine will continue
steering circuit is completely bled down by to idle for approximately 5 minutes to allow for
turning the steering wheel back and forth proper engine cool-down before stopping.
several times. The front wheels should not turn
when the hydraulic pressure is relieved. If the
4. Turn the key switch to the OFF position. The
front wheels can still be turned, notify
engine will shutdown when the timing sequence
maintenance personnel.
is complete. When the engine stops, this will
5. Make sure that the link voltage light in the activate the hydraulic bleed down timer and turn
control cabinet is off. Notify maintenance off the 24 VDC electric circuits that are
personnel if a light remains illuminated for controlled by the key switch.
longer than five minutes after the engine is shut
NOTE: To cancel the 5 minute idle timer sequence,
down.
press the engine shutdown timer switch to the OFF
6. Close and lock all windows. Remove the key (lower) position. If the key switch is in the OFF
from the key switch and lock the cab to prevent position, the engine will stop. If the key switch is in
unauthorized truck operation. Dismount the the ON position, the engine will continue to run.
truck properly. Put wheel chocks in place.

A03039 12/11 General Safety & Operating Instructions A3-43


SUDDEN LOSS OF ENGINE POWER FUEL DEPLETION
If the engine suddenly stops, there is enough The high pressure injection (HPI) fuel system uses
hydraulic pressure stored in the brake and steering fuel to adjust fuel delivery timing by creating a
accumulators to allow the operation of the steering hydraulic link between the upper plunger and the tim-
and brake functions. However, this oil supply is ing plunger. Metered fuel is also used for lubricating
limited, so it is important to stop the truck as quickly the injector plunger and barrel. The maximum
and safely as possible after the loss of engine power. demand for metered fuel is required during high
speed / low load conditions.
If the brake supply pressure drops to a pre-
determined level, the low brake oil pressure warning
light will illuminate and sonalarm will sound. If the
brake pressure continues to decrease, the auto-apply
feature will activate and the service brakes will apply
automatically to stop the truck.
Operating the truck to fuel depletion forces the
1. Bring the truck to a safe stop as quickly as injector train into a no-follow condition. No fuel
possible by using the foot pedal to apply the flow between the plungers may cause damage to
service brakes. If possible, safely steer the the injectors and the overhead due to adhesive
truck to the side of the road while braking. wear, resulting in costly repairs and unnecessary
downtime.

Dynamic retarding will not be available. Do not


use the service brakes for continuous retarding Allowing the Komatsu truck to operate until fuel
purposes. depletion can lead to unsafe operating
2. Move the directional control lever to PARK as conditions possibly resulting in an
soon as the truck has stopped moving. uncontrollable vehicle and/or personal injury.
3. Turn the key switch to the OFF position and
notify maintenance personnel immediately.
4. If traffic is heavy near the disabled machine,
mark the truck with warning flags during
daylight hours or use flares at night. Adhere to
local regulations.

A3-44 General Safety & Operating Instructions 12/11 A03039


DISABLED TRUCK DUMPING Lowering the Body
PROCEDURE 1. Place the hoist lever of the good truck in FLOAT
Sometimes it is necessary to dump a load from the to lower the body. If necessary, momentarily
body of a truck if the hoist system is inoperable. The place the hoist control in POWER UP until the
following instructions describe the use of a “good” body is able to descend in FLOAT. Do not
truck to provide the hydraulic power required to raise accelerate the engine.
the body of the “disabled” truck to dump the load. 2. After the body is lowered, shut down the truck,
In the following example, Figure 3-13 illustrates a bleed the hydraulic system, and disconnect the
typical hookup from the good truck. The disabled hoses.
truck may be the same truck model or a different 3. Reduce the power down relief valve pressure
Komatsu truck model. on the good truck to normal by turning the
adjustment counterclockwise the same number
Hookup of turns as required in Step 2b of “Raising the
Make sure that there is an adequate, clear area to Body.”
dump the loaded body. When the good truck is in 4. Check the power down relief pressure. Refer to
position, turn off the engine and allow the hydraulic Section L10, Hydraulic Check-Out Procedure.
system to bleed down. Make sure that the pressure
5. Check the hydraulic tank oil level.
has bled off before connecting the hoses.
1. With the good truck parked as close as possible
to the disabled truck, attach a hose from the
power up quick disconnect (4, Figure 3-13) to
the power down circuit of the disabled truck.
The hose must be rated to withstand 17 000
kPa (2,500 psi) or greater pressure.
NOTE: The power down circuit will use a smaller
diameter hose (tube) than the power up circuit.
2. Connect another hose from the power down
quick disconnect (3) to the power up circuit of
the disabled truck.
NOTE: If both trucks are the same model, the hoses
will be installed at the quick disconnects shown in
Figure 3-13 and will be crossed when connected.
FIGURE 3-13. PUMP MODULE, HOSE HOOKUP
Raising the Body
1. On the disabled truck, move the hoist control 1. Hoist Valve
lever to power up and then release it to place 2. Tubes to LH Hoist Cylinder
the hoist pilot valve in the HOLD position. Leave 3. Power Down Quick Disconnect (Connect to power
up circuit of disabled truck.)
in this position during entire procedure.
4. Power Up Quick Disconnect (Connect to power
2. Start the engine on the good truck, place the down circuit of disabled truck.)
hoist control in the POWER DOWN position and 5. Overcenter Manifold
increase the engine rpm to high idle to dump
the disabled truck. If the body of the disabled
truck fails to raise, increase the good truck
power down relief pressure as follows:
a. Shut down engine and allow the hydraulic
system to bleed down.
b. Remove the cap from the hoist pilot valve
relief valve (2), located in the hydraulics
components cabinet behind the cab. While
counting the number of turns, slowly turn the
relief valve adjustment screw clockwise until
it bottoms. Repeat Step 2.

A03039 12/11 General Safety & Operating Instructions A3-45


NOTES

A3-46 General Safety & Operating Instructions 12/11 A03039


WARNINGS AND CAUTIONS
The following pages give an explanation of the KEY SWITCH
warning, caution, and service instruction plates and
decals attached to the truck. The plates and decals A warning decal is below the key switch located to
listed here are typical of this Komatsu model, but the right of the steering column on the instrument
because of customer options, individual trucks may panel. The warning stresses the importance of
have plates and decals that are different from those reading the operator's manual before operation.
shown here.
The plates and decals must be kept clean and
legible. If any decal or plate becomes damaged or
illegible, replace it with a new one.

GRADE/SPEED CHART
A grade/speed retard chart is located on the left front
post of the operator's cab. It provides the
recommended maximum speeds to be used when
descending various grades with a loaded truck.
Always refer to the decal in operator's cab. This
decal may change with optional truck equipment
such as wheel motor drive train ratios, retarding
grids, tire sizes, etc.

ROPS/FOPS
A plate attached to the right rear corner of the cab
states that the Rollover Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS) meet
various SAE performance requirements.
The plate also contains a WARNING about making
modifications or repairs to the structure.
Unauthorized modifications or repairs will void the
certification.

A04061 12/11 Warnings and Cautions A4-1


BATTERIES This decal is placed on the battery box near the
battery disconnect switches to indicate that the
A danger decal is located on the front exterior of the battery system (24VDC) is a negative (-) ground
battery box. It stresses the need to keep from making system.
any sparks near the battery. When another battery or
24VDC power source is used for auxiliary power, all
switches must be OFF before making any
connections. When connecting auxiliary power
cables, positively maintain correct polarity. Connect
the positive (+) posts together and then connect the
negative (-) lead of the auxiliary power cable to a A decal that outlines the correct battery cable
good frame ground. Do not connect to the negative removal procedure is located on the front exterior of
posts of the truck battery or near the battery box. the battery box.
This hookup completes the circuit but minimizes the
danger of sparks near the batteries.
Sulfuric acid is corrosive and toxic. Use proper safety
gear, goggles, rubber gloves and a rubber apron
when handling and servicing batteries. If sulfuric acid
is swallowed, gets into your eyes or contacts your
skin, get proper medical help immediately.

CAPACITORS
This decal is located on the front of the contactor box
and on the inside of the left control cabinet door.
When any of the indicator lights are on, high voltage
is present throughout the propulsion and retarding
system. Extreme care should be exercised.

This decal is located on the front exterior of the


battery box. It warns about the potential hazard of
stored energy remaining in the hydraulic system if
the battery disconnect switch is opened before the
steering accumulators have bled down completely.

A4-2 Warnings and Cautions 12/11 A04061


CRUSHING HAZARD CYLINDER PRESSURE
Warning decals are mounted on the frame in front of These danger decals are mounted on the outside of
both front tires and to the rear of both front tires. each frame rail to remind technicians to read the
They warn that the clearances change when the warning labels attached to the side of each of the
truck is steered and could cause serious injury. accumulators (see below) before releasing internal
nitrogen pressure or disconnecting any hydraulic
lines or hardware. There are similar decals mounted
on top of each of the accumulators (both steering
and brake) with the same danger message.

Warning decals are attached to both the hydraulic


tank and fuel tank to alert technicians not to work on These warning decals are mounted on the side of
the truck with the body in the raised position unless each of the accumulators (both steering and brake)
the body-up retention device (pins or cable) is in to alert technicians to discharge all gas and hydraulic
position. pressure, and to read the maintenance/service
manual before performing any service.

This danger decal is attached to all four suspensions.


It contains instructions for releasing internal pressure
before disconnecting any hardware. Serious injury
can occur if these directions are not followed.

A04061 12/11 Warnings and Cautions A4-3


FILLING THE HYDRAULIC TANK HYDRAULIC OIL PRESSURE
A decal mounted on the side of the hydraulic tank A warning plate is attached to the hydraulic tank to
provides instructions for filling the hydraulic tank. warn technicians that high pressure hydraulic oil is
present during operation. When it is necessary to
To lessen the chances of system contamination,
open the hydraulic system, be sure the engine is
keep the system open to the atmosphere only as
stopped and the key switch is OFF to bleed down
long as absolutely necessary. Service the tank with
hydraulic pressure. There is always a chance of
clean Type C-4 hydraulic oil. All oil that is being put
residual pressure being present. Open fittings slowly
into the hydraulic tank should be filtered through 3
to allow all pressure to bleed off before removing any
micron filters.
connections.

A caution decal is attached below the hydraulic tank Two warning decals are located on the doors of the
oil level sight gauge. Check the oil level with the body hydraulic brake cabinet to warn technicians not to
down, engine stopped, and key switch OFF. Add oil disconnect any hydraulic brake lines until the
per filling instructions if the oil level is below the top machine has been properly shut down.
of the sight glass.

A4-4 Warnings and Cautions 12/11 A04061


HOT OIL SPRAY RADIATOR
This decal is placed on both front wheel hubs to warn A warning decal is mounted on top of the radiator
about hot oil inside the wheel hubs. Remove the oil surge tank cover near the radiator cap. The engine
level plug carefully to avoid injury. cooling system is pressurized. Always turn the key
switch OFF and allow the engine to cool before
removing the radiator cap. Unless the pressure is
first released, removing the radiator cap after the
engine has been running for a time will result in hot
coolant being expelled from the radiator. Serious
scalding and burning may result.

WHEEL MOTOR OIL LEVEL


A wheel motor oil level decal is attached to the gear
cover on both electric wheel motors. This decal
stresses that the truck must be parked for 20 minutes
EMERGENCY LADDER
prior to checking the oil level in order to get an
accurate reading. This decal is located by the emergency ladder on
both sides of the truck.

HOT EXHAUST ACCUMULATOR DRAIN VALVES


A caution decal is also attached to the door of the Warning decals are applied to both brake
rear axle hatch and around the retarding grid cabinet accumulators located inside the hydraulic brake
to alert personnel that hot exhaust air is present and cabinet behind the operator cab. These decals
may cause injury. remind servicing technicians to close the
accumulator drain valves after they have been
opened to bleed the brake pressure. It further warns
not to overtighten the drain valves in order to prevent
damage to the valve seat(s).

A04061 12/11 Warnings and Cautions A4-5


EMERGENCY DUMP PROCEDURE WELDING
A decal which provides the operator or technician This caution decal is placed near the battery
with the emergency procedure for dumping a loaded, disconnect switches to alert service technicians to
disabled truck by using a functional truck for always disconnect the battery charging alternator
hydraulic power is located on the frame near the left lead wire before making welding repairs.
hoist cylinder.
In addition, always isolate electronic control
Refer to Section L in the shop manual for additional components and disconnect the positive and
information about using this procedure. negative battery cables of the vehicle. Failure to do
so may seriously damage the battery and electrical
equipment.

Always fasten the welding machine ground (-) lead to


the piece being welded. The grounding clamp
EMERGENCY TOWING PROCEDURE must be attached as near as possible to the weld
area. Never allow welding current to pass through
A decal which provides the operator or technician ball bearings, roller bearings, suspensions, or
with the emergency procedure for towing a disabled hydraulic cylinders. Always avoid laying welding
truck is located on the left frame rial near the steering cables over or near the vehicle electrical harnesses.
accumulators. Welding voltage could be induced into the electrical
harness and possibly cause damage to components.

EMERGENCY SHUTDOWN
This decal is placed on the ground level engine
shutdown switch, which may be mounted on either
side of the front bumper. It specifies that this switch is
for emergency shutdown only.

A4-6 Warnings and Cautions 12/11 A04061


INFORMATION DISPLAY HIGH VOLTAGE
This information decal is placed on the left door of A high voltage danger decal is attached to the door of
the control cabinet. the rear hatch cover. High voltage may be present!
Only authorized personnel should access this rear
housing.

These danger decals are mounted on all the AC


drive control housings and cabinets. High voltage
may be present! Only authorized personnel should
WIRELESS SIGNALS access this component.
Wireless signals from the truck’s VHMS system can
interfere with other wireless signals in the area. This
interference can cause a malfunction in a blast zone
resulting in an unintended detonation. Know the
locations of blast zones in the area and keep a safe
distance to avoid unintentional blasts.

A04061 12/11 Warnings and Cautions A4-7


LIFTING INSTRUCTIONS
This page illustrates a variety of decals which are If any of these decals is damaged or defaced so it is
placed on deck mounted cabinets, housings, and no longer legible, it should be replaced immediately.
structures that must be lifted in a specific manner and
Maintenance personnel must follow these lifting
from specific points in order to safely move them.
instructions.

A4-8 Warnings and Cautions 12/11 A04061


PRODUCT IDENTIFICATION PLATE The Product Identification Number (PIN) consists of a
total of 19 characters. The first and last characters
A product identification plate is located on the frame are tamper preventive symbols (*). The remaining 17
in front of the right side front wheel. It shows the alpha/numeric characters are used to identify the
Truck Model Number, Maximum GVW, and Product following five characteristics of the machine:
Identification Number (PIN).
WMC - Character positions 1, 2 and 3 identify the
Worldwide Manufacturer Code (WMC). The WMC
designates the manufacturer of the product. Komatsu
brand products are identified with the letters KMT.
MDS - Character positions 4, 5, 6, 7 and 8 identify
the Machine Descriptor Section (MDS). The MDS
code identifies general information regarding
machine specifications. The MDS is a code for the
machine type and model.
CL - Character position 9 identifies the Check Letter
(CL). The CL is used to verify the accuracy of the
individual PIN.
FC - Character positions 10 and 11 identify the
Factory Code (FC). The FC identifies the Komatsu
factory in charge of claims for the product. The FC for
electric drive trucks is 61.
SN - Character positions 12, 13, 14, 15, 16 and 17
identify the Serial Number (SN). The SN is a unique
sequential number.

A04061 12/11 Warnings and Cautions A4-9


LUBRICATION CHART
The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P2,
Lubrication and Service, for more complete lubrication instructions.

A4-10 Warnings and Cautions 12/11 A04061


TORQUE TABLES AND CONVERSION CHARTS

This manual provides dual dimensioning for many


specifications. Metric units are specified first, with
References throughout the manual to standard
U.S. standard units in parentheses. When torque val-
torques or other standard values will be to one of
ues are not specified in the assembly instructions
the following tables. Do not use standard values
contained in this manual, use the standard torque
to replace specific torque values in assembly
value for the hardware being used. Standard value
instructions.
torque tables are contained in this chapter for metric
and SAE hardware.
NOTE: This truck is assembled with both metric and For values not shown in any of the charts or tables,
SAE (U.S.) hardware. Reference the correct table standard conversion factors for most commonly used
when determining the proper torque value. measurements are provided in the following tables.

INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

TABLE 1 Standard Tightening Torque For Metric Cap screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
TABLE 2 Standard Tightening Torque For SAE Grade 5 & 8 Cap Screws and Nuts . . . . . . . . . . . . . . . . 12-3
TABLE 3 Standard Tightening Torque 12-Pt, Grade 9, Cap Screws (SAE) . . . . . . . . . . . . . . . . . . . . . . . 12-4
TABLE 4 Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
TABLE 5 Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
TABLE 6 Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
TABLE 7 JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
TABLE 8 Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
TABLE 9 O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
TABLE 10 O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
TABLE 11 Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
TABLE 12 Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
TABLE 13 Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

A05001 2/11 Torque Tables and Conversion Charts A5-1


EFFECT OF SPECIAL LUBRICANTS STANDARD TIGHTENING TORQUES
On Fasteners and Standard Torque Values For Class 10.9 Cap screws & Class 10 Nuts
The Komatsu engineering department does not The following specifications apply to required
recommend the use of special friction-reducing assembly torques for all metric class 10.9 finished
lubricants, such as Copper Coat, Never-Seez®, and hexagon head cap screws and class 10 nuts.
other similar products, on the threads of standard
• Cap screw threads and seats shall not be
fasteners where standard torque values are applied.
lubricated when assembled. These specifications
The use of special friction-reducing lubricants will are based on all cap screws, nuts, and hardened
significantly alter the clamping force being applied to washers being phosphate and oil coated.
fasteners during the tightening process.
If zinc-plated hardware is used, each piece must
If special friction-reducing lubricants are used with be lubricated with simple lithium base chassis
the standard torque values listed in this chapter, grease (multi-purpose EP NLGI) or a rust
excessive stress and possible breakage of the preventive grease (see list, this page) to achieve
fasteners may result. the same clamping forces provided below.

Where the torque tables specify “Lubricated • Torques are calculated to give a clamping force
Threads” for the standard torque values listed, these of approximately 75% of proof load.
standard torque values are to be used with simple • The maximum torque tolerance shall be within
lithium base chassis grease (multi-purpose EP NLGI) ±10% of the torque value shown.
or a rust-preventive grease (see below) on the
• In the following table under “Cap Screw Size”, the
threads and seats unless specified otherwise. first number represents the shank diameter
NOTE: Ensure the threads of fasteners and tapped (mm). The second number represents threads
holes are free of burrs and other imperfections before per millimeter.
assembling. Example: M20 x 2.25

Suggested* Sources for Rust Preventive Grease: M20 = shank diameter (20 mm)

• American Anti-Rust Grease #3-X from Standard 2.25 = thread pitch in millimeter
Oil Company (also American Oil Co.)
• Gulf NoRust #3 from Gulf Oil Company.
• Mobilarma 355, Product No. 66705 from Mobil
Oil Corporation.
• Rust Ban 326 from Humble Oil Company.
TABLE 1.
• Rustolene B Grease from Sinclair Oil Co. Standard Tightening Torque
for Metric Class 10.9 Cap screws & Class 10 Nuts
• Rust Preventive Grease - Code 312 from the
Southwest Grease and Oil Company. Cap Screw Torque Torque Torque
Size N•m ft lb kg•m
NOTE: This list represents the current engineering M6 x1 12 9 1.22
approved sources for use in Komatsu manufacture. It
M8 x 1.25 30 22 3.06
is not exclusive. Other products may meet the same
specifications of this list. M10 x 1.5 55 40 5.61
M12 x 1.75 95 70 9.69
M14 x 2 155 114 15.81
M16 x 2 240 177 24.48
M20 x 2.25 465 343 47.43
M24 x 3 800 590 81.6
M30 x 3.5 1600 1180 163.2
M36 x 4 2750 2028 280.5

A5-2 Torque Tables and Conversion Charts 2/11 A05001


STANDARD TIGHTENING TORQUES
For SAE Grade 5 and Grade 8 Cap screws
The following specifications apply to required assem-
bly torques for all grade 5 and grade 8 cap screws. • The maximum torque tolerance shall be ±10% of
the torque value shown.
• Cap screw threads and seats shall be lubri- • In the following table under Cap Screw Size, the
cated when assembled. first number represents the shank diameter (in.).
Unless instructions specifically recommend The second number represents threads per inch.
otherwise, these standard torque values are to be
Example: 7/16 - 20
used with simple lithium base chassis grease
(multi-purpose EP NLGI) or a rust- preventive 7/16 = shank diameter (7/16 inch (0.438 inch))
grease (see list, previous page) on the threads.
20 = threads per inch
• Torques are calculated to give a clamping force
of approximately 75% of proof load.

TABLE 2.
Standard Tightening Torque
for SAE Hex Head Cap Screw And Nut Assembly

Cap Torque - Torque - Cap Torque - Torque -


Screw Grade 5 Grade 8 Screw Grade 5 Grade 8
Size N·m ft lb kg·m N·m ft lb kg·m Size N·m ft lb kg·m N·m ft lb kg·m
1/4-20 9.5 7 0.97 13.6 10 1.38 3/4-16 319 235 32.5 454 335 46.3
1/4-28 10.8 8 1.11 14.9 11 1.52 7/8-9 475 350 48.4 678 500 69.2
5/16-18 20.3 15 2.07 28 21 2.90 7/8-14 508 375 51.9 719 530 73.3
5/16-24 22 16 2.21 30 22 3.04 1.0-8 712 525 72.6 1017 750 103.7
3/8-16 34 25 3.46 47 35 4.84 1.0-12 759 560 77.4 1071 790 109.3
3/8-24 41 30 4.15 54 40 5.5 1.0-14 773 570 78.8 1085 800 110.6
7/16-14 54 40 5.5 79 58 8.0 1 1/8-7 881 650 89.9 1424 1050 145
7/16-20 61 45 6.2 84 62 8.57 1 1/8-12 949 700 96.8 1546 1140 158
1/2-13 88 65 9 122 90 12.4 1 1/4-7 1234 910 125.9 2007 1480 205
1/2-20 95 70 9.7 129 95 13.1 1 1/4-12 1322 975 134.8 2142 1580 219
9/16-12 122 90 12.4 169 125 17.3 1 3/8-6 1627 1200 166 2630 1940 268
9/16-18 129 95 13.1 183 135 18.7 1 3/8-12 1776 1310 181 2874 2120 293
5/8-11 169 125 17.3 237 175 24.2 1 1/2-6 2142 1580 219 3471 2560 354
5/8-18 183 135 18.7 258 190 26.2 1 1/2-12 2305 1700 235 3756 2770 383
3/4-10 298 220 30.4 420 310 42.8
1 ft. lb. = 0.138 kg·m = 1.356 N.m

A05001 2/11 Torque Tables and Conversion Charts A5-3


STANDARD TIGHTENING TORQUES
For SAE Grade 9 Cap screws
The following specifications apply to required assem-
bly torques for all 12-point, grade 9 (170,000 psi min-
imum tensile), cap screws.
• Cap screw threads and seats shall be lubri-
cated when assembled.
Unless instructions specifically recommend
otherwise, these standard torque values are to be
used with simple lithium base chassis grease (multi-
purpose EP NLGI) or a rust- preventive grease (see
list, this page) on the threads.
• Torques are calculated to give a clamping force
of approximately 75% of proof load.
• The maximum torque tolerance shall be ±10%
of the torque value shown.

TABLE 3.
Standard Tightening Torque
for 12-Point, Grade 9 Cap Screws
Torque Torque Torque
Cap Screw Size*
N·m ft lb kg·m
0.250 - 20 16 12 1.7
0.312 - 18 33 24 3.3
0.375 - 16 57 42 5.8
0.438 -14 95 70 9.7
0.500 -13 142 105 14.5
0.562 - 12 203 150 20.7
0.625 - 11 278 205 28.3
0.750 - 10 488 360 49.7
0.875 - 9 780 575 79.4
1.000 - 8 1166 860 119
1.000 - 12 1240 915 126
1.125 - 7 1670 1230 170
1.125 - 12 1800 1330 184
1.250 - 7 2325 1715 237
1.250 - 12 2495 1840 254
1.375 - 6 3080 2270 313
1.375 - 12 3355 2475 342
1.500 - 6 4040 2980 411
1.500 - 12 4375 3225 445
* Shank Diameter (in.) - Threads per inch

A5-4 Torque Tables and Conversion Charts 2/11 A05001


TABLE 4.
Tightening Torque For
T-Bolt Type Hose Clamp (SAE J1508 Type TB)
Newton meters Inch Pounds
Thread Size Band Width
(N·m) (in. lb)
0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ± 0.6 N·m 75 ± 5 in lb

TABLE 5.
Tightening Torque For
Split Flange Clamp Bolts
Cap Screw Thread Width Newton meters Foot Pounds Kilogram meters
Diameter Across Flat (N·m) (ft lb) (kg·m)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
10 14 66 48 6.7
12 17 112 83 11.5
16 22 279 206 28.5

TABLE 6.
Tightening Torque For
Flared Tube And Hose Fittings
Thread Width Newton meters Foot Pounds Kilogram meters
Diameter of Nut Across Flat (N·m) (ft lb) (kg·m)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
14 19 25 18 2.5
18 24 50 36 5
22 27 80 58 8
24 32 140 101 14
30 36 175 130 18
33 41 195 145 20
36 46 245 180 25
42 55 295 215 30

A05001 2/11 Torque Tables and Conversion Charts A5-5


TABLE 7.
Torque Chart For JIC 37° Swivel NutS
With Or Without O-ring Seals
Size Tube Size Threads UNF-2B Newton meters Foot Pounds
Code (OD) (N·m) (ft lb)
–2 0.125 0.312 – 24 5±1 4±1
–3 0.188 0.375 – 24 11 ± 4 8±3
–4 0.250 0.438 – 20 16 ± 4 12 ± 3
–5 0.312 0.500 – 20 20 ± 4 15 ± 3
–6 0.375 0.562 – 18 24 ± 7 18 ± 5
–8 0.500 0.750 – 16 40 ± 7 30 ± 5
– 10 0.625 0.875 – 14 54 ± 7 40 ± 5
– 12 0.750 1.062 – 12 75 ± 7 55 ± 5
– 14 0.875 1.188 – 12 88 ± 7 65 ± 5
– 16 1.000 1.312 – 12 108 ± 7 80 ± 5
– 20 1.250 1.625 – 12 136 ± 14 100 ± 10
– 24 1.500 1.875 – 12 163 ± 14 120 ± 10
– 32 2.000 2.500 – 12 312 ± 27 230 ± 20

TABLE 8.
Torque Chart For
Pipe Thread Fittings

Size Pipe Thread With Sealant With Sealant Without Sealant Without Sealant
Code Size N·m ft lb N·m ft lb
–2 0.125 – 27 20 ± 4 15 ±3 27 ± 7 20 ± 5
–4 0.250 – 18 27 ± 7 20 ±5 34 ± 7 25 ± 5
–6 0.375 – 18 34 ± 7 25 ±5 48 ± 7 35 ± 5
–8 0.500 – 14 48 ± 7 35 ±5 61 ± 7 45 ± 5
– 12 0.750 – 14 61 ± 7 45 ±5 75 ± 7 55 ± 5
– 16 1.000 – 11.50 75 ± 7 55 ±5 88 ± 7 65 ± 5
– 20 1.250 – 11.50 95 ± 7 70 ±5 108 ± 7 80 ± 5
– 24 1.500 – 11.50 108 ± 7 80 ±5 129 ± 14 95 ± 10
– 32 2.000 – 11.50 129 ± 14 95 ±10 163 ± 14 120 ± 10

A5-6 Torque Tables and Conversion Charts 2/11 A05001


TABLE 9.
Torque Chart For
O-ring Boss Fittings

Newton meters Foot Pounds


Size
Tube Size (OD) Threads UNF-2B (N·m) (ft lb)
Code
–2 0.125 0.312 – 24 4±3 4±2
–3 0.188 0.375 – 24 7±3 5±2
–4 0.250 0.438 – 20 11 ± 4 8±3
–5 0.312 0.500 – 20 14 ± 4 10 ± 3
–6 0.375 0.562 – 18 18 ± 4 13 ± 3
–8 0.500 0.750 – 16 33 ± 7 24 ± 5
– 10 0.625 0.875 – 14 43 ± 7 32 ± 5
– 12 0.750 1.062 – 12 65 ± 7 48 ± 5
– 14 0.875 1.188 – 12 73 ± 7 54 ± 5
– 16 1.000 1.312 – 12 98 ± 7 72 ± 5
– 20 1.250 1.625 – 12 109 ± 7 80 ± 5
– 24 1.500 1.875 – 12 109 ± 7 80 ± 5
– 32 2.000 2.500 – 12 130 ± 14 96 ± 10

TABLE 10.
Torque Chart For
O-ring Face Seal Fittings

Size Tube Size Newton meters Foot Pounds


Threads UNF-2B (N·m) (ft lb)
CodeE (O.D.)
–4 0.250 0.438 – 20 15 ± 1 11 ± 1
–6 0.375 0.562 – 18 24 ± 3 18 ± 2
–8 0.500 0.750 – 16 48 ± 5 35 ± 4
– 10 0.625 0.875 – 14 69 ± 7 51 ± 5
– 12 0.750 1.062 – 12 96 ± 10 71 ± 7
– 16 1.000 1.312 – 12 133 ± 8 98 ± 6
– 20 1.250 1.625 – 12 179 ± 10 132 ± 7
– 24 1.500 1.875 – 12 224 ± 20 165 ± 15

A05001 2/11 Torque Tables and Conversion Charts A5-7


TABLE11.
Common Conversion Multipliers
Metric To English
Multiply
To Convert From To
By
millimeter (mm) inch (in.) 0.0394
centimeter (cm) inch (in.) 0.3937
meter (m) foot (ft) 3.2808
meter (m) yard (yd) 1.0936
kilometer (km) mile (mi) 0.6210

square centimeters (cm ) 2


square inch (in. ) 2 0.1550

square centimeters (cm2) square feet (ft2) 0.001

cubic centimeters (cm3) cubic inch (in.3) 0.061

liters (l) cubic inch (in.3) 61.02

cubic meters (m3) cubic feet (ft3) 35.314

liters (l) cubic feet (ft3) 0.0353

grams (g) ounce (oz) 0.0353


milliliter (ml) fluid ounce (fl oz) 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pounds (lb) 0.2248
Newton meters (N·m) kilogram meters (kg·m) 0.102
Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram meters (kg·m) foot pounds (ft lb) 7.2329
kilogram meters (kg·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038

kilograms/cm2 (kg/cm2) pounds/square inch (psi) 14.2231

kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068

kilogram (kg) short ton (tn) 0.0011


metric ton short ton (tn) 1.1023
liters (l) quart (qt) 1.0567
liters (l) gallon (gal) 0.2642
Watts (W) horsepower (hp) 0.00134
kilowatts (kW) horsepower (hp) 1.3410

A5-8 Torque Tables and Conversion Charts 2/11 A05001


TABLE 12.
Common Conversion Multipliers
English to Metric
To Convert Multiply
To
From By
inch (in.) millimeter (mm) 25.40
inch (in.) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61

square inch (in.2 ) square centimeters (cm )2 6.45

square feet (ft2) square centimeters (cm2) 929

cubic inches (in.3) cubic centimeters (cm3) 16.39

cubic inches (in.3) liters (l) 0.016

cubic feet (ft3) cubic meters (m3) 0.028

cubic feet (ft.3) liters (l) 28.3

ounce (oz) kilogram (kg) 0.028


fluid ounce (fl oz) milliliter (ml) 29.573
pound (lb) kilogram (kg) 0.454
pound (lb) Newton (N) 4.448
inch pounds (in. lb) Newton meters (N·m) 0.113
foot pounds (ft lb) Newton meters (N·m) 1.356
foot pounds (ft lb) kilogram meters (kg·m) 0.138
kilogram meters (kg·m) Newton meters (N·m) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
pounds/square inch (psi) kilograms/square centimeter 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (l) 0.946
gallon (gal) liters (l) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745

A05001 2/11 Torque Tables and Conversion Charts A5-9


TABLE 13.
Temperature Conversions
Formula: F° - 32  1.8 = C° or C° x 1.8 + 32 = F°
Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit
C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76

NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.

A5-10 Torque Tables and Conversion Charts 2/11 A05001


STORAGE AND IDLE MACHINE PREPARATION
There may be periods when it is necessary for a SHORT TERM IDLE PERIODS
machine to be idle for an extended period of time. If
properly prepared, a stored machine may promptly There may be periods when a vehicle is idle from 30
and safely be put back into operation. Improper to 60 days, but must be ready for use at any time. To
preparation, or complete lack of preparation, can most effectively hande this type of situation, follow
make the job of getting the vehicle back to operating the procedure below to prevent any deterioration
status difficult. from the beginning of vehicle idle time.
1. Keep the vehicle fully serviced.
The following information outlines the essential steps
for preparing a unit for extended storage, and the 2. Perform a visual check of the vehicle every
necessary steps for bringing the unit back to week. Start and run the engine until it is at
operational status. Additional information is given to operating temperature. Move the vehicle
help restore machines that were not put into storage, around the yard for a few minutes to ensure that
but merely shut down and left idle for a long period of all internal gears and bearings are freshly
time. lubricated.
3. Operate all hydraulic functions through their
Much of this material is of a general nature since the
complete range to ensure that the cylinder rods
environment (where the machine has been standing
and seals are fully lubricated.
idle) will play a big part in its overall condition. A hot,
humid climate will affect vehicle components much 4. Check and operate all systems.
differently than a dry desert atmosphere or a cold 5. Once a month, perform the 10 Hour service
arctic environment. These climatic aspects must be items shown in the Operation and Maintenance
considered and appropriate actions taken when Manual. Keep batteries properly serviced.
restoring a long term idle vehicle.
These instructions are not intended to be all
inclusive, but are minimum guidelines. The final aim
should always be to provide the operator with a safe,
reliable, fully productive vehicle.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-1


PREPARATION FOR STORAGE
For long term idle periods, proper preparation will 6. The cooling system should be completely
pay large dividends in time and money when future drained, chemically flushed, and refilled with a
operation of the vehicle is scheduled. conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
1. The engine should be prepared for storage Section P, Lubrication and Service, for the
according to instructions found in the engine proper anti-freeze and conditioner
manufacturer's manual. concentrations. After refilling the system,
2. The vehicle should be in top operating condition always operate the engine until the thermostats
with all problems corrected. The paint should be open to circulate the solution through the
in good condition, with no rust or corrosion. All cooling system.
exposed, machined or unpainted surfaces
NOTE: NEVER store a vehicle with a dry cooling
should be coated with a good rust preventive
system.
grease.
3. After the vehicle has been parked in its storage
location, all hydraulic cylinders, including
Hydrair suspensions, should be retracted as
much as possible (steering cylinders centered).
Wipe the exposed portion of all cylinder rods Any operating fluid, such as hydraulic oil,
clean and coat them (including the seals on the escaping under pressure can have sufficient
end of the barrel) with a good preservative force to enter a person's body by pentrating the
grease. skin. Serious injury and possible death may
4. If long term storage is anticipated, the vehicle result if proper medical treatment by a physician
should be blocked up with the tires clear of the familiar with this injury is not received
ground to remove the vehicle weight from the immediately.
tires. Lower the tire pressure to 103 - 172 kPa 7. New hydraulic filters should be installed and the
(15 - 25 psi). Completely cover the tires with hydraulic tank fully serviced with Type C-4 oil as
tarpolins to minimize rubber oxidation and specified in Section P, Lubrication and Service.
deterioration.
8. Disconnect the batteries, if possible. Batteries
5. Clean the radiator. Refer to Section C, Cooling should be removed and stored in a battery shop
System, for the proper cleaning instructions. or a cool dry location on wooden blocks. Do not
store batteries on a concrete floor. Clean the
battery compartment. Remove all corrosion and
paint the compartment with an acid proof paint.
9. The wheel axle housings should be fully
serviced with recommended lubricants. Seal all
The cooling system is pressurized due to thermal
vents.
expansion of coolant. Do not remove the radiator
cap while the engine and coolant are hot. Severe 10. The exhaust openings and air cleaners should
burns may result. be covered tightly with moisture barrier paper
and sealing tape.

A7-2 Storage Procedures and Idle Machine Preparation 11/05 A07003


11. All lubrication points (grease fittings) should be REMOVAL FROM STORAGE
serviced with the recommended lubricants.
If the storage preparations were followed when
12. Relieve the tension from all drive belts. The placing the vehicle into storage, getting it back to
engine manufacturer recommends insertion of operational status is a matter of reversing those
heavy kraft paper between the belts and pulleys steps.
to prevent sticking.
NOTE: Before starting the job of restoring a vehicle
13. All vandalism covers and locks should be in to operation, obtain copies of the Operation and
place and secured. Maintenance Manual, Service Manual, Engine
14. All cab windows should be closed, locked and Manuals and Parts Book, if possible, and follow all
sealed, and the cab door should be locked to special instructions regarding servicing the vehicle
prevent vandalism and weather effects. and its components.
15. The fuel tank should be completely drained of In addition to removing the storage materials, the
fuel, fogged with preservative lubricant (NOX- following actions should be taken:
RUST MOTOR STOR., SAE10), and closed 1. Inspect the entire vehicle carefully for rust and
tightly. All fuel filters should be replaced. corrosion. Correct as necessary.
16. If possible, all available service publications 2. Service the engine according to the engine
(vehicle and engine) and a current parts catalog manufacturer's Operation and Maintenance
should be packaged in a moisture proof Manual.
package and placed in the cab to aid whomever
3. Clean the radiator. Refer to Section C, Cooling
will eventually place the unit back in operation.
System, for cleaning instructions.
17. Ensure that the water drain holes in the truck 4. The cooling system should be completely
body are open. drained, chemically flushed, and refilled with a
conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
Fluid Specifications in Section P, Lubrication
and Service, for the proper anti-freeze and
conditioner concentrations. After refilling the
system, always operate the engine until the
thermostats open to circulate the solution
through the cooling system.
5. Thoroughly inspect all drive belts and hydraulic
oil lines for damage, wear or deterioration.
Replace any suspected lines. Do not take
chances on possible ruptures or blow-outs.
6. New hydraulic filters should be installed and the
hydraulic tank checked and serviced with Type
C-4 oil as specified in Section P, Lubrication
and Service.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-3


7. Open the fuel tank drain valve to remove any 16. Refer to the Operation and Maintenance
moisture or sediment that may have Manual for engine startup and vehicle checkout
accumulated while in storage. Close the drain procedures. Check all hose and line
valve and fill the fuel tank with diesel fuel. connections for leaks when the engine is
running.
17. Before moving the vehicle, cycle all hydraulic
controls, steering controls, and braking systems
to verify proper operation. Check all
Never blend gasoline, gasohol and/or alcohol instruments and gauges to ensure that all
with diesel fuel. This creates an extreme fire systems are operational.
hazard and, under certain conditions, may cause
an explosion. 18. When all systems are operational and all known
problems are corrected, road test the vehicle in
8. Ensure that all hydraulic controls, steering a smooth, level, unobstructed area to check
linkage and throttle linkage points are lubricated steering response, service brake efficiency, and
and operate freely before starting the engine. hydraulic functions.
9. All electrical connections must be clean and
19. Recharge any fire protection equipment before
tight. Ensure that all ground straps and cables.
the vehicle is returned to service.
are secure
10. Install fully charged batteries in the vehicle.
Clean the connectors and connect the battery
cables. The battery compartment must be free
of corrosion. Secure the batteries with hold-
downs.
11. Check all electrical cables for deterioration,
cracks and other damage. Replace any
defective cables.

Air pressure must be released from tires with bad


cuts or wear that extends into the plies before
removal from the vehicle. Also, do not allow
personnel to stand in removal path of tires.
12. Check all tires carefully for damage. Inflate the
tires to the proper pressure.
13. If disconnected, reconnect the parking brake
linkage.
14. Completely service the vehicle as
recommended in Section P, Lubrication and
Service, for both 10 and 100 Hour inspections.
15. Adjust all drive belts to the specified tension.

A7-4 Storage Procedures and Idle Machine Preparation 11/05 A07003


RECONDITIONING AN IDLE VEHICLE
3. Inspect tires thoroughly for wear, cuts and
cracks on the treads and side walls.
a. Any tire suspected of being unserviceable
should be removed and thoroughly
inspected before being inflated.
Never attempt to operate a vehicle that has been
standing idle for a long period until all systems b. If the tires are removed, clean and inspect all
which affect steering, brakes, engine, wheel components. All rust and corrosion
transmission and running gears have been must be removed and parts repainted as
completely reconditioned. An unsafe vehicle can needed before mounting the tires.
cause serious injuries and/or major property c. Mount and inflate tires as shown in
damage. Operation and Maintenance Manual. Follow
Reconditioning a vehicle that has been subjected to all safety rules
long idle periods without being properly prepared for 4. Inspect the service brakes carefully. Before
storage - merely shut down and left to the elements - disabling the brake circuit, block all wheels to
may present a major expenditure of time and money prevent possible movement of the vehicle.
when it is to be put into operation.
a. All brake lines and connections must be
1. Remove all debris and thoroughly clean the clean and free of rust, corrosion and
vehicle before starting any inspection or damage.
maintenance.
b. When reconditioning the braking system, the
2. Remove the batteries and move them to a service brake hydraulic circuits should be
battery shop for service and charging, or checked out according to the instructions in
replace as necessary. Section J, Brake Circuit Check-Out
Procedure.
5. The engine should be inspected and serviced
according to the engine manufacturer's
Operation And Maintenance Manuals.
Do not disassemble an inflated tire. Remove the
valve core slowly and allow pressure to bleed off a. Ensure that the exhaust is clear and clean. If
before attempting to remove the lockring. Also, water entry is suspected, disconnect the air
eye protection must be worn during tire deflation tubes at the turbochargers to check for water
to protect against any foreign object being before attempting to start the ethe ngine.
projected into the eyes. b. Replace the fuel filters and fill filter cans with
fresh fuel for engine priming.

Do not mix rim parts of different rim


manufacturers. Rim parts may resemble those of
a different manufacturer, but the required Have a new safety filter (secondary) element on
tolerances may be wrong. Use of mismatched rim hand before removing the old one. Do not keep
parts is hazardous. the intake system open to the atmosphere any
longer than absolutely necessary.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-5


c. Replace both the primary and safety filter 7. Drain the hydraulic tank. If the oil is not
(secondary) elements in the air cleaners. contaminated and is stored in clean containers,
Check all intake lines between the air it may be reused if filtered through 3-micron
cleaners and the engine. All clamps must be filter elements when being pumped back into
tight. The plunger in the filter condition the tank. Do not attempt to use contaminated
indicators must move freey. hydraulic oil, especially if water entry into the
system is suspected.
d. Inspect the tubes in the precleaner section of
the air cleaner assembly. Use a light to NOTE: If filling is required, use clean hydraulic oil
inspect the tubes. The light should be visible only. Refer to the Lubrication Chart in Section P,
through the end of the tube. If clogging is Lubrication and Service, for proper oil specifications.
evident, the precleaner must be cleaned
a. Replace the hydraulic filter elements and
according to the instructions in Section C, Air
clean the suction strainer elements. While
Cleaners.
the suction strainers are removed, inspect
e. Drain and flush the engine cooling system. and clean the inside of the tank thoroughly to
Fill with coolant and inhibitors after checking remove all sediment and foreign material.
all lines, hoses and connections. Refer to
b. Inspect all hydraulic lines for deterioration
Section P, Lubrication and Service, for anti-
and damage. Replace any suspected lines.
freeze recommendations. Radiator cores
Do not risk possible hose ruptures or blow
must be clear of dirt and debris.
outs.
c. Check all hydraulic components (pumps,
valves and cylinders) for damage and
corrosion. Secure all mountings and
connections. The control valves must move
To prevent injuries, always release spring freely with no binding.
tension before replacing the fan belt. d. Check the exposed portions of all hydraulic
f. Check and tighten the engine fan drive belts. cylinder rods for rust, pitting and corrosion. If
If necessary, install a new belt set. the plating has deteriorated, the cylinder
should be removed and overhauled or
g. Check and tighten the engine mounts. replaced. Pitted or scored plating will cause
6. If fuel was left in the tanks, it must be removed. leakage at the cylinder seals.
Do not attempt to use old diesel fuel. 8. Check the front wheel hub, final drive and wheel
a. With the tanks empty, remove the inspection axle lubricant. If contamination is suspected,
plates and thoroughly check the interior of the oil should be drained completely and the
the tanks. Remove any sediment and component serviced with clean recommended
contamination. If the fuel was contaminated, lubricant. If major contamination is present,
the lines should be disconnected and blown disassembly and overhaul will be necessary.
clear. 9. Check the parking brake. Since it is spring
b. Check all fuel lines for deterioration or applied, the brake pads may be stuck tightly to
damage. Replace lines as necessary. the disc. It may be necessary to remove and
overhaul the parking brake assembly.
c. Install the inspection covers with new
gaskets.
d. Fill the tanks with the specified diesel fuel.
e. Replace the fuel filters.

A7-6 Storage Procedures and Idle Machine Preparation 11/05 A07003


10. Lubricate all grease fittings that are not part of ENGINE OPERATION
the automatic lubrication system with the
recommended lubricants. Pay special attention After all reconditioning procedures have been
to the steering linkage connections. All pivot completed, a static check of engine operation,
points must move freely with no binding. systems operations, and verification of the braking
and steering functions must be done before the
11. Check the battery charging alternator for vehicle is moved.
corrosion or deterioration. The alternator rotor
must move freely with no binding or roughness. .
Inspect, install and properly tension the
alternator drive belts.
12. Ensure that the steering cylinder ball joints link
and hydraulic connections are secure. Before starting the engine, clear the immediate
13. Examine the Hydrair suspensions for damage. area of personnel and obstructions. Ensure that
all tools and loose equipment have been
a. Discharge the nitrogen from the suspensions
removed from the vehicle. Always sound the
as outlined in Section H, Hydrair II
horn as a warning before starting the engine or
Suspensions.
actuating any operational controls.
b. Check the conditon of the suspension oil and Never start the engine in a building unless the
cylinder wipers. If the wipers are cracked or doors and windows are open and ventilation is
hardened, the suspension must be rebuilt. adequate.
Recharge the suspension with new oil if the
1. Turn the key switch ON. The warning lights for
old oil is deteriorated.
low brake and steering pressure should
c. Check the exposed chrome portions of illuminate and the horn should sound. If it does
cylinder for rust, pitting and corrosion. If the not, check all components in the circuit and
plating is deteriorated, the suspension correct the problem before continuing.
should be removed and overhauled or 2. Turn the key switch to the START position to
replaced. Pitted or scored plating will rapidly crank the engine. Release the key when the
cause leakage at the seals. engine starts. Watch the engine oil pressure
d. Recharge the suspensions as outlined in gauge. If the pressure does not show within 10 -
Section H, Hydrair II Suspensions. 15 seconds, turn off the engine and locate the
problem.
14. If not done previously, install fully-charged
batteries and ensure that the hook-up is correct. 3. While the engine is warming up, inspect the
coolant, oil and fuel lines for leaks. Check the
hydraulic pump and hydraulic lines for leaks.
4. When the engine is at operating temperature,
check the operation of the throttle circuit.
Acceleration should be smooth. Watch the
gauges for any abnormal activity. Proper
temperatures and pressures are shown in the
Operation and Maintenance Manual.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-7


After The Engine Has Started
Any machine which is unsafe and/or not in top 5. After all known problems have been corrected,
operating condition should not be assigned to an the vehicle is ready for a road test. This test
operator for production use. should be performed only by a capable and
experienced operator in a large open area
1. Become thoroughly familiar with the steering where plenty of maneuvering room is available.
and emergency controls. Test the steering in
the extreme right and left directions. If the One of the road test items that should be
steering system is not operating properly, turn performed is the repeated test of braking
off the engine immediately. Determine the efficiency at progressively higher speeds. Start
steering system problem and have repairs at slow speeds. Do not operate at higher
made before resuming operation. speeds until the machine is determined to be
operating safely.
2. Operate each of the brake circuits at least twice
prior to operating and moving the machine. 6. When the vehicle is ready for production use, it
should be visually rechecked and fully serviced
a. Activate each circuit individually using the according to Section P, Lubrication and
controls in the cab with the engine running Service.
and the hydraulic circuit fully charged.
A few of the conditions which might be encountered
b. If any application or release of any brake
after a machine has been exposed to the elements
circuit does not appear proper or if
for a long period of time include:
sluggishness is apparent, turn off the engine
and notify maintenance personnel. Do not • increased corrosion and fungus growth on
operate the machine until the brake circuit in electrical components in humid/tropical areas.
question is fully operational. • accelerated rust formation in humid climates.
3. Check all gauges, warning lights and
• increased sand and dust infiltration in windy, dry
instruments before moving the machine to dusty areas.
ensure proper system operation and gauge
function. Pay special attention to the braking • deterioration of rubber products in extreme cold
and steering circuit warning lights. If any areas. Cables, hoses, O-rings, seals and tires
warning lights come on, turn off the engine may become weather checked and brittle.
immediately and determine the cause. • animal or bird's nests in unsealed openings.
4. Cycle the hoist controls and steering several
times to remove any trapped air. Complete the
steering cycles in both directions to verify
steering response, smoothness and reliability.
Check the seals and lines for leaks.

A7-8 Storage Procedures and Idle Machine Preparation 11/05 A07003


ENGINE STORAGE
When an engine is to be stored or removed from 6. Seal all engine openings. The material used for
operation for a period of time, special precautions this purpose must be waterproof, vaporproof
should be taken to protect the interior and exterior of and possess sufficient physical strength to
the engine and other parts from rust and corrosion. resist puncture and damage from the expansion
of entrapped air.
All rust and corrosion must be completely removed
from any exposed part before applying a rust An engine prepared in this manner can be returned
preventive compound. Therefore, it is recommended to service in a short period of time by removing the
that the engine be processed for storage as soon as seals at the engine openings, checking the engine
possible after removal from operation. coolant, fuel oil, lubricating oil, transmission oil, and
priming the raw water pump (if used).
The engine should be stored in a building which is
dry and can be heated during the winter months.
Moisture absorbing chemicals are commercially
Extended Storage (More Than 30 Days)
available for use when excessive moisture is
prevalent in the storage area. 1. Drain the cooling system and flush with clean,
softened water. Refill the system with clean,
Temporary Storage (30 Days Or Less) softened water and add a rust inhibitor.
1. Drain the oil from the crankcase. Fill the 2. Remove, check and recondition the injectors, if
crankcase to the proper level with the necessary, to ensure that they will be ready to
recommended viscosity and grade of new oil. operate when the engine is restored to service.
2. Fill the fuel tank with the recommended grade Reinstall the injectors. Time them and adjust
of fuel oil. Operate the engine for two minutes at the exhaust valve clearance.
1200 rpm with no load. Turn off the engine. Do 3. Circulate the coolant by operating the engine
not drain the fuel system or the crankcase. until the normal operating temperature of 71° -
3. Check the air cleaner and service it, if 85° C (160° - 185° F) is reached.
necessary. 4. Stop the engine.
4. If freezing weather is expected during the 5. Drain the oil from the crankcase, then reinstall
storage period, add an ethylene glycol base and tighten the drain plug. Install new
antifreeze solution in accordance with the lubricating oil filter elements and gaskets.
manufacturer's recommendations. 6. Fill the crankcase to the proper level with a 30-
5. Clean the entire exterior of the engine (except weight preservative lubricating oil (MIL-L-
the electrical system) with fuel oil and dry it with 21260C, Grade 2).
compressed air.

To prevent possible personal injury, wear


adequate eye protection and do not exceed a
compressed air pressure of 276 kPa (40 psi).

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-9


7. Drain the fuel tank. Refill with enough No. 1 16. Remove and clean the batteries and battery
diesel fuel or pure kerosene to allow the engine cables with a baking soda/water solution and
to operate for about ten minutes. If it is not rinse them with fresh water. Do not allow the
convenient to drain the fuel tank, use a soda solution to enter the battery. Add distilled
separate portable supply of the recommended water to the electrolyte, if necessary. Store the
fuel. battery in a cool - never below 0° C (32° F) -
dry place. Keep the battery fully charged and
NOTE: If the engine is stored where condensation of
check the level and the specific gravity of the
water in the fuel tank may be a problem, add pure,
electrolyte regularly. Never set batteries on a
waterless isopropyl alcohol (isopropanol) to the fuel
concrete floor. Place them on wooded blocks.
at a ratio of one pint to 125 gallons(473 L) of fuel, or
0.010% by volume. Where biological contamination 17. Insert heavy paper strips between the pulleys
of fuel may be a problem, add a biocide, such as and belts to prevent sticking.
Biobor JF or an equivalent, to the fuel. When using a 18. Seal all engine openings, including the exhaust
biocide, follow the manufacturer's concentration outlet, with moisture resistant tape. Use
recommendations and all cautions and warnings. cardboard, plywood or metal covers where
8. Drain and disassemble the fuel filter and practical.
strainer. Discard the used elements and
19. Clean and dry the exterior painted surfaces of
gaskets. Fill the cavity between the element and
the engine and spray with a suitable liquid
shell with No. 1 diesel fuel or pure kerosene,
automotive body wax, a synthetic resin varnish
and install on the engine. If spin-on fuel filters
or a rust preventive compound.
and strainers are used, discard the used
cartridges, fill the new ones with No. 1 diesel 20. Protect the engine with a weather-resistant
fuel or pure kerosene, and install on the engine. tarpaulin and store it under cover, preferably in
a dry building with temperatures above 0° C
10. Operate the engine for five minutes to circulate
(32° F).
the clean fuel oil throughout the fuel system.
11. Service the air cleaner.
12. Turbocharger bearings are pressure lubricated
through the external oil line leading from the
engine cylinder block while the engine is
operating. However, the turbocharger air inlet Outdoor storage of engines is not recommended.
and turbine outlet connections should be sealed However, if an engine must be kept outdoors,
off with moisture resistant tape. follow the preparation and storage instructions
above. Do not use plastic sheeting for outdoor
13. Apply a rust preventive compound to all
storage. Plastic may be used for indoor storage.
exposed, non-painted surfaces.
However, when used outdoors, moisture can
14. Drain the cooling system. condense on the inside of the plastic and cause
15. Drain the preservative oil from the engine ferrous metal surfaces to rust and/or pit
crankcase. Reinstall and tighten the drain plug. aluminum surfaces. If a unit is stored outside for
any extended period of time, severe corrosion
damage can result.

A7-10 Storage Procedures and Idle Machine Preparation 11/05 A07003


21. Inspect the stored engine periodically. If there RESTORING AN ENGINE AFTER
are any indications of rust or corrosion, EXTENDED STORAGE
corrective steps must be taken to prevent
damage to the engine parts. Perform a 1. Remove the covers and tape from all of the
complete inspection at the end of one year and openings of the engine, fuel tank and electrical
apply additional treatment, as required. equipment. Do not overlook the exhaust
outlet or the intake system.
2. Wash the exterior of the engine and flywheel
with fuel oil to remove the rust preventive
compound.
3. Remove the paper strips from between the
pulleys and the belts.
4. Remove the drain plug and drain the
preservative oil from the crankcase. Reinstall
the drain plug. Then, refer to Lubrication and
Service, Section P, and fill the crankcase with
the recommended grade of lubricating oil to
proper level using a pressure prelubricator.
5. Fill the fuel tank with the engine manufacturer's
specified fuel.
6. Close all of the drain cocks and fill the engine
cooling system with clean, softened water and a
rust inhibitor. If the engine is to be exposed to
freezing temperatures, fill the cooling system
with an ethylene glycol base antifreeze solution.
Refer to the coolant specifications in Section P,
Lubrication and Service.
7. Install and connect the fully charged batteries.
8. Service the air cleaner as outlined in Section C,
Air Cleaners.
10. Remove the covers from the turbocharger air
inlet and turbine outlet connections.
11. After all of the preparations have been
completed, start the engine. The small amount
of rust preventive compound which remains in
the fuel system will cause a smoky exhaust for
a few minutes.
NOTE: Before subjecting the engine to a load or high
speed, it is advisable to check the engine tune-up.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-11


ELECTRIC DRIVE TRUCKS
These instructions provide the recommended It is also important to note that these instructions
procedures for protecting equipment from damage cannot possibly anticipate every type of storage
during both short term and long-term storage condition and, therefore, cannot prevent all
periods. Also included are instructions for placing this equipment deterioration problems caused by
equipment into service after having been stored. inadequate storage. These instructions are not
intended to be all inclusive, but are minimum
For the purposes of this instruction, a short term guidelines for achieving the best possible equipment
storage period is considered to be less than three life and the lowest operating cost when the
months; a long-term storage period is considered to equipment is returned to service.
be three months or longer.
NOTE: Local conditions and/or experience may
General Electric recommends a maximum storage require additional procedures and/or additional
period of three years, with these storage procedures storage precautions.
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
made to determine the lasting qualities of long-term protective measure which can be taken is to drive the
storage protection measures. Such inspections will truck once a week for at least 30 minutes. Prior to
indicate the need for renewing protective measures driving the truck, the rotating equipment should be
when necessary to prevent equipment deterioration. Meggered and:

Proper storage of this equipment is vital to equipment • If greater than 2 megohms, run normally.
life. Bearings, gears, and insulation may deteriorate • If less than 2 megohms, isolate the condition and
unless adequate protective measures are taken to correct it before running.
protect against the elements. For example, bearings
Driving the truck circulates oil in the gearcase to
and gears in the motorized wheel gear case are
keep gears and bearings lubricated and free from
susceptible to the formation of rust, insulation in
rust. It also prevents deterioration of the brushes,
rotating electrical equipment can accumulate
commutators and slip rings.
moisture, and bearings may become pitted.
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 period as indicated above, perform the following:
protective materials to areas not specifically 1. Drain the oil from the gearcase and install rust
recommended. preventive 4161 (a product of Van Straaten
Chemical Co.) or equivalent. Fill per General
Electric Motorized Wheel Service Manual.

A7-12 Storage Procedures and Idle Machine Preparation 11/05 A07003


2. Megger the wheels as indicated in the 9. Install a 500 watt heat source inside all control
instructions above. Operate the truck for at least groups which house electronic control
30 minutes to ensure that the rust preventive equipment. These heat sources are to be
compound has been thoroughly circulated energized below 0° C (32° F) and de-energized
throughout the gearcase. Stop the truck and above 5° C (41° F).
drain the rust preventive compound. 10. Install a 500 watt heat source inside the
NOTE: Do not run a loaded truck with rust preventive commutator chamber of both motorized wheels
compound in the wheel motor gearcases. and inside the alternator slip ring chamber. This
will minimize the accumulation of moisture. A
hole in the bottom of the hubcap will
accommodate the electrical cord for the heat
source in the motorized wheels. These heat
sources are to be energized continuously.
Do not operate trucks without oil in the wheel
11. Seal the compartment doors with a
motor gearcases.
weatherproof tape to prevent entry of rain, snow
3. Perform a megohmmeter test. Refer to the and dirt (allow breathing).
truck's Vehicle Test instructions for the correct
procedure. Record the Megger readings for
future reference. They will be helpful in
Storing A Truck That Is Not Operational
determining if deterioration is being
experienced when additional Megger tests are When a truck which is not fully operational is being
made as part of the periodic inspection. stored for any period of time, perform the following:
4. Lift all brushes in the motorized wheels, blowers 1. Drain the oil from the gearcase and install rust
and the alternator. They must be removed from preventive compound 4161 (or equivalent). Fill
the brushholder. Disconnecting brush pigtails is per General Electric Motorized Wheel Service
not required. Manual.
5. Cover any open ductwork with screening 2. Jack up each side of the truck (one side at a
material to prevent rodents from entering. Then time) enough to rotate the tires.
tape over the screen to prevent the entry of
3. Connect a D-C welder as described in the
water and dirt (allow breathing).
Vehicle Test Instructions (Wheel Motor inst.
6. Examine all exposed machined surfaces for 400A, arm & field in stress 900- 1000 rpm arm).
rust or dirt accumulation. Remove all
4. Rotate each motorized wheel (one at a time) for
contamination as necessary. Remove rust by
at least 30 minutes to ensure that the rust
using a fine abrasive paper. Old flushing
preventive compound has been thoroughly
compound can be removed with mineral spirits
circulated throughout the gearcase. Disconnect
(GE-D5B8). Methanol should be used to
the welder. Remove the jacks. Drain the
remove all residue. When clean, coat with Tarp
gearcase.
B rust preventive. Refer to General Electric
Motorized Wheel Service Manual for
specifications.
7. Loosen exciter drive belts (where applicable).
8. Open all switches in the control compartment.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-13


5. If the truck is partially dismantled, pay close 2. Check all other weatherproofing tape. Replace
attention to ductwork, blower shrouds, etc., any that has become loose or is missing.
which may be exposed to weather conditions. 3. Check all heat sources. Replace or repair any
These areas will require the same sealing that have become inoperative.
measures as in Step 5 above which deals with
4. Check all machine surfaces that were coated
protecting ductwork. Cover exposed blower
with flushing compound when storage began. If
housings to prevent entry of water and dirt.
the compound appears to be deteriorating, it
6. Perform Steps 3 through 11 in “Storing A Truck must be cleaned off and renewed.
That Is Operational” in this section.

Placing Equipment Into Service After Storage


Storing A Major Component
If a truck has been operated weekly throughout the
When storing a motorized wheel, alternator, blower storage period, perform a complete visual inspection
or control group for any period of time, always store it of the motorized wheels, blowers, alternator and
inside a warm, climate-controlled environment. Do control compartments. Repair any defects that are
not attempt to store individual components where found, then place the truck directly into service.
they would be exposed to inclement weather,
climatic changes, high humidity and/or temperature If the truck was not operated weekly throughout the
extremes. storage period, perform the following procedures:
1. Remove all weatherproofing tape from control
compartment doors and ductworks.
Periodic Inspections 2. Remove all screening material from the
ductwork.
It is important that periodic inspections (every three
months) of stored equipment be performed to ensure 3. Remove all heat sources from the motorized
the continued serviceability of all protective wheels, control compartments and the
measures initially taken when the storage period alternator.
began. The following items should be checked at 4. Fill with recommended oil. Refer to the
each inspection interval: Motorized Wheel Service Manual for the type
1. Remove the weatherproof tape from the and amount oil to be used. This oil should be
compartment doors and perform a Megger test drained and new oil should be added after 500
as described in the Vehicle Test Instructions. hours of operation.
Record the test results and compare them with 5. Clean all motorized wheel grease fittings in the
the recorded Megger readings taken when axle box. Ensure that all grease lines are
storage first began, and those taken throughout completely full of grease, then add the
the storage period. Remove all test equipment recommended amount of grease to all fittings.
and close the compartment. Reseal the 6. Install brushes in the motorized wheels, blowers
compartment doors with new weatherproof and alternator. Make sure that the brushes
tape. If Megger readings indicate a move freely in their carbonways and that they
deterioration of insulation quality (to below 2.0 have enough length to serve until the truck's
megohms), more protection may need to be next inspection period. Install new brushes if
provided. necessary. Ensure that all brush pigtail screws
are tight.

A7-14 Storage Procedures and Idle Machine Preparation 11/05 A07003


7. Perform a megohmmeter test. Refer to the 10. Check the retarding grids and insulators for
truck's Vehicle Test Instructions for the correct loose connections and dirt accumulation. Clean
procedure. If Megger readings are less than 2.0 and tighten connections as necessary.
megohms, the problem could be an 11. Where applicable, check exciter drive belts for
accumulation of moisture in the motor or cracks and deterioration. If acceptable, set the
alternator. If this is the case, the faulty belt tension to specification.
component will have to be isolated and dried
out using procedures outlined in the G.E. 12. Before starting the engine, turn on the control
Service Manual. power. Check that the contactors and relays
pick up and drop out normally.
8. Perform a thorough inspection of the motorized
wheels, alternator, blowers and control 13. Perform a startup procedure on the complete
compartments. Look for: system to ensure maximum performance during
service. Refer to the truck's Vehicle Test
•Rust or dirt accumulation on machine
Instructions for the complete test procedure.
surfaces
•Damaged insulation
•Any accumulation of moisture or debris, After all storage protection has been removed, the
especially in the ductwork truck has been cleaned and inspected, all repairs
have been made, the motorized wheel gearcase has
•Loose wiring and cables been filled with new oil, the dirt seals have been
•Any rust on electrical connectors in the control completely purged with new grease, and the system
compartment has been completely checked, the truck can be
•Any loose cards in the card panels placed into service. However, it is recommended that
the truck be driven unloaded at a low speed of no
9. Clean and make repairs as necessary.
more than 16 km/h (10 mph) for the first hour of
operation.

A07003 11/05 Storage Procedures and Idle Machine Preparation A7-15


NOTES

A7-16 Storage Procedures and Idle Machine Preparation 11/05 A07003


SECTION B
STRUCTURES
INDEX

STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1

DUMP BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1

B01016 Index B1-1


NOTES

B1-2 Index B01016


SECTION B2
STRUCTURAL COMPONENTS
INDEX

PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3

DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

RH DECK AND RETARDING GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

LH DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6

CENTER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

B02028 10/11 Structural Components B2-1


NOTES

B2-2 Structural Components 10/11 B02028


STRUCTURAL COMPONENTS
PREPARATION NOTE: Depending on optional equipment installed
on the truck, additional steps may be required before
the decks or other structures are removed.
Prior to removal or repair procedures, it may be
necessary to remove the body to provide clearance
for any lifting equipment. If body removal is not
required, the body should be raised and the body
• Do not attempt to work in deck area until the retention sling installed at the rear of the truck. Refer
body retention sling has been installed. to “Securing the Dump Body” in Section A3.
• Do not step on or use any power cable as a
handhold when the engine is running.
After the truck is parked for repairs, the truck must be
• Do not open any electrical cabinet covers or shut down properly to ensure the safety of those
touch the retarding grid elements until all working in the areas of the deck, control cabinets and
shutdown procedures have been followed.
retarding grids. Refer to “Normal Engine Shutdown
• All removal, repairs and installation of Procedure” and “Capacitor Discharge System” in
propulsion system electrical components Seciton A3.
and cables must be performed by an
electrical maintenance technician who is
properly trained to service the system.
• In the event of a propulsion system
malfunction, a qualified technician should
inspect the truck and verify that the
propulsion system does not have dangerous
voltage levels present before repairs are
started.

B02028 10/11 Structural Components B2-3


DIAGONAL LADDER, GRILLE AND 8. Lift the grille and hood assembly from the truck
HOOD ASSEMBLY and move it to a work area.

Removal Installation
1. Attach an appropriate lifting device to the 1. Use an appropriate lifting device to lift grille and
diagonal ladder. The combined weight of hood assembly (4, Figure 2-1) into position on
diagonal ladder (1, Figure 2-1), support (2) and the truck.
the handrails is approximately 300 kg (660 lb). 2. Align the mounting hardware holes with the
2. Remove ladder mounting hardware (3). brackets attached to the radiator assembly.
Install hood mounting hardware (5). Tighten the
3. Lift the structure off the truck. Collect shims (6).
capscrews to the standard torque.
4. Disconnect wiring harnesses and remove cable
3. Adjust and tighten both radiator bumpers.
clamps as necessary to allow removal of the
grille and hood assembly. 4. Use an appropriate lifting device to lift diagonal
ladder (1) and support (2) into position over the
5. Attach an appropriate lifting device to hood and
mounting pads on the front bumper. Align the
grille assembly (4). The weight of the grille and
mounting holes and install shims (6) as needed
hood assembly is approximately 500 kg (1,100
to level the structure.
lb).
5. Install ladder mounting hardware (3). Tighten
6. Remove all hood mounting hardware (5) on
the capscrews to the standard torque.
both sides of the hood.
6. Connect all cables, wiring harnesses, hoses
7. Loosen the radiator bumpers on both decks.
and clamps that were removed previously.

FIGURE 2-1. DIAGONAL LADDER, GRILLE & HOOD REMOVAL


1. Diagonal Ladder 3. Ladder Mounting Hardware 5. Hood Mounting Hardware
2. Support 4. Grille and Hood Assembly 6. Shims

B2-4 Structural Components 10/11 B02028


RH DECK AND RETARDING GRID 6. Install an appropriate lifting device to the lifting
eyes at each corner of the deck and take up any
Removal slack. Do not attach the lifting device to the
1. Remove the access covers from the retarding handrails. The weight of the RH deck (with
grid. Tag and disconnect all electrical leads in handrails) is approximately 1 030 kg (2,270 lb).
preparation for removal. 7. Remove deck mounting hardware (2) at the
deck support and the front upright.
NOTE: Removal of the retarding grid is optional. If
repairs to the retarding grid are required, refer to the 8. Loosen the radiator bumpers on both decks.
applicable equipment manufacturer’s publication for 9. Carefully lift deck structure (1) from the deck
service and maintenance procedures. supports.
2. Attach an appropriate lifting device to the lifting
Installation
eyes on the retarding grid. The weight of the
retarding grid (with handrails) is approximately Repeat the removal procedure in reverse order to
3 900 kg (8,600 lb). install the right deck and components. Clean all
3. Remove retarding grid mounting hardware (3, mount mating surfaces and tighten all hardware to
Figure 2-2) at six locations. standard torque.
4. Lift the retarding grid clear of the deck and Ensure that all wiring harnesses, clamps and hoses
move it to a work area. are undamaged and reinstalled securely. Replace
5. Disconnect deck lighting harness (4). Remove any components as necessary.
any wiring harnesses, cables or hoses as
needed. The lighting harness and clamps do
not require removal.

FIGURE 2-2. R.H. DECK STRUCTURE MOUNTING


1. Deck Structure 3. Retarding Grid Mounting 4. Deck Lighting Harness
2. Deck Mounting Hardware Hardware 5. Radiator Bumper

B02028 10/11 Structural Components B2-5


LH DECK 3. Install an appropriate lifting device to the lifting
eyes at each corner of the deck and take up any
slack. Do not attach the lifting device to the
handrails. The weight of the LH deck (with
handrails) is approximately 820 kg (1,810 lb).
4. Remove deck mounting hardware (2) at the
If air conditioning system components must be deck support and the front upright.
removed, refer to Section N4 for instructions on 5. Loosen the radiator bumpers on both decks.
discharging the air conditioning system before
disconnecting any air conditioning lines and 6. Carefully lift deck structure (1) from the deck
servicing the air conditioning system after supports.
installation.
Installation
Removal Repeat the removal procedure in reverse order to
1. Remove the operator cab. Refer to Section N2, install the right deck and components. Clean all
Truck Cab And Components, for cab removal mount mating surfaces and tighten all hardware to
and installation instructions. standard torque.
2. Disconnect deck lighting harness (3, Figure 2- Ensure that all wiring harnesses, clamps and hoses
3). Remove any wiring harnesses, cables or are undamaged and reinstalled securely. Replace
hoses as needed. The lighting harness and any components as necessary.
clamps do not require removal.

FIGURE 2-3. L.H. DECK STRUCTURE MOUNTING


1. Deck Structure 3. Deck Lighting Harness
2. Deck Mounting Hardware 4. Radiator Bumper

B2-6 Structural Components 10/11 B02028


CENTER DECK Installation
Repeat the removal procedure in reverse order to
Removal
install the center deck. Clean all mount mating
1. Install an appropriate lifting device to the deck surfaces and tighten all hardware to standard torque.
and take up any slack. The weight of the center
deck is approximately 285 kg (630 lb). Ensure that all wiring harnesses, clamps and hoses
are undamaged and reinstalled securely. Replace
2. Remove deck mounting hardware (2, Figure 2- any components as necessary.
4).
3. Ensure that all wiring harnesses, cables and
hoses have been removed as necessary.
Carefully lift center deck (1) from the truck.

FIGURE 2-4. CENTER DECK MOUNTING

1. Center Deck 2. Deck Mounting Hardware

B02028 10/11 Structural Components B2-7


NOTES

B2-8 Structural Components 10/11 B02028


SECTION B3
DUMP BODY
INDEX

DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4

BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6

Body Pad Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7

BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8

HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8

BODY-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8

BODY RETENTION SLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8

ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9

B03020 12/11 Dump Body B3-1


NOTES

B3-2 Dump Body 12/11 B03020


DUMP BODY
DUMP BODY Removal
1. Park truck on a hard, level surface and block all
the wheels. Attach cables and a lifting device to
the dump body and take up the slack as shown
in Figure 3-1.
2. Remove the mud flaps from both sides of the
Inspect the condition and rating of all lifting body. Remove any electrical wiring and hoses
devices, slings, chains, and cables. Refer to the that are attached to the body.
manufacturer's manual for correct capacities and
3. Attach chains around the upper end of both
safety procedures when lifting components.
hoist cylinders to support them after the pivot
Replace any questionable items.
pins are removed.
Ensure that the lifting device is rated for at least a
4. At the hoist cylinder upper mounting bracket,
45 ton capacity. Slings, chains, and cables used
remove nut (6, Figure 3-2), flat washer (5) and
for lifting components must be rated to supply a
shoulder bolt (4). Use a brass drift and hammer
safety factor of approximately 2X the weight
to drive pivot pin (3) from mounting bracket (1).
being lifted. When in doubt as to the weight of
components or any service procedure, contact NOTE: The pivot pins may be retained with a
the Komatsu area representative for further capscrew and locknut as originally shipped from the
information. factory. Upgrading to the current shoulder bolt
Lifting eyes and hooks should be fabricated from configuration is recommended.
the proper materials and rated to lift the load NOTE: Do not lose two spacers (2) between the
being placed on them. cylinder bearing and mounting bracket (1).
Never stand beneath a suspended load. Use of
guy ropes are recommended for guiding and
positioning a suspended load.
Before raising or lifting the body, ensure there is
adequate clearance between the body and
overhead structures or electric power lines.

FIGURE 3-1. DUMP BODY REMOVAL


FIGURE 3-2. HOIST CYLINDER UPPER MOUNT
1. Lifting Cables 2. Guide Rope
1. Mounting Bracket 4. Shoulder Bolt
2. Spacer 5. Flat Washer
3. Pivot Pin 6. Nut

B03020 12/11 Dump Body B3-3


5. Remove nut (3, Figure 3-3), flat washer (2) and 5. Align the hoist cylinder bearing eye with the
shoulder bolt (1) from both body pivots. bore of hoist cylinder upper mounting bracket
6. Attach a body pivot pin support fixture to the (1, Figure 3-2).
bracket on the underside of the dump body to 6. Align the bolt hole in pivot pin (3) with the bolt
aid in supporting the pin as it is removed. hole in mounting bracket (1). Install the pivot pin
7. Remove body pivot pin (4) far enough to allow through the first spacer (2), then align the
shims (8) to drop out. Complete removal of pins second spacer with the bore on the other side of
is not necessary unless new pins are being hoist cylinder bearing eye. Finish installing the
installed. pin through second spacer (2).
7. Install shoulder bolt (4) through each pin.
NOTE: To prevent the body pivot pins from falling
while removing the dump body, use chains to secure NOTE: Do not use a flat washer under the head of
them to the truck. the shoulder bolt. This will ensure that the shoulder
8. Lift the dump body clear of the chassis and bolt does not run out of threads when tightening.
move it to a work area. Block up the body to 8. Install flat washer (5) and nut (6) onto the
prevent damage to the body guide. threaded end of each shoulder bolt. Tighten the
9. Inspect bushings (5), (7), and (9), body ears (6), nuts to 339 N·m (250 ft lb).
and the frame pivot for excessive wear or If self-locking nut (PC3201) is being used,
damage. Replace bushings and repair the pivot tighten the nut and flat washer securely against
area as necessary. the shoulder of the bolt.
Installation NOTE: If the original capscrew/locknut configuration
is being used, tighten the locknut to 203 N·m (150 ft
1. Park the truck on a hard, level surface and
lb). Upgrading to the current shoulder bolt
block all the wheels. Attach cables and a lifting
configuration is recommended.
device to the dump body and take up the slack
as shown in Figure 3-1. Lower the body over 9. Install all mud flaps, electrical wiring and hoses
the truck frame and align the body ears with the to the body.
frame pivot bores.
2. Install shims (8, Figure 3-3) in both body pivots,
as required, to fill the outside gaps and center
the body on the frame pivot.
NOTE: Do not install shims on the inside. A
minimum of one shim is required at the outside end
of both frame pivots.
3. Align the hole in body pivot pin (4) with the bolt
hole in the pin retainer on the outer body pivot
ear. Push the body pivot pin through the outer
body pivot ear, the frame pivot, and the inner
body pivot ear.
4. Install shoulder bolt (1) through the body pivot
pin. Install flat washer (2) and nut (2). Tighten
the nut to 339 N·m (250 ft lb).
If self-locking nut (PC3201) is being used,
tighten the nut and flat washer securely against
the shoulder of the bolt.
NOTE: If the original capscrew/locknut configuration
is being used, tighten the locknut to 203 N·m (150 ft
lb). Upgrading to the current shoulder bolt
configuration is recommended.

B3-4 Dump Body 12/11 B03020


FIGURE 3-3. DUMP BODY PIVOT PIN
1. Shoulder Bolt 4. Body Pivot Pin 7. Pivot Bushing
2. Flat Washer 5. Pivot Bushing 8. Shim
3. Nut 6. Body Pivot Ear 9. Body Pivot Bushing

B03020 12/11 Dump Body B3-5


BODY PADS
NOTE: It is not necessary to remove the dump body 2. Install the body retention sling. Refer to
to replace the body pads. Body pads should be “Securing The Dump Body” in Section A3,
inspected during scheduled maintenance inspections General Safety & Operating Instructions, for the
and replaced if worn excessively. body retention sling installation procedure.
1. Raise unloaded dump body (1, Figure 3-4) to a 3. Place blocks between the body and frame.
height that is sufficient to allow access to all of Secure the blocks in place.
the body pads. 4. Remove mounting hardware (4).
5. Remove body pad (2) and shims (3). Note the
number of shims installed at each pad location.
The rear pad on each side should have one less
shim than the other pads.
6. Install new body pads with the same number of
To avoid serious personal injury or death, the shims that were removed in step 3.
body retention sling must be installed anytime 7. Install mounting hardware (4). Tighten the nuts
personnel are required to perform maintenance to 88 N·m (65 ft lb).
on the truck with the dump body in the raised
8. Remove the blocks and body retention sling.
position.
Lower the dump body onto the frame.

FIGURE 3-4. BODY PAD INSTALLATION


1. Dump Body 3. Shim
2. Body Pad 4. Mounting Hardware

B3-6 Dump Body 12/11 B03020


Body Pad Shimming Procedure 9. Subtract the body pad thickness of 39.7 mm
(1.56 in.) from each measurement that was
Proper contact between the body pad and frame is
recorded in Step 8. There will be a total of eight
required to ensure maximum pad life. All pads
measurements “B” per side. Refer to Figure 3-5.
(except the rear pad on each side) should contact the
frame with approximately equal compression of the “A” - 39.7 mm (1.56 in.) = “B”
rubber. A gap of approximately 1.9 mm (0.075 in.) is 10. Divide each measurement “B” by the single
required at each rear pad. This can be accomplished shim thickness of 1.5 mm (0.06 in.) to deter-
by using one less shim at each rear pad. mine the number of shims required for each
If pad contact appears to be unequal, perform the mounting location.
following shimming procedure. “B” / 1.5 mm (0.06 in.) = number of shims
1. Park the truck on a flat, level surface.
11. Remove one shim from the calculation for the
2. Raise the unloaded dump body to a height that most rearward body pad on both sides.
is sufficient to allow access to all of the body
pads. NOTE: Using half shims is allowed if necessary. Half
shims must be installed at the top of the stack.
NOTE: The frame rail and the body bolster do not
have to be parallel.

To avoid serious personal injury or death, the


body retention sling must be installed anytime
personnel are required to perform maintenance
on the truck with the dump body in the raised
position.
3. Install the body retention sling. Refer to
“Securing The Dump Body” in Section A3,
General Safety & Operating Instructions, for the
body retention sling installation procedure.
4. Remove all of the body pads and shims.
5. Bolt one spacer block (XC2293) to each side of
the body. Use the pad mounting holes closest to
the front of the dump body.
6. Remove the body retention sling. Lower the
dump body onto the spacer blocks.
7. Check the dump body’s position and fit on the
truck. If there is any interference when the body
is on the spacer blocks, contact your local
Komatsu distributor to resolve the issue. FIGURE 3-5. MEASUREMENT DETAILS
8. With the body lowered, measure the distance
1. Shims 2. Body Pad
from the frame rail to each pair of bolt holes at
the dump body’s pad mounting locations. There
will be a total of eight measurements “A” per
side. Refer to Figure 3-5.

B03020 12/11 Dump Body B3-7


BODY GUIDE HOIST LIMIT SWITCH
1. Inspect the body guide wear points each time a Refer to Section D3, 24VDC Electrical System
body pad inspection is performed. Body guide Components, for the hoist limit switch adjustment
(2, Figure 3-6) should be centered between procedure.
wear plates (3) with a maximum gap of 4.8 mm
(0.19 in.) at each side (new wear plates).
2. If the gap becomes excessive, install new parts.
BODY-UP SWITCH
Refer to Section D3, 24VDC Electrical System
Components, for the body-up switch adjustment
procedure.

BODY RETENTION SLING

To avoid serious personal injury or death, the


body retention sling must be installed anytime
personnel are required to perform maintenance
on the truck with the dump body in the raised
position.
Refer to “Securing The Dump Body” in Section A3,
General Safety & Operating Instructions, for the body
retention sling installation procedure.

FIGURE 3-6. BODY GUIDE

1. Dump Body 3. Body Guide Wear


2. Body Guide Plates

B3-8 Dump Body 12/11 B03020


ROCK EJECTORS 3. If the rock ejector arm becomes bent, it must be
removed and straightened.
Rock ejectors are placed between the rear dual
wheels to keep rocks or other material from lodging 4. At each shift change, inspect mounting brackets
between the tires. Failure to maintain the rock (4, Figure 3-8), pins (2) and stop blocks (3) for
ejectors could allow debris to build up between the wear and damage. Repair as necessary.
dual wheels and cause damage to the tires.

Inspection
1. The rock ejectors must be positioned on the
center line between the rear tires within 6.0 mm
(0.25 in.).
2. With the truck parked on a level surface, rock
ejector arm (1, Figure 3-7) should be
approximately 454.5 mm (17.9 in.) from wheel
housing (2).
NOTE: With the rock ejector arm hanging vertical as
shown in Figure 3-7, there must be no gap at stop
block (3, Figure 3-8).

FIGURE 3-8. ROCK EJECTOR MOUNTING


BRACKET
1. Rock Ejector Arm 3. Stop Block
2. Pin 4. Mounting Bracket

FIGURE 3-7. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm 2. Wheel Housing

B03020 12/11 Dump Body B3-9


NOTES

B3-10 Dump Body 12/11 B03020


SECTION B4
FUEL TANK
INDEX

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

FUEL TANK VENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5

FUEL GAUGE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6

QUICK FILLFUEL RECEIVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6

B04025 12/11 Fuel Tank B4-1


NOTES

B4-2 Fuel Tank 12/11 B04025


FUEL TANK
FUEL TANK Cleaning
Removal The fuel tank has a drain cock and a cleaning port in
the side that allow steam or solvent to be used for
1. Raise the truck body and install the body
cleaning tanks that have accumulated foreign
retention sling.
material.
2. Loosen filler cap (5, Figure 4-1) and open the
drain cock on the bottom of fuel tank (1) to drain It is not necessary to remove the tank from the truck
the fuel from the tank into clean containers. for cleaning of sediment. However, rust and scale on
Tighten the filler cap when the fuel is completely the walls and baffles may require complete tank
drained. removal. This allows cleaning solutions to be in
contact with all interior surfaces by rotating the tank
3. Disconnect the wire harness from hoist circuit
in various positions.
filter assemblies (11) and steering circuit filter
assembly (12). Remove ground wire (13). Before a cleaning procedure of this type, the fuel
4. If equipped, close the inline shutoff valves. gauge sender, vent assembly (8, Figure 4-1) and all
Remove fuel return hose (6), fuel supply hose hose connections must be removed and temporarily
(7) and quick fill hose (10). Cap the hoses and sealed. After cleaning is complete, the temporary
tank fittings to prevent contamination. plugs can be removed.
5. Remove hoist circuit filter assemblies (11) and If the tank is to remain out of service, a small amount
steering circuit filter assembly (12) from the fuel of light oil should be sprayed into the tank to prevent
tank. Support the filter assemblies by placing a rust. Seal all openings for rust prevention.
chain over the frame rail. It is not necessary to
remove the hydraulic hoses. Installation
1. Thoroughly clean the frame mounting brackets
and the mounting hardware holes. Re-tap the
threads if damaged.

The weight of the empty fuel tank is


approximately 1 690 kg (3,725 lb). Use lifting
devices with adequate capacity to remove the
fuel tank. The weight of the empty fuel tank is
6. Attach a lifting device to the lifting eyes on each approximately 1 690 kg (3,725 lb). Use lifting
side of the tank. devices with adequate capacity to install the fuel
7. Remove capscrews (14), lockwashers (15), flat tank.
washers (16), large washers (17) and rubber 2. Attach a lifting device to the lifting eyes on each
mounts (16). Remove capscrews (2), side of the tank. Lift the fuel tank into position
lockwashers (3) and mounting caps (4). over the frame trunnion mounts and lower it into
8. Lift the fuel tank from the brackets and move it position.
to a work area. 3. Install mounting caps (4, Figure 4-1),
lockwashers (3) and capscrews (2). Do not
Repair tighten the capscrews at this time.
If a tank has been damaged and requires structural 4. Install rubber mounts (18), large washers (17),
repair, perform such repairs before final cleaning. flat washers (16), lockwashers (15) and
capscrews (14). Tighten the lower mounting
capscrews to 420 ± 42 N·m (310 ± 31 ft lb).
5. Tighten the upper mounting capscrews to 711 ±
72 N·m (525 ± 53 ft lb).
If a tank is to be weld repaired, special 6. Install hoist circuit filter assemblies (11) and
precautions are necessary to prevent fire or steering circuit filter assembly (12) on the tank.
explosion. Consult local authorities for safety
regulations before proceeding.

B04025 12/11 Fuel Tank B4-3


7. Connect fuel return hose (6) fuel supply hose 8. Install ground wire (13). Connect the wire
(7) and quick fill hose (10). Open the inline harness to hoist circuit filter assemblies (11)
shutoff valves, if equipped. and steering circuit filter assembly (12).

FIGURE 4-1. FUEL TANK REMOVAL & INSTALLATION


1. Fuel Tank 7. Fuel Supply Hose 13. Ground Wire
2. Capscrew 8. Vent Assembly 14. Capscrew
3. Flat Washer 9. Overflow Tube (if equipped) 15. Lockwasher
4. Mounting Cap 10. Quick Fill Hose 16. Flat Washer
5. Filler Cap 11. Hoist Circuit Filter Assemblies 17. Large Washer
6. Fuel Return Hose 12. Steering Circuit Filter Assembly 18. Rubber Mount

B4-4 Fuel Tank 12/11 B04025


FUEL TANK VENT ASSEMBLY
NOTE: The relief pressure of the fuel tank vent
assembly is 70 - 89 kPa (10 - 13 psi).

Disassembly
1. Remove clamp (3, Figure 4-2), cover (2) and
screen (1).
NOTE: Fuel tanks that have been modified to add an
overflow tube will not be equipped with the clamp,
cover and screen. New vent assembly (PB9887) has
a fitting for the overflow tube installed in the vent
passage.
2. Remove ball cage (10), solid ball (11) and float
balls (12).
3. Unscrew end fitting (7) from body (4).
4. Remove stem (8) and valve spring (5).

Assembly
1. Clean and inspect all parts. If any parts are
damaged, replace the entire assembly.
2. Place valve spring (5, Figure 4-2) into position
in body (4).
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 FIGURE 4-2. VENT ASSEMBLY (TA1978)
the breather. Install clamp (3).
1. Screen 7. End Fitting
NOTE: Fuel tanks that have been modified to add an 2. Cover 8. Stem
overflow tube will not be equipped with the clamp, 3. Clamp 9. O-Ring
cover and screen. New vent assembly (PB9887) has 4. Body 10. Ball Cage
a fitting for the overflow tube installed in the vent 5. Valve Spring 11. Solid Ball
passage. 6. O-Ring 12. Float Ball
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
properly on the stem. If not, adjust the cage
accordingly.

B04025 12/11 Fuel Tank B4-5


FUEL GAUGE SENDER QUICK FILL FUEL RECEIVERS
Fuel gauge sender (1, Figure 4-3) provides an Fuel receiver assembly (4, Figure 4-3) is mounted on
electrical signal to operate the fuel gauge on the the front of the fuel tank. Fuel receiver assembly (5)
instrument panel. is mounted to the bottom of the hydraulic tank. It is
connected to the rear of the fuel tank by hose (6).
Removal
The quick fill fuel system is a pressurized system that
1. Drain the fuel below the level of the fuel gauge is rated at a maximum of 568 l/m (150 gpm). When
sender. filling the tank, vent assembly (8, Figure 4-1) allows
2. Disconnect the wires from terminals (3). air to escape to prevent the tank from over-
3. Remove sender mounting hardware (2). pressurizing. When the fuel level reaches the float
Carefully remove the sender and gasket. balls in the vent, the balls rise with the fuel. When the
fuel level reaches its maximum level, the float balls
Installation block air flow out of the vent, causing pressure to rise
in the fuel tank. When pressure reaches 55 - 70 kPa
1. Clean the mating surfaces. Install a new gasket.
(8 - 10 psi), the fuel nozzle should turn off.
2. Install fuel gauge sender (1, Figure 4-3) in the
tank. Ensure the float is oriented properly and If the nozzle fails to turn off and fuel continues to fill
moves freely. the tank, a relief valve in the vent will open at 79 kPa
(11.5 psi) to prevent over-pressurization of the tank. If
3. Install sender mounting hardware (2) and
filling persists and the fuel reaches the top of the
tighten the capscrews to the standard torque.
tank, fuel will flow out of the vent until the nozzle is
4. Connect the wires to terminals (3). turned off.
5. Fill the fuel tank and check for leaks.
If fuel spills from the vent, or if the tank does not
completely fill, check the vent to see whether the
float balls are in place and overflow tube (9) is clean.
If the vent is operating properly, the problem will most
likely be in the fuel supply system.
NOTE: Keep the cap on each fuel receiver to prevent
dirt buildup in valve area and nozzle grooves.

FIGURE 4-3. FUEL GAUGE SENDER & QUICK FILL FUEL RECEIVERS
1. Fuel Gauge Sender 4. RH Fuel Receiver Assembly
2. Mounting Hardware 5. LH Fuel Receiver Assembly
3. Terminals 6. Quick Fill Hose

B4-6 Fuel Tank 12/11 B04025


SECTION C
ENGINE
INDEX

POWER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-1

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1

POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1

AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1

FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-1

C01014 Index C1-1


NOTES

C1-2 Index C01014


SECTION C2
POWER MODULE
INDEX

POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3

PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3

REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-8

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-10

HOOKUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-11

C02029 Power Module C2-1


NOTES

C2-2 Power Module C02029


POWER MODULE
The radiator, engine and alternator assemblies are PREPARATION FOR REMOVAL
mounted on a roller-equipped subframe which is
1. Properly park the truck and shutdown the
contained within the truck's main frame. It is referred
engine. Refer to “Normal Engine Shutdown” in
to as a “power module”. This arrangement permits
Section A3, General Safety & Operating
removal and installation of these components with a
Instructions.
minimum amount of disconnect and by utilizing the
unique “roll in/roll out” feature. 2. To ensure that the link will not be energized
during test and repair procedures, turn GF
Although the instructions in this section are primarily
Cutout Switch (2, Figure 2-1) in the control
based upon the “roll out” method for major
cabinet to the CUTOUT position by pulling the
component removal, the radiator and fan may be
switch out and moving the switch downward as
removed as separate items. Instructions for radiator
shown.
and fan removal are included later in this section. If
any optional equipment is installed on the truck,
additional removal and installation steps that are not
listed may be required.
The procedures outlined in this section of the manual
are general instructions for power module removal
and installation. It may be necessary to perform
some procedures in a different order or use different
methods for component removal and installation,
depending on the lifting equipment available at the FIGURE 2-1. INFORMATION DISPLAY PANEL
mine site. Prior to removal or repair procedures, it 1. Control Power Switch
may be necessary to remove the body to provide 2. GF Cutout Switch
clearance for lifting equipment to be used. If body 3. Capacitor Charge Light
removal is not required, raise the body and install the
body retention sling at the rear of the truck.
Read and observe the following instructions before
attempting any repairs. 3. Open the battery disconnect switches.
4. Tag or mark all hydraulic lines, fuel lines and
electrical connections to ensure correct hookup
during installation of the power module. Plug all
ports and cover all hose fittings and
connections when disconnected to prevent
• Do not attempt to work in the deck area until contamination.
body safety cables have been installed.
NOTE: It is not necessary to remove the radiator
• Do not step on or use any power cable as a before removing the power module. However, the
handhold when the engine is running. coolant must be drained and the piping connected to
• Do not open any control cabinet covers or the brake cooling heat exchanger must be removed.
touch the retarding grid elements until all If radiator removal is needed or only radiator repair is
shutdown procedures have been followed. necessary, refer to Section C3, Cooling System.
• All removal, repairs and installation of 5. If radiator removal is required, refer to Section
propulsion system electrical components B2, Structural Components, for hood and grille
must be performed by an electrical removal instructions. The power module may
maintenance technician properly trained to be removed with the hood installed if desired.
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.

C02029 Power Module C2-3


FIGURE 2-2. PUMP DRIVE SHAFT REMOVAL
1. Bottom Drive Shaft 2. Pump Drive Shaft
Cover 3. Alternator

6. Remove bottom drive shaft cover (1, Figure 2-


2). Disconnect pump drive shaft (2) at the flange
mounted on the alternator (3).
7. Remove the alternator blower ducts from the
alternator. Be careful not to tear the flexible
neoprene material.
a. Disconnect cables and hoses as required.
FIGURE 2-3. ALTERNATOR BLOWER DUCTS
b. Remove wheel motor blower transition (1,
1. Wheel Motor Blower Transition
Figure 2-3) and the gasket.
2. Control Cabinet Blower
c. Remove control cabinet blower transition Transition Flexible Duct
flexible duct (2) and the gasket. 3. Drive Axle Blower Hose
d. Remove drive axle blower hose (3).
e. Cover all openings to prevent foreign
material from entering the system.

C2-4 Power Module C02029


8. Remove engine air intake duct support rods (9, 11. Loosen T-bolt clamps (5) on hump hoses (4)
Figure 2-4). Remove any hoses or electrical between the four engine air inlet ducts and air
cables attached to center deck. cleaner outlet ducts.
9. Remove the center deck. Refer to Section B2, 12. Disconnect the inlet ducts at each of the four
Structural Components, for the removal turbochargers. Remove the inlet ducts from
procedure. truck. Cover the openings at the turbochargers.
10. Disconnect the air cleaner restriction indicator
nylon tubes at the inlet ducts.

FIGURE 2-4. ENGINE AIR INLET PIPING

1. Air Cleaner Assemblies 7. Reducer Elbow


2. Left Rear Intake Duct 8. T-Bolt Clamp
3. Left Front Intake Duct 9. Duct Support Rod
4. Hump Hose 10. Right Front Intake Duct
5. T-Bolt Clamp 11. Right Rear Intake Duct
6. T-Bolt Clamp

C02029 Power Module C2-5


FIGURE 2-5. ENGINE EXHAUST PIPING

1. Clamps 3. Exhaust Tubes


2. Mounting Hardware

13. Remove clamps (1, Figure 2-5) from the


hangers.
14. Remove mounting hardware (2) that retains
exhaust tubes (3) to the turbocharger outlet
flanges. Remove the exhaust tubes. Cover the
FIGURE 2-6. WATER SHUTOFF VALVES &
turbocharger outlet openings on the engine.
HEAT EXCHANGER PIPING
15. Remove the alternator power cable protective
cover. Disconnect all electrical cables, oil lines 1. Water Shutoff Valves
and fuel lines that would interfere with power 2. Heat Exchanger Piping
module removal. Cover or plug all lines and
their connections to prevent entrance of dirt or
foreign material. 17. Drain the engine coolant into clean containers
16. Close cab heater water shutoff valves (1, Figure for re-use after engine installation. Refer to
2-6), disconnect the water lines and drain the Section P2, Lubrication & Service, for the
water from the heater core. Secure the water coolant system capacity.
lines away from engine compartment to prevent 18. Disconnect and remove heat exchanger piping
interference with power module removal. (2, Figure 2-6) from the engine water pump and
the radiator.

C2-6 Power Module C02029


19. Remove radiator upper support rod (1, Figure 2-
7) at each side of radiator.
20. Remove the diagonal ladder from truck. Refer to
Section B2, Structural Components, for the
removal procedure.
21. Refer to Section N4, Heater/Air Conditioner, for
the procedures required to properly remove the
refrigerant.
NOTE: The system contains HFC-134A refrigerant.

Federal regulations prohibit venting air


conditioning system refrigerants into the
FIGURE 2-7. RADIATOR UPPER SUPPORT ROD
atmosphere. An approved recovery/recycle
station must be used to remove the refrigerant 1. Radiator Upper Support Rod
from the air conditioning system.

22. After the air conditioning system has been


discharged, disconnect the refrigerant hoses
that are routed to the cab at the compressor
and the receiver/drier.

C02029 Power Module C2-7


REMOVAL 4. Check the engine and the alternator to ensure
that all cables, wires, hoses, tubing and
1. Remove the mounting hardware and front
linkages have been disconnected.
engine mounts (1, Figure 2-8) to the main frame
on both sides of the engine. 5. Place a jack under the rear of the power
module. Raise the rear portion of engine
2. Install a safety chain around the engine
subframe and install the subframe rollers (see
subframe cross member and the main frame to
Figure 2-9). Lower the rear portion of the
prevent the power module from rolling when the
subframe carefully until the rollers rest on the
subframe rollers are installed.
main frame guide rail.
3. Remove the capscrews and engine mounting
caps that secure subframe mounting bushings NOTE: Subframe rollers are supplied in the truck tool
(2) at the rear of the subframe. group and can be installed in the storage position
after use as shown in Figure 2-9.

FIGURE 2-8. POWER MODULE REMOVAL & INSTALLATION

1. Front Engine Mounts 3. Engine/Alternator Cradle


2. Subframe Mounting Bushings 4. Front Subframe Lifting Point

C2-8 Power Module C02029


FIGURE 2-10. POWER MODULE LIFTING POINTS
1. Lifting Tool 4. Engine
2. Alternator 5. Power Module
3. Lifting Points Subframe

FIGURE 2-9. SUBFRAME ROLLERS 7. Roll the power module forward so that
1. Roller Assembly adequate clearance is provided in front of the
2. Subframe control cabinet for the lifting device to be
3. Capscrews attached to engine/alternator cradles (3, Figure
2-8) and front subframe lifting points (4). Place
stands or blocks under the front of the subframe
and lower the hoist until the front of the
subframe is supported. Install a safety chain to
prevent the subframe from rolling.
8. Attach lifting tool (1, Figure 2-10) to the hoist
The complete power module, including the hood and attach it to the engine/alternator cradles
and grille, weighs approximately 17 000 kg and the front subframe lifting points as shown in
(37,500 lb). Ensure that the lifting device to be Figure 2-10. Remove the safety chain.
used has adequate capacity.
9. Raise the power module slightly to determine
Lift the power module only at the lifting points on whether it is on an even plane. Move the power
the subframe and engine/alternator cradle module straight out of the truck to a clean work
structure. Refer to Figure 2-10. area for disassembly.
For further disassembly of the engine, alternator and
6. Position the hoist to front subframe lifting points radiator, refer to the appropriate section of this
(4, Figure 2-8). Raise the engine subframe until manual.
the engine is on a level plane. Remove the
safety chain.

C02029 Power Module C2-9


INSTALLATION 6. Lower the power module to the subframe guide
rails, relax the hoist slightly, and roll the power
1. Inspect the main frame guide rails. Remove any
module into truck frame as far as possible
debris which would interfere with power module
before the lifting chains contact the control
installation.
cabinet.
2. Clean the main frame rear support brackets.
7. Place stands or blocks under the front of the
Apply a light film of soap solution to each
subframe to support the assembly while
subframe mounting bushings (2, Figure 2-8)
repositioning the hoist.
located at the rear of the subframe.
8. Install a safety chain around the truck frame
3. Check the subframe rollers to ensure that they
and the subframe to prevent the power module
roll freely and are in the “roll out” position (see
from rolling forward.
Figure 2-9).
9. Place a small block behind each rear subframe
4. Attach lifting tool (1, Figure 2-10) to the engine/
roller to prevent rolling.
alternator cradles and front subframe lifting
points (see Figure 2-10). 10. Lower the hoist to allow the subframe to rest on
the stands and rollers. Remove the lifting tool.
11. Attach the hoist to the front lifting eyes on the
subframe.

The complete power module, including the hood 12. Remove the small blocks behind the subframe
and grille, weighs approximately 17 000 kg rollers. Remove the safety chain and slowly roll
(37,500 lb). Ensure that the lifting device to be the power module into position over the main
used has adequate capacity. frame mounts. Lower the hoist until the front
subframe mounts are aligned and seated on the
front main frame mounts. Install the safety
5. Raise the power module and align the subframe chain.
rollers within the main frame guide rails. 13. Place a jack under the rear of the subframe to
support the power module. Raise the power
module just enough to permit removal of the
subframe rollers.
14. Lower the rear portion of the subframe until the
subframe mounting bushings (2, Figure 2-8) are
seated in the rear mounting brackets on the
main frame of the truck.
15. After the subframe is seated in the frame
mounts, the safety chain may be removed from
the front subframe member.
16. Install front engine mounts (1, Figure 2-8). and
the mounting hardware. Tighten the capscrews
to 1017 ± 72 N·m (750 ± 53 ft lb).
17. Install the rear engine mounting caps and
secure the caps with lubricated capscrews.
Tighten the capscrews to 552 ± 20 N·m (407 ±
15 ft lb).
FIGURE 2-11. POWER MODULE INSTALLATION

C2-10 Power Module C02029


HOOKUP 7. Install heat exchanger piping (2) to the heat
exchanger, engine water pump and radiator.
1. Install all ground straps between the frame and
subframe. Reconnect the electrical harnesses 8. Inspect the transition gaskets and replace them
at the power module subframe connectors. if damaged. Install wheel motor blower
transition (1, Figure 2-3) and control cabinet
2. Install the diagonal ladder on the front platform.
blower transition (2). Install drive axle blower
Refer to Section B2, Structural Components, for
hose (3).
the installation procedure.
9. Connect pump drive shaft (2, Figure 2-2) to the
3. Install the center deck. Refer to Section B2,
alternator. Tighten the capscrews to the
Structural Components, for the installation
standard torque. Install bottom drive shaft guard
procedure.
(1).
4. Install the engine air intake duct supports.
Install the intake ducts between the 10. Connect all remaining electrical, oil lines and
turbochargers and air cleaner outlet ducts (see fuel lines. Connect the air filter restriction
Figure 2-4). Clamp them securely to ensure that indicator hoses.
a positive seal is made. Refer to Figures 2-4 11. Close the battery disconnect switches.
and 2-12 for correct installation and alignment
12. Connect the hoses routed from the cab to the
examples.
receiver/drier and air conditioning compressor.
5. Install exhaust tubes (3, Figure 2-5).
13. Refill the radiator and service the engine with
6. Connect the cab heater inlet and outlet hoses, appropriate fluids. Refer to Section P2,
then open both water shutoff valves (1, Figure Lubrication & Service, for the service capacities.
2-6).
14. Recharge the air conditioner system. Refer to
Section N4, Heater/Air Conditioner.

FIGURE 2-12. AIR INLET PIPING CONNECTIONS

C02029 Power Module C2-11


NOTES

C2-12 Power Module C02029


SECTION C3
COOLING SYSTEM
INDEX

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5

Filling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

REPAIRING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8

Pressure Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9

COOLANT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9

C03034 7/07 Cooling System C3-1


NOTES

C3-2 Cooling System 7/07 C03034


COOLING SYSTEM
RADIATOR 3. Refer to Section N4, Heater / Air Conditioner,
for the procedures required to properly remove
Removal the refrigerant from the air conditioning system.
1. Drain the coolant into clean containers for NOTE: The system is charged with HFC-134A
possible reuse after engine installation. Refer to refrigerant.
Section P, Lubrication and Service, for the
a. Remove the refrigerant hose clamps and
cooling system capacity.
receiver/drier (3, Figure 3-1) from the front
2. If the radiator is being removed without the left side of the radiator shroud. Disconnect
complete power module, remove the grille and the harness from the low pressure switch on
hood according to the removal instructions in the receiver/drier.
Section B, Structural Components.
b. Remove the clamps and disconnect inlet
hose (4, Figure 3-2) and outlet hose (5) at
the condenser. Remove mounting hardware
(3) and remove condenser (2) from radiator
assembly (1).
Federal regulations prohibit venting air
c. Cap all hoses to prevent contamination.
conditioning system refrigerants into the
Remove any remaining clamps attaching the
atmosphere. An approved recovery/recycle
hoses and wiring to the radiator shroud.
station must be used to remove the refrigerant
Reposition the hoses and wiring to allow
from the air conditioning system.
removal of the radiator and shroud
assembly.
4. Disconnect the lines at the fuel cooler. Remove
all clamps that secure the lines to the radiator.

FIGURE 3-1. RECEIVER/DRIER LOCATION


1. Condenser 3. Receiver/Drier
2. Accumulator

FIGURE 3-2. AIR CONDITIONER CONDENSER


1. Radiator Assembly 4. Inlet Hose
2. Condenser 5. Outlet Hose
3. Mounting Hardware

C03034 7/07 Cooling System C3-3


FIGURE 3-4. FAN GUARDS
1. Fan Guard (LH) 3. Radiator Shroud
2. Fan Guard (RH)
FIGURE 3-3. RADIATOR PIPING, BOTTOM VIEW
1. Drain Cock 4. Outlet Elbow (Rear)
2. Outlet Elbow (Front) 5. Heat Exchanger 9. Attach the hoist to the radiator and take up any
3. Radiator Mounting 6. Engine Subframe slack.
Hardware
NOTE: The radiator and shroud assembly weighs
approximately 2600 kg (5730 lbs).
5. Unclamp and separate all upper hoses between 10. Remove upper support rods (2, Figure 3-5) and
the radiator and the engine. stabilizer bars (3), if equipped.
6. Remove outlet elbows (2, Figure 3-3) and (4) at 11. Remove radiator mounting hardware (4, Figure
the bottom tanks. Cap all coolant lines to 3-3) that secures the radiator and to the power
prevent contamination. module subframe.
7. Remove and cap the hoses from the radiator 12. Loosen the radiator bumpers on both decks.
top tank and surge tank.
13. Ensure that all hoses and wiring harnesses
8. Remove the capscrews and lockwashers to free
have been removed. Lift the radiator slightly
fan guards (1, Figure 3-4) and (2) from radiator
with the hoist and move the radiator forward
shroud (3). The two halves of the fan guard may
until it is clear of the engine fan. Move the
be disassembled and removed or the complete
radiator to a work area for service.
guard may be moved to the rear to clear the
shroud during removal of the radiator.

C3-4 Cooling System 7/07 C03034


6. Tighten radiator mounting hardware (4) at the
lower radiator mounting brackets to the
standard torque.
7. For added stability, stabilizer bars (3) may be
installed. Install the stabilizer bars at the
radiator brackets and subframe as shown, then
tighten the mounting hardware to the standard
torque.
8. Install fan guards (1, Figure 3-4) and (2) using
the original mounting hardware.
10. Install the upper hoses between the radiator
and the engine. Seat the hoses fully and tighten
the clamps securely.
11. Install outlet elbows (2, Figure 3-3) and (4) with
new gaskets.
12. Route the lines to the fuel cooler and clamp
them in place. Attach the lines to the fuel cooler
fittings.
13. Install the air conditioning system components.
a. Install condenser (2, Figure 3-2), hoses (4)
and (5), and all clamps.
b. Install receiver/drier (3, Figure 3-1) and
clamp the hoses. Attach the harness to the
low pressure switch.
FIGURE 3-5. RADIATOR MOUNTING c. Clamp all hoses and wiring to the studs
1. Radiator 4. Radiator Mounting using the original clamps. Refer to Section N,
2. Upper Support Rod Hardware Heater / Air Conditioner, for complete
3. Stabilizer Bar instructions on evacuating and recharging
the air conditioning system.
14. Install the grille and hood according to the
Installation instructions in Section B, Structural
Components. Make sure that both radiator
1. Attach a hoist to the radiator and lift it into
bumpers are adjusted and secured.
position on the power module subframe.
2. Install radiator mounting hardware (4, Figure 3- 15. Make sure that all coolant drains are closed, all
5) at the lower radiator mounting brackets. Do pipe plugs are installed, and all hoses are
not tighten at this time. connected securely. Service the cooling system
with the proper mixture of antifreeze as
3. Inspect the rubber bushings for upper support recommended in Section P, Lubrication and
rods (2) and replace them if worn or damaged. Service. Check for leaks and correct as needed.
4. Install upper support rods (2) and the mounting
16. Start and operate the engine until the cooling
hardware at both ends. Do not tighten at this
system reaches normal operating temperature.
time.
Recheck for leaks during engine operation.
5. Adjust the upper support rods until the radiator Turn off the engine and correct any leaks.
is positioned perpendicular to the subframe
within ± 3.0 mm (0.12 in.) measured at top of
radiator. When the position is established,
tighten the upper support rod locknuts and
recheck the perpendicularity of the radiator.

C03034 7/07 Cooling System C3-5


Filling Procedure REPAIRING THE RADIATOR
Internal Inspection
If desired, an internal inspection can be performed on
the radiator before complete disassembly. The
inspection involves removing tubes from the radiator
core and cutting them open. This type of inspection
The cooling system is pressurized due to thermal can indicate overall radiator condition, as well as
expansion of coolant. DO NOT remove the coolant and additive breakdown.
radiator cap while the engine and coolant are hot. To perform this inspection, remove four random
Severe burns may result. tubes from the air inlet side of the radiator. Remove
1. With engine and coolant at ambient tubes from both the top and bottom cores, and near
temperature, remove the radiator cap. each end of the radiator. Refer to Disassembly and
Assembly in this section for the proper instructions
Note: If coolant is added using the Wiggins quick fill for removing and installing tubes. Analyze any
system, the radiator cap must be removed before contaminant residue inside the tube to determine the
adding coolant. cause of contamination. Flush the system before
2. Fill the radiator with the proper coolant mixture returning the truck to service. Contact your nearest
(as specified by the engine manufacturer) until L&M Radiator facility for further instructions or visit
coolant is visible in the sight gauge. the L&M website at www.mesabi.com.
3. Install the radiator cap.
4. Operate the engine for five minutes, then check
the coolant level. External Cleaning
5. If coolant is not visible in the sight gauge, Many radiator shops use a hot alkaline soap, caustic
repeat steps 1 through 4 of this procedure. Any soda or chemical additives in their boil-out tanks,
excess coolant will be discharged through the which can attack solders. These tanks are generally
vent hose after the engine reaches normal not recommended. Before such tanks are used for
operating temperature. cleaning, ensure that the cleaning solutions are
NOTE: Engine coolant must always be visible in the not harmful to solder. Otherwise, damage to the
sight gauge before truck operation. radiator will result. Completely rinse the cleaned
tube or core in clean water after removing it from the
boil-out tank.
As an alternative to boil-out tanks, radiators can be
cleaned externally with a high pressure washer and
soap. In most cases, it may be best to blow out any
dry dirt with a high pressure air gun prior to washing
the core with the high pressure washer.
Pressure washers should not exceed 8 275 kPa
(1,200 psi). Unlike conventional cores, the spray
nozzle can be used right up next to the core. Starting
from the air exit side, place the high pressure washer
nozzle next to the fins. Concentrate on a small area,
slowly working from the top down. Spray straight into
the core, not at an angle. Continue washing until the
exit water is free of dirt. Repeat from the opposite
side.

C3-6 Cooling System 7/07 C03034


Disassembly

To aid in removal of the tubes, clean the radiator


prior to disassembly. Heating the seals with hot
water helps to loosen the grip on the tubes.
Cleaning the radiator prior to disassembly also
reduces the risk of internal contamination. After
cleaning, spray lubricating oil at the top end of
the tubes.
FIGURE 3-7. INSTALLATION TOOL (VJ6567)

2. After the tube is loose, position the installation


tool (VJ6567) at the bottom of the tube to be
removed. Refer to Figure 3-7. The upper jaw of
the installation tool should be positioned just
below the rectangular section of the tube. The
bottom jaw should rest on the seal. Squeeze
the installation tool just enough to allow the
bottom of the tube to be removed from the
bottom seal.
NOTE: To ease in the removal of tubes, use the
breaker tool and installation tool simultaneously.
FIGURE 3-6. BREAKER TOOL (XA2307)

1. Start at the top row of tubes. Use the breaker


tool (XA2307) to loosen the tube to be removed.
When using the breaker tool, position it at the
top or bottom of the tube. Never position it in the
middle of the tube or damage may result. Use
the breaker tool to lightly twist the tube back
and forth within the seals to loosen the grip.
Refer to Figure 3-6.

FIGURE 3-8. ANGLING TUBE DURING REMOVAL

3. Pull the tube from the top seal while


simultaneously twisting the tube. Angle the tube
only far enough to clear the radiator. Refer to
Figure 3-8. Removing the tube at an excessive
angle may cause damage to the tube.
4. Remove all the top tubes before removing the
bottom tubes. After all of the tubes are
removed, use pliers to remove the seals from
the tanks. Discard all seals. New seals must be
used for assembly.

C03034 7/07 Cooling System C3-7


Cleaning and Inspection
1. Use a drill with a 19 mm (3/4 in.) wire brush to
remove any foreign material from the tube
holes, then wipe the holes clean.
2. Clean the inside of the tanks and tubes. In most
cases, just flushing the inside with soap and a
high pressure hot water washer will be
sufficient. If not, contact an L&M manufacturing
facility for further instructions or visit the L&M
website at www.mesabi.com.
3. Check for signs of internal blockage in the tubes
and tanks. If desired, you may cut open tubes
for inspection. If contamination is present, the
tube should be analyzed. The radiator must be FIGURE 3-9. PROPER SEAL INSTALLATION
properly flushed of all contaminants and
corrective action must be taken to prevent such
contamination from occurring in the future.
Refer to Internal Inspection in this section. 2. Use a 13 mm (1/2 in.) diameter brush to
lubricate the seals with lube/release agent
4. Buff the tube ends with a polishing wheel and a (XA2308).
copper polishing compound. If any debris can
not be removed by buffing, using an emery 3. Use a spray bottle to lubricate the tube ends
cloth, steel wool or a wire wheel with a wire size with the lube/release agent.
of 0.15 - 0.20 mm (0.006 - 0.008 in.) is 4. When installing tubes, start at one end and
acceptable. Be careful not to mar the tube ends. work toward the center. After you reach the
center, move to the opposite end, and again
Assembly work toward the center. If any of the tubes are
difficult to install, do not force the tube. Remove
NOTE: For easier installation, soak the seals in hot
the tube and determine the problem. Possible
water before installing.
causes may be:
1. Install new tube seals onto the bottom tank and
the bottom side of the center tank. Do not install •adequate seal/tube lubrication
seals in the top core at this time. Seals for the •improperly installed seal
top of the tubes do not have locking grooves;
•damaged seal or tube end
bottom tube seals do. Ensure the correct seals
are installed in the proper position. •tube angle excessive during installation and/or
tube not centered in seal.
The seal holes must be dry during installation.
Use a rubber mallet and a flat metal plate to
lightly tap the seals into place. Using excessive Inspect the seals and tube ends for damage
force will drive the seals in too far. When before trying to reinstall a tube. Replace as
installed properly, the seals should be slightly necessary.
convex. Improperly installed seals are concave
with a smaller diameter hole. Refer to Figure 3-
9.

C3-8 Cooling System 7/07 C03034


5. Working from the front of the radiator (opposite Pressure Testing
of fan side), install the bottom row of tubes
The radiator should be pressure tested at 103 kPa
starting with the fan side row.
(15 psi) for 30 minutes. Various methods of pressure
When installing the tubes, center the top of the testing include the following:
tube in the top seal while angling the tube only
as much as necessary. Twist the tube while • Pressurize the radiator and submerge into a test
applying upward force. Push the tube into the tank. Watch for leaks.
seal until enough clearance is available to • Lay the front side of the radiator on the floor. Cap
install the bottom end of the tube into the off ports, and fill the radiator with hot water.
bottom seal. Pressurize the radiator and check for leaks.
6. Center the bottom end of the tube in the bottom • Cap off radiator ports. Install an air pressure
seal. Push the tube downward until the formed gauge and pressurize to 103 kPa (15 psi).
bead on the tube is seated inside the lock ring Remove the air source and monitor the pressure
groove in the seal. If necessary, use the gauge.
installation tool (VJ6567) to pull the tube • Pressurize the radiator with air, and spray sealed
downward into the seal. The tool has a hooking joints with soapy water.
device on the end of one of the handles for
aiding in installation. Refer to Figure 3-10.
Additional service information can be found on
the L&M Radiator website at www.mesabi.com.

COOLANT SYSTEM
TROUBLESHOOTING
If abnormal coolant temperatures are experienced,
perform the following visual inspections and tests:
1. Check the coolant level and thoroughly inspect
the system for leaks.
a. Check for proper coolant/antifreeze mixture.
b. Follow the recommendations of the engine
FIGURE 3-10. USING INSTALLATION TOOL TO manufacturer regarding use of cooling
INSTALL TUBE system additives.
2. Inspect the radiator fins for restrictions. Ensure
7. Ensure that all tube beads are seated in their the air flow through the radiator is not restricted
respective bottom seals. Align and straighten all by debris or bent radiator fins.
tubes during the installation of each row to allow 3. Inspect the fan blades for damage.
maximum air flow through the radiator. 4. Check the radiator cap sealing surfaces.
8. Install tube stay ends. Install the felt air baffles 5. If equipped with a fan clutch, refer to Section C7
behind the front and back rows while for complete instructions for testing and repairs,
completing tube installation. if required.
6. Refer to the engine manufacturer's service
manual for information about testing and
replacing the cooling system thermostats.

C03034 7/07 Cooling System C3-9


NOTES

C3-10 Cooling System 7/07 C03034


SECTION C4
POWER TRAIN
INDEX

ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3

ALTERNATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5

Measuring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5

Joining the Alternator and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-7

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

C04027 1/11 Power Train C4-1


NOTES

C4-2 Power Train 1/11 C04027


POWER TRAIN
ALTERNATOR REMOVAL
The following instructions cover the removal of the
main alternator from the engine after the power
module has been removed from the truck.

The alternator weighs approximately 3720 kg


(8200 lbs). Ensure the lifting device to be used
has adequate capacity. Lift the alternator only at
the lifting eyes on the alternator.
1. Attach a hoist with two lifting chains to both
lifting eyes (8, Figure 4-2) on top of alternator
(1).
2. Block up the rear of the engine.
3. Loosen cradle adjustment setscrews (3, Figure
4-1). FIGURE 4-1. CRADLE STRUCTURE
4. Loosen engine-to-cradle capscrews (5, Figure 1. Cradle Structure 4. Subframe
4-2). 2. Jam Nut 5. Gap
3. Adjustment Setscrew

FIGURE 4-2. ENGINE AND ALTERNATOR


1. Alternator 4. Flywheel Housing 7. Subframe
2. Mounting Hardware 5. Capscrews 8. Alternator Lifting Eyes
3. Cradle Structure 6. Engine

C04027 1/11 Power Train C4-3


5. Remove the access cover at the front, right side
of engine flywheel housing (4). Reach through
the access openings and remove 12 capscrews
(6, Figure 4-3) that join engine drive ring (7) to
alternator rotor (8). Rotate the crankshaft to
align each capscrew with the access hole.
NOTE: Ensure that all 12 capscrews have been
removed.
6. Remove 16 capscrews (3) that secure flywheel
housing adapter (2) to alternator housing (1).
NOTE: The clearance between the head of capscrew
(3) and flywheel housing (4) will not permit complete
removal of the capscrews at all locations. Ensure that
all of the capscrew threads are completely
disengaged from alternator housing (1).
7. Take up any slack in the hoist. Remove
mounting hardware (2, Figure 4-2) that secures
the alternator to the cradle structures.
8. Keep the alternator as level as possible and
move away from engine.
9. Note the location and quantity of the shims.
Keep the shims for possible reuse during
installation.
NOTE: For further disassembly instructions for the
alternator, refer to the GE Service Manual. FIGURE 4-3. ALTERNATOR TO ENGINE
MOUNTING
1. Alternator Housing 5. Capscrew
2. Flywheel Housing 6. Capscrews
Adapter 7. Engine Drive Ring
3. Capscrews 8. Alternator Rotor
4. Flywheel Housing

C4-4 Power Train 1/11 C04027


ALTERNATOR INSTALLATION Measuring Procedure
1. Thoroughly clean the alternator housing
mounting surface, rotor drive adapter mounting
surface and flywheel housing adapter mounting
surfaces.
2. Mount a magnetic base on the front of the
The following instructions must be followed to engine and a dial indicator on the front of the
ensure proper alignment and engine crankshaft crankshaft. Measure total crankshaft endplay.
endplay. Failure to follow these instructions can
Verify end play is within 0.13 - 0.38 mm (0.005 -
result in serious damage to the engine and/or
0.015 in.).
alternator.
Total Crankshaft Endplay_________________
• Never pry on the engine crankshaft damper.
3. Refer to Figure 4-4. Move the engine crankshaft
• Loosen or remove fan belts before measuring to the rear of its end travel.
crankshaft endplay to ensure that the crankshaft
moves easily and completely. a. Carefully measure Dimension “C” at four
locations, 90° apart:
• When taking measurements, always take four
equally spaced readings and average them. 1st measurement:___________________
2nd measurement:__________________
• Always measure from mating surface to mating 3rd measurement:___________________
surface. 4th measurement:___________________
• A reference to crankshaft rotation - clockwise Dimension “Cavg”:______________
(CW) or counterclockwise (CCW) - is the b. Add 1/2 (one-half) of Total Crankshaft
direction of rotation when looking at the front
Endplay from step 2 to Dimension “Cavg”.
(damper end) of engine.
c. Record (Step 3a + Step 3b) as
• Crankshaft end play: 0.13 - 0.38 mm
(0.005 - 0.015 in.) Measurement “C”:___________________

SERVICE DATA - Eccentricity & Runout Limits


Description T.I.R
Maximum Eccentricity of Flywheel 0.66 mm
Housing Bore (0.026 in.)
Maximum Face Runout of Flywheel 0.25 mm
Housing (0.010 in.)
Maximum Eccentricity of Flywheel 0.18 mm
(Coupling Assembly) (0.007 in.)
Maximum Axial Runout of Flywheel 0.25 mm
Face (Coupling Assembly) (0.010 in.)

FIGURE 4-4. SHIM LOCATION


1. Alternator Housing “A” - Dimension “A”
2. Alternator Rotor “B” - Drive Shims
3. Flywheel Housing “C” - Dimension “C”
Adapter “D” - Housing Shims
4. Engine Flywheel
Housing
5. Engine Drive Ring

C04027 1/11 Power Train C4-5


4. Refer to Figure 4-5 to determine alternator
endplay:
a. Using flat steel bar (3) bolted rigidly to
alternator rotor (2), install 5/8" - 11NC
capscrew (4) finger tight at each end into
alternator housing (1).
b. Move alternator rotor (2) axially toward the
rear (slip ring end) by alternately tightening
capscrews (4) one-half turn at a time. Do not
exceed 16 N·m (12 ft lb) on each
capscrew. This establishes the maximum
permissIble rear travel for the alternator
rotor.
c. Alternately loosen capscrews (4) one turn at
a time until all torque is released. Carefully
remove steel bar (3).
Refer to Figure 4-4.
d. Carefully measure Dimension “A” at four
locations, 90° apart, and average the
measurements. Do not move the alternator
rotor.
1st measurement:___________________
2nd measurement:___________________
3rd measurement:___________________
4th measurement:___________________
Dimension “Aavg”:____________ FIGURE 4-5. ALTERNATOR END-PLAY
e. Add 0.25 mm (0.010 in.) to Dimension
“Aavg”. 1. Alternator Housing 3. Steel Bar
2. Alternator Rotor 4. Capscrew
f. Record (Step 4d + Step 4e) as
Measurement “A”:___________________
5. To determine the correct shims to use,
compare Measurement “C” (Step 3c) with
Measurement “A” (Step 4f). b. If A is greater than C, subtract: (A - C) = D
a. If C is greater than A, subtract: (C - A) = B D = ________________Shim pack thickness
B = ______________Shim pack thickness to be installed at location D, Figure 4-4.
to be installed at location B, Figure 4-4.

Alternator-to-Flywheel Housing Adapter


Rotor-to-Drive Ring Location “D”
Location “B” Shim Part Number Shim Thickness
Shim Part Number Shim Thickness 0.10 mm
EJ1056
0.10 mm (0.004 in.)
EL3332
(0.004 in.) 0.18 mm
EJ1055
0.18 mm (0.007 in.)
EL3331
(0.007 in.)

C4-6 Power Train 1/11 C04027


Joining the Alternator and Engine

The alternator weighs approximately 3 720 kg


(8,200 lb). Ensure the lifting device to be used
has adequate capacity. Lift the alternator only at
the lifting eyes.
1. Use two lifting eyes (8, Figure 4-2) provided on
the alternator. The top front lifting eye should be
equipped with some method of adjusting the
alternator to keep it horizontal.
2. Carefully move the alternator into place and
engage engine drive ring (6, Figure 4-6) into
alternator rotor drive (7) using shims “B”, if
required. Refer to step 5a. in “Measuring
Procedure”.
3. Install flywheel housing adapter capscrews (2)
into alternator housing (1). Tighten to 237 N·m
(175 ft lb).
4. Install capscrews (5) through engine drive ring
(6) into alternator rotor adapter (7). Rotate the
crankshaft to access and align holes. Tighten
capscrews (5) to 237 N·m (175 ft lb). FIGURE 4-6. ALTERNATOR TO ENGINE
5. Install alternator-to-cradle mounting hardware MOUNTING
(2, Figure 4-2). Tighten to 712 N·m (525 ft lb).
1. Alternator Housing 5. Capscrew
6. Tighten engine-to-cradle capscrews (5) to 465 2. Point Capscrew 6. Engine Drive Ring
N·m (345 ft lb). 3. Flywheel Housing 7. Alternator Rotor
Adapter “B” - Drive Shims
4. Engine Flywheel “D” - Housing Shims
Housing

The total engine crankshaft endplay (step 7) must


equal the original measurement or 0.51 mm
Never pry on the engine crankshaft damper. (0.020 in.), whichever is smaller.
Severe engine damage can result.
If the endplay after the alternator and engine are
7. Mount a magnetic base on the front of the assembled is less than 0.51 mm (0.020 in.), and
engine and a dial indicator on the front of the less than the original engine crankshaft endplay,
crankshaft. Measure total crankshaft endplay. reshimming is required.
9. Rotate the crankshaft one full revolution and
Total Crankshaft Endplay:________________ listen for any unusual noise caused by moving
components contacting stationary parts.
8. Compare the value above to the measurement 10. Install the engine side cover, if removed. Install
taken before the alternator was installed on the the lockwire on all alternator mounting
engine. capscrews.
11. Install the access cover on the flywheel housing.

C04027 1/11 Power Train C4-7


ENGINE Service
Complete instructions for the disassembly, assembly
Removal
and maintenance of the engine and its components
NOTE: Refer to previous sections for removal can be found in the engine manufacturer's service
procedures for the power module, alternator, and manual.
radiator assembly.
Installation
1. Align the engine with subframe (7, Figure 4-2)
and install the capscrews at the front engine
mounts.
2. Align and install capscrews (2) through the rear
The engine weighs approximately 9 300 kg
engine mounts and into cradle structure (3), but
(20,515 lb). Ensure that the lifting device to be
do not tighten at this time.
used has adequate capacity.
3. Install the alternator on the engine. Refer to
1. Disconnect any remaining wiring or hoses Alternator Installation in this section.
between engine (6, Figure 4-2) and subframe
(7). 4. Adjust setscrew (3, Figure 4-1) to equalize gap
(5) between cradle structure (1) and subframe
2. Remove the capscrews at the front engine (4) at the left side and right side. Lock the
mounts. setscrew with jam nut (2).
3. To ensure that the engine stays level while
lifting, attach a spreader bar with lifting straps to
the engine lifting eyes. Remove engine-to-
cradle structure mounting capscrews (5).
4. Lift the engine from the subframe and move to
clean work area for further disassembly.

C4-8 Power Train 1/11 C04027


SECTION C5
AIR CLEANERS
INDEX

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

SERVICING THE AIR CLEANERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

Replacing The Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

Cleaning The Main Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5

Servicing The Precleaner Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-6

EVACUATOR VALVES (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7

AIR INTAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7

C05013 12/11 Air Cleaners C5-1


NOTES

C5-2 Air Cleaners 12/11 C05013


AIR CLEANERS
OPERATION SERVICING THE AIR CLEANERS
Air required by the diesel engine passes through the
air cleaner assemblies mounted on each side of the
radiator. These air cleaners discharge heavy
particles of dust and dirt by centrifugal action and
then remove finer particles by passing air through
The engine must be turned off before servicing
filter cartridges.
the air cleaner assemblies or opening the engine
The engine demand for air creates a vacuum in the air intake system. Never start the engine with the
air cleaners and causes outside air to be drawn in filter elements removed. Serious engine damage
through air inlets on the air cleaners. Dirty air can result.
entering here is drawn through a series of tubes that
• Inspect and empty dust collector cups at regular
are designed to produce a cyclonic action. As the air
intervals. Daily inspection is recommended.
passes through the outer portion of the tubes, a Never allow the dust level to build up to the tube
circular motion is set up causing dust and dirt (precleaner) chamber.
particles to be thrown from the air stream into dust
collectors (1, Figure 5-1). At the same time, the air • During operation or after the engine has been
stream turns and is directed up through the center of turned off, observe the air filter restriction gauges
mounted on the overhead panel in the cab.
the tubes into the filter chamber. Here the air passes
When a gauge shows maximum restriction, filter
through the main filter element and safety filter service is required.
element and out the clean air outlet to the engine's
air intake system. The function of the safety filter is to • Check all engine air inlet tubes, hoses and
increase overall reliability and engine protection. clamps. All connections must be air tight to
prevent dirt from entering.
• Air cleaner housing fasteners and mountings
must be tight.
• After the filters have been serviced, reset the air
filter restriction gauges by pressing the reset
button on the face of the gauge.

Replacing The Filter Element


1. Turn off the engine. Clean any dirt and dust
from the area around air cleaner element cover
(4, Figure 5-1).
2. Loosen large wing nut (5, Figure 5-2) on the air
cleaner cover to free main filter element (10).
Pull the main filter element from the assembly.
3. Inspect the main filter element carefully for
damage, holes or breaks which might affect
reuse of the element. If the element appears
serviceable, proceed with the cleaning
procedure. If defects are found in the element,
wing nut (5) must be removed from the
assembly and installed on the new element.
4. Check safety filter indicator (7). If the solid red
FIGURE 5-1. ENGINE AIR CLEANERS area is showing, replacement of the safety filter
1. Dust Collectors 3. Air Intake Cover is required. If the center is green, the safety
2. Precleaner Section 4. Element Cover filter does not require replacement.

C05013 12/11 Air Cleaners C5-3


6. Reset the safety filter indicator from red to
green by gently blowing air into the threaded
hole from gasket side of the indicator nut.
7. Install the new safety filter element. Tighten the
Have a new safety (secondary) filter element on wing nut to 13 N•m (10 ft lbs).
hand before removing the used filter element. Do 8. Install main filter element (10) into the air
not keep the intake system open to the cleaner and secure it with wing nut (5). Tighten
atmosphere any longer than necessary. the wing nut hand tight. Do not use a wrench or
5. If the safety filter element must be replaced, pliers. If the original filter element is being
remove the indicator and remove the safety reused, ensure the sealing gasket is not
filter element. Discard the filter element. Do not damaged. The gasket must seal completely.
clean the damaged filter element. 9. Close and latch the dust collectors on the
bottom of the air cleaner assembly.

FIGURE 5-2. AIR CLEANER ASSEMBLY

1. Dust Collector 5. Wing Nut 9. Safety Filter Element 13. Precleaner Gasket
2. Dust Collector Gasket 6. Wing Nut Gasket 10. Main Filter Element 14. Safety Filter Element
3. Tube 7. Safety Filter Indicator 11. Main Element Gasket Gasket
4. Unfiltered Air Inlet 8. End Cover 12. Clean Air Outlet

C5-4 Air Cleaners 12/11 C05013


Cleaning The Main Filter Element

Only the main filter elements may be cleaned,


and then only if they are structurally intact. Do
not reuse an element that is damaged. Do not
clean and reuse the safety (secondary) filter
elements. Replace them with new parts.
After inspection, determine the condition of the main
filter element and choose either the washing method FIGURE 5-3. INSPECTING FILTER ELEMENT
or compressed air method for cleaning the element.
If the element is clogged with carbon, soot, oil and/or
dust, the complete washing procedure will produce Clean dust loaded elements with dry filtered
the best results. compressed air as follows:
1. Maximum nozzle pressure must not exceed
207 kPa (30 psi). The distance from the nozzle
Wash elements with water and detergent as follows:
to the surface of the filter element must be at
1. Soak the element in a solution of detergent and least 25 mm (1 in.) to prevent damage to the
water for at least 15 minutes. Rotate the filter material.
element back and forth in the solution to loosen 2. As shown in Figure 5-4, direct the stream of air
dirt deposits. Do not soak elements for more from the nozzle against the inside of the filter
than 24 hours. element. This is the clean air side of the
2. Rinse the element with a stream of fresh water element and air flow should be opposite of
in the opposite direction of normal air flow until normal air flow.
rinse water runs clear. Maximum permissible 3. Move the air flow up and down vertically with
water pressure is 276 kPa (40 psi). A complete the pleats in the filter material while slowly
and thorough rinse is essential. rotating the filter element.
3. Dry the element thoroughly. If drying is done 4. When cleaning is complete, inspect the filter
with heated air, the maximum temperature must element as shown in Figure 5-3. If holes or
not exceed 60°C (140°F) and must be ruptures are noted, discard the element and
circulated continually. Do not use a light bulb to replace with a new element.
dry elements.
4. After cleaning, inspect the element thoroughly
for the slightest ruptures and damaged gaskets.
A good method for detecting paper ruptures is
to place a light inside the filter element, as
shown in Figure 5-3, and inspect the outer
surface of the filter element. If holes or ruptures
are found, do not reuse the element. Discard
and replace with a new element.

FIGURE 5-4. CLEANING FILTER ELEMENT


WITH COMPRESSED AIR

C05013 12/11 Air Cleaners C5-5


Servicing The Precleaner Section NOTE: The precleaner section may be separated
from the air cleaner assembly without removing the
The tubes in precleaner section (2, Figure 5-1)
entire air cleaner from the truck.
should be cleaned at least once per year and at each
engine overhaul. More frequent cleaning may be 1. Remove air intake cover (3, Figure 5-1).
necessary depending upon operating conditions and Remove the mounting hardware that secures
and the local environment. the precleaner section to the air cleaner
assembly. Remove the precleaner section. The
To inspect the tubes in the precleaner section, safety filter element must remain in place to
remove the main filter element. Do not remove the protect the engine intake.
safety filter element. Loosen the clamps and remove
dust collector (1, Figure 5-2). Use a light to inspect 2. Loosen the clamps and remove dust collector
the tubes. All tubes should be clear and the light (1) from the precleaner section. Wash the dust
should be visible. collector with a water and liquid soap solution.
3. Submerge the precleaner section in a solution
NOTE: Both the main and safety elements must be of Donaldson D-1400 and warm water (see
installed in the air cleaner while Steps 1 and 2 are Figure 5-6). Mix the solution according to the
being accomplished to prevent any possibility of dirt directions on the package. The tube section
being forced into the engine intake area. must be down. Soak for 30 minutes, then
Dust can be removed with a stiff fiber brush (see remove the precleaner section from the
Figure 5-5). Do not use a wire brush. Dust may also solution. Rinse thoroughly with fresh water and
be removed effectively using compressed air. blow dry.
Heavy plugging of the tubes may require soaking and Severe plugging may require the use of an
washing the entire precleaner section. Refer to the Oakite 202 and water solution instead. The
following procedure. solution should be 50% Oakite 202 and 50%
fresh water.
4. Check the precleaner gaskets carefully for any
evidence of air leaks. Replace if necessary.
5. Install the precleaner section and gaskets on
the air cleaner assembly. Install all mounting
hardware that was removed.
6. Install the dust collector and gasket on the
precleaner section. Secure the dust collector
with mounting clamps.

FIGURE 5-5. REMOVING DUST FROM


PRECLEANER TUBES

FIGURE 5-6. WASHING AND SOAKING


PRECLEANER SECTION

C5-6 Air Cleaners 12/11 C05013


EVACUATOR VALVES (if equipped) AIR INTAKE TROUBLESHOOTING
The optional evacuator valve, located at the bottom To ensure maximum engine protection, all
of each dust collector, is an important part of the connections between the air cleaners and the engine
functionality of the air cleaner. It is an integral part of intake are tight and sealed. If air leaks are
the pre-cleaning stage on two-stage air cleaners. The suspected, check the following:
dust cup, where pre-cleaned dust is collected, is
1. Check all intake lines, tubes and hump hoses
normally under a slight vacuum when the engine is
for breaks, cracks, and holes which could allow
running. The normal engine pulsing of the vacuum
an intake air leak.
causes the evacuator valve to open and close. This
action automatically expels any collected dust and 2. Check that all air cleaner gaskets are sealing
water. The evacuator valve also unloads when the properly.
engine is stopped. 3. Check the main and safety filter elements for
ruptures, holes or cracks.
• Never paint the evacuator valve. Solvents and
chemicals will shorten the usable life. 4. Check the air cleaner assembly for structural
damage, cracks, breaks or other defects which
• If the evacuator valve is cracked, torn, remains could allow air leakage. Check that all mounting
open or is missing, dust particles that are
hardware is tightened properly.
normally expelled can deposit themselves onto
the filter and will shorten air filter service life.
Replace the evacuator valve.

FIGURE 5-7. EVACUATOR VALVE

C05013 12/11 Air Cleaners C5-7


NOTES

C5-8 Air Cleaners 12/11 C05013


SECTION C7
FAN CLUTCH
INDEX

REMOVAL & INSTALLATION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-3

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-6

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-16

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-20

TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-34

C07001 Fan Clutch C7-1


NOTES

C7-2 Fan Clutch C07001


FAN CLUTCH

REMOVAL & INSTALLATION TOOLING

TOOL A - FRONT SLEEVE BEARING

TOOL B - REAR SLEEVE BEARING

C07001 Fan Clutch C7-3


TOOL C - FRONT AND REAR SLEEVE BEARING REMOVER

TOOL D - WEAR SLEEVE AND RETAINER/SEAL ASSEMBLY INSTALLER;


BEARING REMOVER; ASSEMBLY PUSHER TOOL

C7-4 Fan Clutch C07001


TOOL E - BEARING INSTALLER

TOOL F - BEARING INSTALLER

C07001 Fan Clutch C7-5


DISASSEMBLY

FIGURE 7-1. FAN CLUTCH EXPLODED VIEW

1. Orifice Fitting 16. External Snap Ring (Spacer) 32. Internal Snap Ring
2. Dowel Pin (Rear) 17. Seal Ring (Hook-Type) 33. Main Bearing (Front)
3. Pitot Tube 18. Bolt 34. O-Ring Seal
4. Wear Sleeve 19. Washer 35. Bearing Retainer (Front)
5. Retainer/Seal Assembly 20. Pulley 36. Oil Seal
6. Shaft Assembly 21. Pulley Adapter 37. Washer
7. Name Plate Kit 22. Seal Ring (Large) 38. Bolt
8. Washer 23. Piston 39. Wear Sleeve
9. Bolt 24. Seal Ring (Small) 40. Retainer/Seal Assembly
10. Oil Seal 25. Spring Washer 41. Sleeve Bearing (Rear, Short)
11. Bearing Retainer (Rear) 26. Shim 42. Fan Mounting Hub
12. Bearing Spacer 27. External Snap Ring 43. Dowel Pin (Front)
(External Snap Ring) 28. External Snap Ring 44. Sleeve Bearing (Front, Long)
13. O-Ring Seal 29. Clutch Hub 45. End Cap
14. Main Bearing (Rear) 30. Facing Plate
15. Internal Snap Ring 31. Steel Clutch Plate

C7-6 Fan Clutch C07001


FIGURE 7-1. FAN CLUTCH CUTAWAY (Typical)
3. Pitot Tube 14. Main Bearing 27. External Snap Ring 37. Washer
4. Wear Sleeve 15. Internal Snap Ring 28. External Snap Ring 38. Bolt
5. Retainer/Seal 16. External Snap Ring 29. Clutch Hub 39. Wear Sleeve
Assembly 17. Seal Ring (Hook-Type) 30. Facing Plate 40. Retainer/Seal Assembly
6. Shaft Assembly 20. Pulley 31. Steel Clutch Plate 41. Sleeve Bearing
8. Washer 22. Seal Ring (Large) 32. Internal Snap Ring (Rear, Short)
9. Bolt 23. Piston 33. Main Bearing 42. Fan Mounting Hub
10. Oil Seal 24. Seal Ring (Small) 34. O-Ring Seal 44. Sleeve Bearing
11. Bearing Retainer 25. Spring Washer 35. Bearing Retainer (Front, Long)
13. O-Ring Seal 26. Shim 36. Oil Seal 45. End Cap

C07001 Fan Clutch C7-7


FIGURE 7-4.
FIGURE 7-2.

1. Support the fan clutch on a bench with fan 3. Remove O-ring seal (34).
mounting hub (42) facing upward. Support the
assembly beneath the pulley. Remove bolts
(38) and washers (37).

FIGURE 7-3. FIGURE 7-5.

2. Install lifting eyes, and attach a hoist and chains


to front bearing retainer (35). Use a small 4. Position the bearing retainer and hub assembly
screwdriver to separate the front bearing on the bench with clutch hub (29) up. Remove
retainer from pulley adapter (21), and set it external snap ring (28).
aside on a bench.

C7-8 Fan Clutch C07001


FIGURE 7-8.

FIGURE 7-6.
7. Remove front oil seal (36).

5. Remove clutch hub (29).

FIGURE 7-9.

FIGURE 7-7.
8. Remove internal snap ring (32).
6. Position the sub-assembly beneath the ram of a
press. Support the assembly beneath the
bearing retainer as close as possible to fan
mounting hub (42). Press the fan mounting hub
out of the front bearing using tooling (B).

C07001 Fan Clutch C7-9


FIGURE 7-10.
FIGURE 7-12.

11. Remove front retainer/seal assembly (40).


9. Turn bearing retainer (35) over on the press Wedge a large chisel or other appropriate tool
bed. Press front bearing (33) out of the bearing behind the retainer to force it off fan mounting
retainer using tooling (D). hub (42).

FIGURE 7-13.

FIGURE 7-11. Use a chisel to make three indentations in wear


sleeve (39) in order to loosen the sleeve. The
indentations should be approximately 120
10. Support beneath the fan mounting hub with end degrees apart from one another. Remove the
cap (45) down, but approximately 50 mm (2 in.) wear sleeve.
above the press bed. Using a solid steel bar or
NOTE: Use caution when using the chisel. Do not cut
equivalent, press the end cap from the fan
through the sleeve. Damage to the shaft can cause
mounting hub.
future leaks.

C7-10 Fan Clutch C07001


FIGURE 7-14.

12. Inspect sleeve bearing (44) and sleeve bearing FIGURE 7-16.
(41). Compare the color of each bearing to the
chart above. The lighter the appearance of the 14. Remove the stack of facing plates (30) and
bearing, the more worn it is. If either bearing steel clutch plates (31) from inside the pulley.
needs replacing, proceed to the next step. If the
bearings are in good condition, skip the next
step.

FIGURE 7-17.

FIGURE 7-15. 15. Remove external snap ring (27), shim (26), and
spring washer (25).
13. Position tooling (C) against sleeve bearing (41).
Press the front sleeve bearing downward to
press it out of the fan mounting hub. Rear
sleeve bearing (44) will be pressed out
simultaneously.

C07001 Fan Clutch C7-11


FIGURE 7-20.

FIGURE 7-18.
18. Support beneath the pulley to prevent it from
dropping to the bench. Remove bolts (9) and
16. Attach wire lifting hooks to piston (23). Use the lockwashers (8).
lifting hooks to pull the piston from pulley
adapter (21).

FIGURE 7-19.

FIGURE 7-21.
17. Remove seal rings (22) and (24) from the
piston. 19. Install lifting eyebolts to the shaft and bearing
retainer assembly. Use a suitable lifting device
to lift the assembly from the pulley. Remove O-
ring seal (13).
NOTE: It may be necessary to use a soft rubber
mallet to separate the shaft and bearing retainer from
the pulley.

C7-12 Fan Clutch C07001


FIGURE 7-22.

20. Position the shaft as shown. Insert a phillips-


FIGURE 7-24.
head screwdriver into pitot tubes (3) to loosen
and remove them from the shaft. Rotate the
pitot tube until the sealant holding it tight is
broken loose. Then grip the pitot tube with a
pair of pliers and gently tap on the pliers to 22. Remove external snap ring (16).
remove the pitot tubes from the hole in the
shaft.

FIGURE 7-25.
FIGURE 7-23.

21. Remove both seal rings (17). 23. Remove internal snap ring (15).

C07001 Fan Clutch C7-13


FIGURE 7-28.

FIGURE 7-26. 26. Use tooling (E) to press rear bearing (14) out of
rear bearing retainer (11).

24. Support the bearing retainer as close as


possible to the bearing bore. Be careful not to
damage the retainer/seal assembly. Press the
shaft out of bearing (14) using tooling (E).

FIGURE 7-29.

27. Use a chisel to make three indentations in wear


sleeve (4). The indentations should be
approximately 120 degrees apart from one
FIGURE 7-27. another. Remove the wear sleeve.
NOTE: Use caution when using the chisel. Do not cut
25. Remove oil seal (10) from bearing retainer (11). through the sleeve. Damage to the shaft can cause
future leaks.

C7-14 Fan Clutch C07001


FIGURE 7-30.

28. Remove rear retainer/seal assembly (5). Drive


the assembly off the shaft or wedge a large
chisel or other appropriate tool behind the
retainer to force it off.

C07001 Fan Clutch C7-15


CLEANING AND INSPECTION
Thoroughly clean all components before inspection.
Check each of the following components, and follow the guidelines for reuse:
• Ball bearings - Replace at time of rebuild.
• Internal snap rings - Must not be damaged or worn. Must be flat and have square edges at outer diameter.
• External snap rings - Must not be damaged or worn. Must be flat and have square edges at inner diameter.
• Seal rings - Replace during rebuild.
• Oil seals - Replace during rebuild.
• Bolts and washers - Reuse unless damaged or worn.
• Retainer/Seal assemblies - Replace if damaged or worn.
• Wear sleeves - Replace during rebuild.
• Sleeve bearings - Inspect color of surface. Refer to Figure 7-14.

FIGURE 7-31. SHAFT ASSEMBLY WEAR DIMENSIONS

1. Check the shaft assembly for wear or damage. Refer to Figure 7-31 for dimensions.
NOTE: Some shafts were manufactured as two-piece assemblies. Do not attempt to separate the shaft assembly.

2. Inspect and clean the pitot tube holes in the shaft. Use a standard reamer (straight flute, 0.3770 in. diameter).
Remove pipe plugs in the shaft for cleaning and reinstall using Loctite® Primer N and #242.

C7-16 Fan Clutch C07001


FIGURE 7-32.

3. Check pulley and adapter dimensions.

FIGURE 7-34.

5. Check piston (23) dimensions.

FIGURE 7-33.

4. Check rear bearing retainer (11) dimensions.

C07001 Fan Clutch C7-17


FIGURE 7-35. PISTON REWORK
(For earlier pistons with the drilled orifice.)

6. Check the piston for a drilled orifice at the inside


face. If the piston contains the orifice, modify
the piston as shown in Figure 7-35.
7. Inspect clutch hub (29) for wear. Wear marks
that may be present on the teeth must not
restrict plate movement. If they have smooth
entry and exit ramps, the notches will not
restrict plate movement and the clutch hub may
be reused.
8. Check steel plates (31) for wear. The plates
must be smooth and free of grooves or heat
related damage. The plates are 3.07 mm (0.121
in.) minimum thickness when new and must be
flat within 0.13 mm (0.005 in.).
9. Inspect facing plates (30). Minimum thickness
for new facing plates is 2.77 mm (0.109 in.).
Grooves are 0.15 mm (0.006 in.) deep. The
plates must be flat within 0.13 mm (0.005 in.).
Check the teeth for excessive wear. When new,
the space between the teeth is approximately
7.11 mm (0.280 in.).
FIGURE 7-36.

10. Inspect fan mounting hub (42).

C7-18 Fan Clutch C07001


FIGURE 7-37.

11. Inspect front bearing retainer (35).


12. Inspect end cap (45) for any wear or raised
nicks.

C07001 Fan Clutch C7-19


ASSEMBLY
NOTE: The fan clutch is reassembled using Loctite ® 2. If removed, install dowel pin (43) into fan
(or equivalent) sealants. Follow manufacturer's mounting hub assembly (42). Refer to Figure 7-
recommendations regarding minimum cure time to 38. Press the pin into the hub, leaving 2.3 mm
prevent oil from washing the sealant from the sealing (0.090 in.) exposed.
surfaces.
If the shaft did not originally come with
pinned bearings, install the dowel per
1. Place end cap (45) in a freezer or on dry ice to instructions in Figures 7-38 and 7-39.
prepare for installation in the following steps.

FIGURE 7-39.

FIGURE 7-38.

C7-20 Fan Clutch C07001


FIGURE 7-40.

FIGURE 7-42.

4. Turn the hub over on the bed of the press.


Using tooling (B), press rear sleeve bearing (41)
into the fan mounting hub until the tool contacts
the shoulder of the hub.

FIGURE 7-41.

3. Using tooling (A), press front (long) sleeve


bearing (44) into the fan mounting hub until the
tool contacts the shoulder of the hub. Ensure
the correct bearing is installed. There are two
sleeve bearings, and each one must be
installed in the proper area of the hub to ensure
the lube passage is not restricted. Refer to
Figure 7-40.

C07001 Fan Clutch C7-21


FIGURE 7-44.

FIGURE 7-43.

5. Press front retainer/seal assembly (40) onto the


fan mounting hub (42) using tooling (D). The
inner race of the retainer should be recessed
1.0 mm (0.040 in.) below the shoulder.
Check carefully to ensure that the retainer/seal
assembly is installed straight and is not bent or
damaged in any way which will cause
interference between it and the bearing retainer
after assembly.

• Front wear sleeve (39) is NOT


interchangeable with rear (notched) wear
sleeve (4). The inside diameter of the front
wear sleeve is color coded red. FIGURE 7-45.
• Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from 6. Coat the inside diameter of front wear sleeve
occurring. (39) and the wear sleeve diameter of the shaft
with Loctite Primer N and #242 (or equivalent).
• Use extreme care when handling the wear Using tooling (D), press the wear sleeve onto
sleeve. The slightest nicks or scratches may
the shaft until it is flush with the shoulder.
cause leakage.
NOTE: Some fan hubs may have a small hole on the
wear sleeve mounting journal. This hole is not used
and will be covered by the wear sleeve.

C7-22 Fan Clutch C07001


FIGURE 7-46.
FIGURE 7-48.
7. Coat the bore of the fan mounting hub (42) with
a thin coating of Loctite Primer N and #242. 9. Install internal snap ring (32).
Remove frozen end cap (45) from the freezer.
Do not apply Loctite to the end cap. Press the
end cap into the hub until the cap bottoms out.

FIGURE 7-47.
FIGURE 7-49.

8. Apply Loctite Primer N and #609 to the mating 10. Turn the retainer over on the press bed. Coat
surfaces of front bearing (33) and front bearing the outside diameter of front oil seal (36) and
retainer (35). Place the bearing into position on the mating surface on the bearing retainer with
the retainer with the notch for the bearing pin Loctite Primer N and #242 (or equivalent).
facing downward.
Use tooling (E) to press the oil seal into the front
Press the front bearing into the bearing retainer bearing retainer until it is flush with the front
using tooling (E) or equivalent. Press ONLY on face. Ensure that the lip of the seal is dry.
the outer race of the bearing until it seats at the Wipe any excess Loctite from the seal area and
bottom of the bore. remove any rubber strings from the seal.

C07001 Fan Clutch C7-23


FIGURE 7-50.

11. Coat the inside diameter of the bearing and the


fan mounting hub bearing journal with Loctite
Primer N and #609 (or equivalent). Place the FIGURE 7-51.
front bearing retainer sub-assembly into
position on the fan mounting hub. Ensure the
notch in the bearing is aligned with the bearing 12. Install clutch hub (29) on the fan mounting hub
dowel pin. Do not allow the seal lip to come in assembly (42) with the open end down. (No
contact with the Loctite. Press the bearing onto special timing is necessary.)
the hub using tooling (D) until it contacts the
wear sleeve.
Wipe any lubricant or sealer from the seal
lip. The seal lip is teflon and must remain
dry for proper sealing to occur.
Spin the bearing retainer at least 25 revolutions
to ensure proper rotation of the bearing and to
burnish the seal.

FIGURE 7-52.

13. Install external snap ring (28) to hold the clutch


hub in place.

C7-24 Fan Clutch C07001


FIGURE 7-53.

FIGURE 7-55.

15. Use tooling (D) to press rear retainer/seal


assembly (5) onto shaft (6). The inner race of
the retainer should be recessed 1.0 mm (0.040
in.) below the shoulder.
Check carefully to ensure that the retainer/seal
assembly is installed straight and not bent or
damaged in any way which will cause
interference between it and the bearing retainer
FIGURE 7-54. after assembly.

14. If removed, install rear dowel pin (2) in shaft


assembly (6). Press the pin until 2.0 mm (0.080
in.) is left exposed above the surface.
If the shaft did not originally come with
pinned bearings, install the dowel per
instructions in Figures 7-53 &7-54.

C07001 Fan Clutch C7-25


FIGURE 7-57.

FIGURE 7-56. 17. Coat the outside diameter of rear bearing (14)
and the mating surface of bearing retainer (11)
with Loctite Primer N and #609 or equivalent.
The end of the bearing with the notch is
installed first. Using tooling (F) or equivalent,
press the bearing into the bearing retainer.
Press ONLY on the outer race of the bearing
until the bearing bottoms out in the bore.
• Rear (notched) wear sleeve (4) is NOT
interchangeable with front wear sleeve (39).
The inside diameter of the rear wear sleeve is
color coded blue.
• Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from
occurring.
• Use extreme care when handling the wear
sleeve. The slightest nicks or scratches may
cause leakage.

16. Coat the inside diameter of rear (notched) wear


sleeve (4) and the wear sleeve diameter of the
fan mounting hub with Loctite Primer N and
#242 (or equivalent). Locate the sleeve so the
notch in the sleeve will be aligned with the small FIGURE 7-58.
lube hole in the shoulder. Using tooling (D),
press the wear sleeve onto the fan mounting
hub until it is flush with the shoulder.
18. Install internal snap ring (15).

C7-26 Fan Clutch C07001


FIGURE 7-59.

19. Some fan clutches were assembled with an external snap ring that is used as a spacer between the bearing
and the oil seal. Newer models were assembled using a notched spacer. If an external snap ring was used,
place snap ring (12) on top of the bearing (oil seal side). If a notched spacer was used, the spacer will be
installed in a later step. Proceed to the next step.

FIGURE 7-60.
FIGURE 7-61.

20. Coat the outside diameter of rear oil seal (10) 21. If a bearing spacer is used instead of a snap
with Loctite Primer N and #242 (or equivalent). ring (as explained in Step 19), place the spacer
Use tooling (E) or an equivalent to install the oil into position in the groove on shaft assembly
seal in the rear bearing retainer until it is flush (6). Note the location of the spacer in Figure 7-
with the rear face. 61.
Do not lubricate the seal. The seal is made of
teflon and must be installed dry.

C07001 Fan Clutch C7-27


FIGURE 7-62.
FIGURE 7-63.

23. Install external snap ring (16). Ensure that the


22. Place the shaft sub-assembly on the press bed. snap ring is fully seated in the groove. It may be
Coat the inside diameter of the bearing and the necessary to tap on the snap ring with a
bearing journal on the shaft with Loctite Primer screwdriver to fully seat it.
N and #609 (or equivalent).
Carefully, lower the rear bearing retainer sub-
assembly in place on the shaft. Do not allow the
seal lip to come in contact with the Loctite.
Ensure the notch in the bearing and the dowel
pin are aligned. If external snap ring (16) was
installed in the bearing retainer, ensure the
opening is aligned with the dowel pin.
Press the bearing onto the shaft until it reaches
the shoulder of the wear sleeve. Wipe any
excess Loctite from the assembly.
Ensure the seal lip is dry. The seal must
remain dry for proper sealing.
Spin the bearing retainer approximately 25
times to burnish the teflon seal on the wear
sleeve. Check for abnormal sounds or other
indications of contact between the retainer/seal
assembly and the bearing retainer. If FIGURE 7-64.
interference is found, remove the bearing
retainer and eliminate the point of interference.
24. Ensure that the pitot tube holes in the shaft are
clean and free of burrs and staking material to
allow the pitot tubes to fit into the holes and seat
completely to the bottom. Apply a thin coating of
Loctite Primer N and #609 (or equivalent) on
the straight end of one pitot tube (3). Coat the
tube to approximately 20 mm (0.75 in.) from the
end.

C7-28 Fan Clutch C07001


Push the pitot tubes to the bottom of the hole.
The outer end of the tube should be located well
within the pulley-locating shoulder of the
bearing retainer. Rotate the tube so the open,
bent end faces in a counterclockwise direction
and is exactly parallel to the surface of the
bearing retainer. (A large phillips-head
screwdriver inserted in the end of the tube can
be used as an alignment gage).
Install the second pitot tube in the same manner
as the first. Stake each pitot tube in three places
(at the 9, 12, and 3 o'clock positions) to prevent
the tubes from rotating in operation.

FIGURE 7-66.

26. Lubricate the seal ring grooves of piston (23)


with an oil-soluble lubricant such as engine
assembly grease. Install small seal ring (24) in
the inside groove and large seal ring (22) in the
outside groove. Refer to Figure 7-66 for proper
orientation.

FIGURE 7-65.

25. Install both hook-type seal rings (17) in the


grooves in the shaft. Rotate the rings so the slits
in the rings are 180 degrees apart from one FIGURE 7-67.
another.

27. Lubricate the external surfaces of seal rings


(22) and (24) with an oil-soluble lubricant such
as engine assembly grease. Also lubricate the
seal mating surfaces in the pulley adapter.

C07001 Fan Clutch C7-29


Do not push the piston in place. Forcing the
piston will usually cause the seal rings to be cut.
28. Carefully place the piston in the pulley. Without
pressing down on the piston, rotate it slowly
back and forth until it falls into place.

FIGURE 7-69.

30. Install spring washer (25), shim (26), and


spirolock ring (27). It will be necessary to press
downward to compress the spring washer while
forcing the spirolock to properly seat in the
groove. The shim must then be centered on the
spring washer to prevent it from interfering with
the movement of the piston.

FIGURE 7-68.

29. Align the tangs of the piston for final assembly


of the fan clutch. Lift the front bearing retainer
sub-assembly in place on the pulley. While
doing so, the slots of the front bearing retainer
will engage the tangs of the piston, and the
retainer will rest against the pulley. FIGURE 7-70.
Then, rotate the bearing retainer (and piston) 31. Place the front bearing retainer sub-assembly
until the bolt holes align in the bearing retainer on the bench with the clutch hub up. Install one
and pulley. Carefully remove the bearing steel clutch plate (31) in place in the bearing
retainer sub-assembly. retainer. Dip one facing plate (30) in new engine
oil. Allow the excess oil to drain off, then place
the facing plate on top of the steel plate.
Repeat this step until all 16 plates have been
installed.

C7-30 Fan Clutch C07001


32. Turn the pulley adapter assembly over and
install two lifting eyes 180 degrees apart. Install
a guide bolt in one bolt hole of the pulley. Refer
to Figure 7-71.
Coat front O-ring seal (34) with petroleum jelly
or an oil-soluble grease. Place the seal in the
groove in the pulley. The grease should secure
the seal in the groove during installation.
Carefully lower the pulley. Ensure that the guide
bolt is aligned with a bolt hole in the bearing
retainer assembly and the O-ring seal is still
securely in place. Lower the pulley until it rests
on the front bearing retainer.

FIGURE 7-71.

FIGURE 7-73.

33. Install at least four bolts (38) with lockwashers


(37) 90 degrees apart. Snug them down.

FIGURE 7-72.

C07001 Fan Clutch C7-31


FIGURE 7-76.

FIGURE 7-74.
36. Install bolts (9) with lockwashers (8). Tighten
each bolt to 49 - 58 N•m (36 - 43 ft lbs).
34. Lubricate O-ring seal (13) with petroleum jelly or
an oil-soluble grease and install it in the pulley
groove.

FIGURE 7-77.
FIGURE 7-75.

35. Lubricate hook-type seal rings (17) on the shaft 37. If removed, install orifice fitting (1) in the “oil in”
assembly. Carefully lower the shaft sub- port of the bracket.
assembly into the pulley bore and onto the
pulley until the retainer rests on the pulley.
Use caution when lowering. Damage to the
sleeve bearings may result if the shaft is cocked
during installation.

C7-32 Fan Clutch C07001


FIGURE 7-78.

38. Turn the assembly over on the bench. Install remaining bolts (38) and lockwashers (37). Tighten each bolt to
49 - 58 N•m (36 - 43 ft lbs).

C07001 Fan Clutch C7-33


TEST PROCEDURE

1. The fan clutch should be fully locked up with 275 kPa (40 psi) oil pressure supplied at the control pressure
port.
2. Operate the fan clutch with 82° C (180° F) oil supplied to the “oil in” port for 2 hours. Manually engage and
disengage the clutch during the test to operate seals in both modes. Restrict the fan mounting hub rotation
while the clutch is disengaged, but ensure that the fan mounting hub is allowed to rotate freely while the clutch
is engaged.

The fan clutch rotation causes the pitot tubes to pump lubricating oil from inside the fan clutch,
maintaining low internal oil pressure. If lubricating oil is supplied to the fan clutch before it is rotating in
the proper direction, internal pressures will become excessive, causing the oil seals to leak.

C7-34 Fan Clutch C07001


SECTION D
ELECTRICAL SYSTEM (24VDC NON-PROPULSION)
INDEX

24VDC ELECTRICAL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1

24VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1

BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-1

KOMTRAX PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-1

INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-1

INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . D13-1

KOMTRAX PLUS FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D14-1

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
FOLLOWED. 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.
•Never open any electrical cabinet covers or touch the retarding grid elements. Additional
procedures 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
possible 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 anyone working in the areas of the deck, electrical cabinet, traction motors, and retarding grids.
The following procedure will ensure that the electrical system is properly discharged before repairs are
begun.

D01046 5/11 Index D1-1


TRUCK SHUTDOWN PROCEDURE
1. Reduce the engine speed to idle. Place the directional control lever in PARK. Make sure that the
parking brake applied indicator light is illuminated.
2. Place the rest switch in the ON position to put the AC drive system in the rest mode. Make sure that
the rest mode indicator light is illuminated.
3. Turn the key switch to the OFF position. A timing sequence will be activated automatically to allow
the engine to cool down before it is turned off.

If the engine does not shut down with the key switch after the timing sequence is done, use the
engine shutdown switch on the operator cab center console. Pull this switch up until the engine
stops.
4. With the key switch OFF and the engine stopped, wait at least 90 seconds. Make sure that the steer-
ing circuit is completely depressurized by turning the steering wheel back and forth several times.
The front wheels should not turn when the hydraulic pressure is relieved. If the front wheels can still
be turned, notify maintenance personnel.
5. Make sure that the link voltage light in the control cabinet is off. Notify maintenance personnel if the
light remains illuminated for longer than five minutes after the engine is shut down.
6. Locate the GF cutout switch in the access panel on the left side of the main control cabinet. Place the
switch in the CUTOUT position. This will prevent the alternator from re-energizing and creating sys-
tem voltage until the switch is returned to its former position.

D1-2 Index 5/11 D01046


SECTION D2
24VDC ELECTRICAL SUPPLY SYSTEM
INDEX

24VDC ELECTRIC SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3

BATTERY SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

24VDC Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

24VDC Auxiliary Battery Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5

Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

Isolation Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

Engine Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

24VDC to 12VDC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6

24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) . . . . . . . . . . . . . . . . . . . . . D2-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7

Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7

Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7

Timer Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8

Prelube System Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8

Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8

Timer Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8

TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . D2-9

D02033 12/11 24VDC Electrical Supply System D2-1


24VDC ELECTRIC START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11

CRANKING MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-11

CRANKING MOTOR TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12

Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12

No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12

Interpreting Results of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-14

Armature Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-16

Field Coil Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-16

Field Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-16

SOLENOID CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-18

Bearing Replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-18

Motor Assembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-18

Pinion Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19

MAGNETIC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19

Coil Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-20

D2-2 24VDC Electrical Supply System 12/11 D02033


24VDC ELECTRICAL SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
The truck uses a 24VDC electrical system which
supplies power for engine starting circuits and most
non-propulsion electrical components. The 24VDC
engine starting circuit is supplied by four heavy duty,
DO NOT SMOKE or allow flame around a dead
Type 8D, 12-volt storage batteries. Several
battery or during the recharging process. The
components require 12VDC and are supplied by
expelled gas from a dead cell is extremely
circuits tapped off the starting batteries.
explosive.
The batteries are of the lead-acid type, each
Excessive consumption of water indicates leakage or
containing six 2-volt cells. With the engine off, power
overcharging. Normal water usage for a unit
is supplied by the batteries. During engine cranking,
power is supplied by the four engine cranking operating eight hours per day is about 30 to 60 cm3
batteries only. When the engine is running, power is (1 to 2 oz.) per cell per month. For heavy duty
supplied by a high capacity alternator that is driven operation (24 hours per day), normal consumption
by the engine. should run about 30 to 60 cm3 (1 to 2 oz.) per cell per
week. Any appreciable increase over these figures
should be considered a danger signal.

Troubleshooting
Two most common problems that occur in the
Lead-acid storage batteries contain sulfuric acid charging system are undercharging and
which, if handled improperly, may cause serious overcharging of the truck's batteries.
burns on skin or other serious injuries to
An undercharged battery is incapable of providing
personnel. Wear protective gloves, aprons and
sufficient power to the truck's electrical system.
eye protection when handling and servicing lead-
acid storage batteries. See the precautions in Some possible causes for an undercharged battery
Section A of this manual to ensure proper are:
handling of batteries and accidents involving
• Sulfated battery plates
sulfuric acid.
• Loose or corroded battery connections
During operation, the storage batteries function as an
electrochemical device that converts chemical • Defective wire in electrical system
energy into the electrical energy that is required for • Loose alternator drive belt
operating the accessories when the engine is off.
• Defective alternator
Overcharging, which causes overheating, is first
indicated by excessive use of water. If allowed to
BATTERIES
continue, the cell covers will push up at the positive
Maintenance and Service ends and, in extreme cases, the battery container will
become distorted and cracked.
The electrolyte level of each cell should be checked
at the interval specified in Section P, Lubrication and Leakage can be detected by continual wetness of the
Service. Add water if necessary. The proper level to battery or excessive corrosion of the terminals,
maintain is 10 to 13 mm (3/8 to 1/2 in.) above the battery carrier and surrounding area. (A slight
plates. To ensure maximum battery life, use only amount of corrosion is normal in lead-acid batteries).
distilled water or other types of water recommended Inspect the case, covers and sealing compound for
by the battery manufacturer. After adding water in holes, cracks and other signs of leakage. Check the
freezing weather, operate the engine for at least 30 battery hold down connections to ensure that the
minutes to thoroughly mix the electrolyte. tension is not great enough to crack the battery or
loose enough to allow vibration to open the seams. A
leaking battery must be replaced.

D02033 12/11 24VDC Electrical Supply System D2-3


To remove corrosion, clean the battery with a solution The rate of self-discharge of a battery kept at 38°C
of ordinary baking soda and a stiff, non-wire brush (100°F) is about six times that of a battery kept at
and flush with clean water. Make sure that none of 10°F (50°F), and self-discharge of a battery kept at
the soda solution is allowed to enter the battery cells. 27°C (80°F) is about four times that one at 10°F
Make sure that the terminals are clean and tight. (50°F). Over a 30 day period, the average self-
Clean terminals are very important in a voltage discharge runs about 0.002 specific gravity per day
regulated system. Corrosion creates resistance in at 27°C (80°F).
the charging circuit, which causes undercharging and
To offset the results of self-discharge, idle batteries
gradual starvation of the battery.
should receive a booster charge (not a quick charge)
NOTE: When washing batteries, make sure that the at least once every 30 days. Batteries allowed to
cell caps are tight to prevent cleaning solution from stand for long periods in a discharged condition are
entering the cells. attacked by a crystallization of the lead sulfate on the
plates. Such batteries are called “sulfated” and are,
Addition of acid will be necessary if considerable
in the majority of cases, irreparably damaged. In less
electrolyte has been lost through spillage. Before
severe cases, the sulfated battery may be restored to
adding acid, make sure that the battery is fully
limited service by prolonged charging at a low rate
charged by putting the battery on charge and taking
(approximately 1/2 normal rate).
hourly specific gravity readings on each cell. When
all the cells are gassing freely and three successive An undercharged battery is extremely susceptible to
hourly readings show no rise in specific gravity, the freezing when allowed to stand in cold weather.
battery is considered charged. Additional acid may
The electrolyte of a battery in various stages of
now be added. Continue charging for another hour
charge will start to freeze at temperatures indicated
and check specific gravity again. Repeat the above
in the table below.
procedure until all cells indicate a specific gravity of
1.260 - 1.265 corrected to 27°C (80°F). The temperatures in the table below indicate the
points at which the first ice crystals appear. Lower
NOTE: Use 1.400 strength sulfuric acid when making
temperatures must be reached for a solid freeze.
specific gravity adjustments. Acid of higher strength
Solid freezing of the electrolyte may crack the battery
will attack the plates and separators before it has a
case and damage the positive plates. As will be
chance to diffuse into the solution.
noted, a charged battery is in no danger of freezing.
If the temperature of the electrolyte is not reasonably Therefore, a battery should be kept charged,
close to 27°C (80°F) when the specific gravity is especially during winter weather.
taken, temperature should be corrected to 27°C
(80°F) as follows:
• For every 5°C (10°F) below 27°C (80°F), 0.004
should be SUBTRACTED from the specific
SPECIFIC GRAVITY FREEZING
gravity reading.
Corrected to 27°C (80°F) TEMPERATURE
• For every 5°C (10°F) above 27°C (80°F), 0.004
1.280 -70°C (-90°F)
should be ADDED to the reading.
1.250 -54°C (-60°F)
Idle batteries should not be allowed to stand
unattended. If equipment is to stand unused for more 1.200 -27°C (-16°F)
than two weeks, the batteries should be removed 1.150 -15°C (+5°F)
and placed in a cool, dry place where they may be 1.100 -7°C (+19°F)
checked periodically and charged when necessary.
Remember, all lead-acid batteries discharge slowly
when not in use. This self-discharge takes place
even though the battery is not connected in a circuit,
and it is more pronounced in warm weather than in
cold weather.

D2-4 24VDC Electrical Supply System 12/11 D02033


BATTERY SUPPLY SYSTEM 24VDC Auxiliary Battery Receptacles
Two receptacles (2) are provided to attach battery
24VDC Battery Charging Alternator
charger leads for charging the batteries. These
Refer to Section D, Battery Charging Alternator, for receptacles can also be used for connecting external
service information regarding the battery charging batteries to aid engine starting during cold weather.
alternator.
When external batteries are used, they should be of
Batteries the same type (8D) as the batteries installed on the
truck. Two pairs of batteries should be used. Each
Four type 8D batteries (3, Figure 2-1) for the 24VDC pair should be connected in series to provide 24VDC,
engine start circuit are located in the battery box in with one pair connected to each receptacle.
the center of the front platform.
For access to the batteries, open the hinged cover by
turning cover latches (1) counterclockwise until
released. Lifting eyes are attached to each end of the
battery box so that the entire battery box assembly
can be removed, if necessary.

FIGURE 2-1. BATTERY BOX COMPONENTS


1. Battery Box Cover Latch 4. Battery Control Box 7. Starter Disconnect Switch
2. Auxiliary Battery Receptacles 5. Circuit Breaker (50 amp) 8. Master Disconnect Switch
3. Batteries 6. Engine Start Relay 9. Isolation Diode

D02033 12/11 24VDC Electrical Supply System D2-5


Battery Disconnect Switches
Battery disconnect switches provide a convenient
method of disconnecting the truck batteries from the
truck electrical circuits without having to remove any
battery cables. Starter disconnect switch (7, Figure 2-
1) opens the starter battery circuit only, preventing
engine startup while still allowing battery power to the
24VDC control system circuits. Master disconnect
switch (8) disconnects the 24VDC system batteries.

Isolation Diode
A Schottky type isolation diode is used to provide
isolation between the electrical system battery
circuits and the dual starter motor start command
circuits. This device controls the direction of current
flow in high current applications. Isolation diode (9)
allows current from the battery charging alternator to
charge the batteries, but prevents current flow from
the batteries to the starter motors when the engine is
started.
NOTE: The isolation diode is no longer available for
service. If the isolation diode must be replaced, order
battery box rework kit (XK0965), which includes a
second engine start relay.

Engine Start Relay


Engine start relay (6) receives the signal to begin
cranking from the start relay located on relay board
RB6. When the engine start relay is activated, it
provides current to the starter motors to engage the
drives and begin cranking the engine, eliminating the FIGURE 2-2. AUXILIARY CONTROL CABINET
need for magnetic switches. (LEFT WALL)

24VDC to 12VDC Converter 1. 24VDC to 12VDC Converter

24VDC to 12VDC converter (1, Figure 2-2) is used to


convert the 24 volt battery system voltage to 12 volts
for various truck components such as the radio, cab
power windows, and the auxiliary power receptacles
in the cab.
The converter is powered by the starter circuit
batteries. Converter output circuits are protected by
CB101, a 50 amp circuit breaker (5, Figure 2-1)
located inside the battery control box.

D2-6 24VDC Electrical Supply System 12/11 D02033


24VDC ELECTRIC CRANKING MOTOR
SYSTEM (WITH PRELUBE)
The Komatsu SDA16V160 engine includes an
engine pre-lubrication system designed to reduce
wear due to dry starts.
The prelube system automatically, safely and quickly
fills filters and all oil passages prior to cranking at
each engine startup. In addition, the system prevents
startup if no oil is present in the engine.
The prelube system includes:
• Remote mounted 24VDC powered pump
• Timer solenoid
• Oil pressure switch
• Oil suction line
• Oil outlet line
• Check valve FIGURE 2-3. ENGINE OIL PRESSURE
• Electrical harness MANIFOLD
1. Engine Prelube Relay 3. Prelube Pressure
2. Timer Solenoid Switch
Operation
The prelube system is activated when the operator
turns the key switch and holds it in the START posi- Check Valve
tion. This allows the current to flow to prelube timer
solenoid (2, Figure 2-3). When this timer solenoid is The oil pressure supply hose will have a check valve
activated, current flows to the prelube motor, driving installed between the prelube pump and the engine.
the prelube pump, but does not allow the cranking The check valve prevents the passage of oil from the
motor motors to engage the cranking motor pinion engine back through the prelube pump to the pan
gears at this time. The prelube pump supplies oil after the engine is started. Check valve leakage back
from the engine oil pan to fill the engine oil filters and to the prelube pump will cause extensive damage to
oil passages prior to cranking. the pump.
When the pressure in the engine cam oil rifle reaches
17.2 kPa (2.5 psi), the circuit to the prelube timer
solenoid is opened. After a three second delay, the Timer Solenoid
current is supplied to the cranking motor solenoids. Timer solenoid (2) controls the prelubrication cycle.
The cranking motor motors will then be activated and Current is supplied to the timer through the key
the pinion gears will be engaged into the flywheel switch. The ground path is completed by the normally
ring gear. Normal cranking will now occur with suffi- closed pressure switch (3).
cient lubrication to protect the engine bearings and
other components. When the switch opens, current is redirected to the
engine cranking motor solenoids for engine cranking.

Pressure Switch
Pressure switch (3) is a 17.2 kPa (2.5 psi), normally
closed (N.C.) switch, located so that it can sense oil
pressure after the engine oil has passed through the
DO NOT attempt to jump start the truck using the
filters. (Normally, this location is the cam cover at the
terminals on the timer solenoid. Internal damage
rear of the engine block.)
to the timer will result.

D02033 12/11 24VDC Electrical Supply System D2-7


MAINTENANCE
Prelube system maintenance must be performed
annually or at 5000 hour intervals as described
below.

Prelube System Operation Checks


Verify system operates according to the two phases
of operation as listed in “Troubleshooting Prelube
Cranking Motor Circuit” on the following page. If a
problem exists, refer to the list of problems and pos-
sible causes for troubleshooting system components.
If system is operating properly, continue with the
inspection of component parts below:

Check Valve
Verify that no internal leakage exists in the check
valve when the engine is running. Check valve leak-
age back to the prelube pump will cause extensive
damage to the pump.
If check valve replacement is required, ensure the
valve is installed with the arrow pointed toward the
engine, and NOT toward the pump.

Timer Solenoid
Inspect the timer solenoid for physical damage and
to verify wiring is in good condition.

D2-8 24VDC Electrical Supply System 12/11 D02033


TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT
Two distinct phases are involved in a complete prelubrication cycle. The two phases are:
1. Prelubrication Phase- Begins when the key switch is held in the START position. A circuit is provided to
ground through the normally closed pressure switch. The circuit is interrupted upon opening of the pressure
switch when the prelube pressure reaches 17.2 kPa (2.5 psi).
2. Delay and Crank Phase- Begins when the pressure switch opens. A three second delay precedes the crank
mode.
Problem Probable Cause
• Cranking motor prelubricates only. Does not delay Indicates oil pressure is not sufficient to open the pres-
or crank. sure switch.
a. No oil or low oil in engine. The pump can not
build sufficient pressure to open switch.
b. Pump failure.
c. Pressure switch has failed (closed) and is
grounding circuit.
d. Oil pressure switch wire chafed and shorting to
block.
• Cranking motor prelubricates continuously Indicates prelube timer solenoid contacts have welded.
regardless of key switch position.
a. Low voltage can cause relay failure.
b. Jump starting of the vehicle with a voltage that
is higher than was designed for the system,
can cause solenoid contacts to weld.

• Cranking motor delays and cranks. No If an operator indicates the ignition is totally dead,
prelubrication mode. ensure the key is being held in the crank position for 3
to 4 seconds. If the engine cranks after a short delay,
this indicates that a ground connection to the pressure
switch has been broken. Without a ground path, the
prelubrication unit will proceed to delay and crank.
a. Check the wire to the pressure switch. If the
wire is removed or cut, replace it.
b. Check the ground strap to engine block. If the
ground strap is missing the block is not
grounded.
c. Check the pressure switch for an open circuit.
Remove the wire, then check for an open cir-
cuit between the switch terminal and the
switch base. If open, replace pressure switch.

• Starting circuit is irregular when in crank mode. a. Check for low or dead batteries.
b. Check alternator output.
c. Check ground connection at “G” terminal of
cranking motor bendix solenoid.
d. Check for defective cranking motor safety
relays.
e. If everything checks OK, replace batteries.
NOTE: Maximum allowable voltage drop is - 2
volts for cranking motor control circuit.

D02033 12/11 24VDC Electrical Supply System D2-9


Problem Probable Cause
• Cranking motor has very long prelubrication cycle. Except for severe cold weather starts, the prelube
cycle must not exceed 45 seconds.
a. Low oil pressure.
b. Ensure oil of the proper viscosity is being
used in respect to outside temperature. (Refer
to engine manufacturer's specifications).
c. Check for suction side air leaks, loose con-
nections, cracked fittings, pump casting, or
hose kinks and blockage.
d. Check the oil pressure switch for the correct
location. Be certain that it has not been
moved into a metered oil flow, as in a bypass
filter or governor assembly.

• Cranking motor has no prelubrication, no delay If the cranking motor is totally inoperative and no pre-
and no crank. lubrication, no delay and crank, this indicates a possi-
ble failure of the prelubrication timer solenoid.
Remove the wire from the pressure switch (ground
wire) and activate the key switch for several seconds.
a. If the cranking motor delays - then cranks, the
Prelube Timer Solenoid is bad. Replace the
timer solenoid assembly.
b. If the cranking motor is still inoperative, check
the truck cranking motor switch circuit. Ensure
proper voltage is available to the Prelube
Timer Solenoid when the key is activated.

• Cranking motor prelubricates, delays, then does Indication is either a timer failure, or a cranking motor
not crank. problem.
a. Place a jumper wire to the cranking motor
solenoid “S” post. If the engine starts to crank,
replace the Prelube Timer Solenoid.
b. If the engine fails to crank when the "S" post
is energized with voltage, check out cranking
motor bendix solenoid and cranking motor
pinion drive.

D2-10 24VDC Electrical Supply System 12/11 D02033


24VDC ELECTRIC START SYSTEM
CRANKING MOTORS
Operation
Heavy duty batteries supply 24VDC to each of the
two cranking motors through magnetic switches acti-
vated by the key switch on the instrument panel.
NOTE: When a Komatsu SDA16V160 engine with a
prelube system is installed, there is a delay between
the time the key switch is moved to the START
position, and the cranking motors actuate.
When the key switch is placed in the START position,
the magnetic switches close, connecting the motor
solenoid “S” terminals to the batteries. When the
solenoid windings are energized, plunger (56,
Figure 2-6) is pulled in, moving cranking motor drive
assembly (71) forward in the nose housing to engage
the engine flywheel ring gear. Also, when the sole-
noid plunger is pulled in, the main solenoid contacts
close to provide current to the motor armature and
cranking takes place. When the engine starts, an
overrunning clutch in the drive assembly protects the
FIGURE 2-4. CRANKING MOTORS
armature from excessive speed until the key switch is
released. When the key switch is released, a return 1. Cap Screws 3. Solenoid
spring causes the drive pinion to disengage. 2. Cranking Motor

After the engine is running, a normally closed pres-


sure switch senses engine oil pressure and opens
the electrical circuit to prevent actuation of the
motor(s) after the engine has started.
Installation
Removal
1. Align cranking motor (2, Figure 2-4) housing
1. Disconnect battery power: with the flywheel housing adaptor mounting
a. Open the master battery disconnect switch holes and slide the cranking motor into position.
to remove power from the system. 2. Insert cranking motor cap screws (1).
b. Disconnect the negative (-) battery cables 3. Connect marked wires and cables to the crank-
first. ing motor and solenoid terminals.
4. Install in the following sequence:
c. Disconnect the battery positive (+) battery
cables last. a. Connect the battery positive (+) cables first.
2. Mark wires and cables and remove them from b. Connect the battery negative (-) cables.
the terminals on cranking motor (2, Figure 2-4) 5. Close the master battery disconnect switch.
and solenoid (3).
3. Remove cranking motor cap screws (1).
4. Remove the cranking motor assembly from fly-
wheel housing.

D02033 12/11 24VDC Electrical Supply System D2-11


CRANKING MOTOR TROUBLESHOOTING
If the cranking system is not functioning properly,
check the following to determine which part of the
system is at fault:
 Batteries -- Verify the condition of the
batteries, cables, connections and charging
circuit.
 Wiring -- Inspect all wiring for damage or
loose connections at the key switch,
magnetic switches, solenoids and cranking
motor(s). Clean, repair or tighten as
required.
If the above inspection indicates the cranking motor
to be the cause of the problem, remove the motor
and perform the following tests prior to disassembly
to determine the condition of the motor and solenoid
and repairs required.
FIGURE 2-5. NO-LOAD TEST CIRCUIT
Preliminary Inspection
1. Check the cranking motor to ensure that the
armature turns freely.
a. Insert a flat blade screwdriver through the
opening in the nose housing.
DO NOT apply voltages in excess of 20 volts.
b. Pry the pinion gear to ensure that the arma- Excessive voltage may cause the armature to
ture can be rotated. throw windings.
2. If the armature does not turn freely, the cranking d. Connect the motor and an ammeter in series
motor must be disassembled immediately. with two fully charged 12 volt batteries.
3. If the armature can be rotated, perform the No-
e. Connect a switch in the open position from
Load Test before disassembly.
the solenoid battery terminal to the solenoid
No-Load Test switch terminal.
2. Close the switch and compare the RPM, cur-
Refer to Figure 2-5 for the following test setup. rent, and voltage reading to the following speci-
fications:
 RPM: 5500 Minimum to 7500 Maximum
 AMPS: 95 Minimum to 120 Maximum
Make sure that the master battery disconnect  VOLTS: 20VDC
switch is open before connections or disconnec-
tions are made during the following procedures.
1. Setup the motor for test as follows:
a. Connect a voltmeter from the motor terminal
to the motor frame.
b. Use an RPM indicator to measure armature
speed.
c. Connect a carbon pile across one battery to
limit battery voltage to 20VDC.

D2-12 24VDC Electrical Supply System 12/11 D02033


Interpreting Results of Tests Disassembly
1. Rated current draw and no-load speed indi- The cranking motor must be disassembled only as
cates normal condition of the cranking motor. far as necessary to repair or replace defective parts.
2. Low free speed and high current draw indi- 1. Note the relative position of the solenoid (53,
cates: Figure 2-6), lever housing (78), nose housing
a. Too much friction; tight, dirty, or worn bear- (69), and C.E. frame (1) so the motor can be
ings, bent armature shaft or loose pole shoes reassembled in the same manner.
allowing armature to drag. 2. Disconnect field coil connector (42) from sole-
b. Shorted armature. This can be further noid motor terminal, and lead from solenoid
checked on a growler after disassembly. ground terminal.
3. Remove the brush inspection plug (52), and
c. Grounded armature or fields. Check Further
brush lead screws (15).
after disassembly.
4. Remove the attaching bolts (34) and separate
3. Failure to operate with high current draw indi-
the commutator end frame (1) from the field
cates:
frame (35).
a. A direct ground in the terminal or fields. 5. Separate the nose housing (69) and field frame
b. “Frozen” bearings (are determined by turning (35) from lever housing (78) by removing
the armature by hand). attaching bolts (70).
4. Failure to operate with no current draw indi- 6. Remove armature (45) and drive assembly (71)
cates: from lever housing (78).
a. Open field circuit. This can be checked after 7. Separate solenoid (53) from lever housing by
disassembly by inspecting internal connec- pulling apart.
tions and tracing circuit with a test lamp.
b. Open armature coils. Inspect the commuta-
tor for badly burned bars after disassembly.
c. Broken brush springs, worn brushes, high
insulation between the commutator bars or
other causes which would prevent good con-
tact between the brushes and commutator.
5. Low no-load speed and low current draw indi-
cates:
a. High internal resistance due to poor connec-
tions, defective leads, dirty commutator and
causes listed under Number 4.
6. High free speed and high current draw indicates
shorted fields. If shorted fields are suspected,
replace the field coil assembly and check for
improved performance.

D02033 12/11 24VDC Electrical Supply System D2-13


Cleaning and Inspection
1. Drive (71, Figure 2-6), armature (45) and fields FIGURE 2-6 CRANKING MOTOR ASSEMBLY
(46) must not be cleaned in any degreasing
tank or with grease dissolving solvents. These 1. C.E. Frame 52. Inspection Plug
will dissolve the lubricant in the drive and dam- 2. Washers 53. Solenoid Housing
age the insulation in the armature and field 3. O-Rings 54. Lockwasher
coils. 4. Insulator 55. Screw
2. All parts except the drive must be cleaned with 5. Support Plate 56. Plunger
mineral spirits and a clean cloth. 6. Brush Plate Insulator 57. Washer
7. Washers 58. Boot
3. If the commutator is dirty, it may be cleaned with 8. Plate & Stud 59. Washer
No. 00 sandpaper. 9. Plate 60. Spring
NOTE: DO NOT use an emery cloth to clean the 10. Brush Holder 61. Retainer
commutator. 11. Lockwasher 62. Snap Ring
4. Inspect brushes (13) for wear. 12. Screw 63. Shift Lever
13. Brush (12 required) 64. Nut
a. If worn excessively when compared with a 14. Lockwasher 65. O-Ring
new brush, they must be replaced. 15. Screw 66. O-Ring
b. Ensure that the brush holders (10) are clean 16. Brush Spring 67. Snap Ring
and the brushes are not binding in the hold- 17. Screw 68. Lever Shaft
ers. 18. Screw 69. Drive Housing
19. Screw 70. Screw
c. The full brush surface must ride on the com- 20. Lockwashers 71. Drive Assembly
mutator. Check by hand to insure that brush 21. Plate 72. Gasket
springs (16) are giving firm contact between 22. Brush Holder Insulator 73. Plug
brushes (13) and commutator. 23. Screw 74. Gasket
d. If springs (16) are distorted or discolored, 24. Lockwasher 75. Brake Washer
they must be replaced. 25. Washer 76. Screw
26. O-Ring 77. Lockwasher
27. Bushing 78. Lever Housing
28. Insulator 79. Washer
29. Washer 80. O-Ring
30. Lockwasher
31. Nut
32. Nut
33. Lockwasher
34. Screw
35. Field Frame
36. Stud Terminal
37. Bushing
38. Gasket
39. Washers
40. Washers
41. Nut
42. Connector
43. Lockwasher
44. Nut
45. Armature
46. Field Coil
47. Shoe
48. Insulator
49. Screw
50. Washer
51. O-ring

D2-14 24VDC Electrical Supply System 12/11 D02033


FIGURE 2-6. CRANKING MOTOR ASSEMBLY

D02033 12/11 24VDC Electrical Supply System D2-15


Armature Servicing 3. Grounds in the armature can be detected by the
use of a 110-volt test lamp and test points. If the
If the armature commutator is worn, dirty, out of
lamp lights when one test point is placed on the
round, or has high insulation, the armature (45,
commutator with the other point on the core or
Figure 2-6) must be put on a lathe and the commuta-
shaft, the armature is grounded. Grounds occur
tor turned down. The insulation must then be under-
as a result of insulation failure which is often
cut 0.79 mm (0.031 in.) wide and 0.79 mm (0.031 in.)
brought about by overheating of the cranking
deep, and the slots cleaned out to remove any trace
motor produced by excessively long cranking
of dirt or copper dust. As a final step in this proce-
periods or by accumulation of brush dust
dure, the commutator must be sanded lightly with No.
between the commutator bars and the steel
00 sandpaper to remove any burrs left as a result of
commutator ring.
the undercutting procedure.
Check the armature for opens, short circuits and
grounds as follows: Field Coil Checks
1. Opens are usually caused by excessively long
Field coils (46, Figure 2-6) can be checked for
cranking periods. The most likely place for an
grounds and opens by using a test lamp.
open to occur is at the commutator riser bars.
Inspect the points where the conductors are 1. Grounds - The ground connections must be
joined to the commutator bars for loose connec- disconnected during this check. Connect one
tions. Poor connections cause arcing and burn- lead of the 110-volt test lamp to field frame (35)
ing of the commutator as the cranking motor is and the other lead to field connector (42). If the
used. If the bars are not too badly burned, lamp lights, at least one field coil is grounded
repair can often be effected by resoldering or and must be repaired or replaced.
welding the leads in the riser bars (using rosin 2. Opens - Connect test lamp leads to ends of
flux), and turning down the commutator in a field coils (46). If lamp does not light, the field
lathe to remove the burned material. The insula- coils are open.
tion must then be undercut.
2. Short circuits in the armature are located by use
of a growler. When the armature is revolved in Field Coil Removal
the growler with a steel strip such as a hacksaw
blade held above it, the blade will vibrate above Field coils can be removed from the field frame
the area of the armature core in which the short assembly by using a pole shoe screwdriver. A pole
circuit is located. Shorts between bars are shoe spreader must also be used to prevent distor-
sometimes produced by brush dust or copper tion of the field frame. Careful installation of the field
between the bars. These shorts can be elimi- coils is necessary to prevent shorting or grounding of
nated by cleaning out the slots. the field coils as the pole shoes are tightened into
place. Where the pole shoe has a long lip on one
side and a short lip on the other, the long lip must be
assembled in the direction of armature rotation so it
becomes the trailing (not leading) edge of the pole
shoe.

D2-16 24VDC Electrical Supply System 12/11 D02033


5. To check for grounds, move battery lead from
“G” (Figure 2-8) and from “MTR” (Figure 2-9) to
the solenoid case. Ammeter must read zero. If
not, the winding is grounded.

FIGURE 2-7. SIMPLIFIED SOLENOID CIRCUIT

SOLENOID CHECKS
A basic solenoid circuit is shown in Figure 2-7. Sole-
noids can be checked electrically using the following
procedure.

Test
1. With all leads disconnected from the solenoid,
make test connections as shown to the sole- FIGURE 2-8. SOLENOID HOLD-IN WINDING TEST
noid, switch terminal and to the second switch
terminal “G”, to check the hold-in winding
(Figure 2-8).
2. Use the carbon pile to decrease the battery volt-
age to 20 volts. Close the switch and read cur-
rent.
 The ammeter must read 6.8 amps
maximum.
3. To check the pull-in winding, connect from the
solenoid switch terminal “S” to the solenoid
motor “M” or “MTR” terminal (Figure 2-9).

To prevent overheating, DO NOT leave the pull-in


winding energized more than 15 seconds. The
current draw will decrease as the winding tem-
perature increases.
4. Use the carbon pile to decrease the battery volt-
age to 5 volts. Close the switch and read cur-
rent.
 The ammeter must read 9.0 to 11.5 amps.
NOTE: High readings indicate a shorted winding. FIGURE 2-9. SOLENOID PULL-IN WINDING
Low readings indicate excessive resistance. TEST

D02033 12/11 24VDC Electrical Supply System D2-17


Assembly
Lubricate all bearings, wicks and oil reservoirs with
SAE No. 20 oil during assembly.

Bearing Replacement:
1. If any of the bronze bearings are to be replaced,
dip each bearing in SAE No. 20 oil before
pressing into place.
2. Install a wick, soaked in oil, prior to installing the
bearings.
3. DO NOT attempt to drill or ream sintered bear-
ings. These bearings are supplied to size. If
drilled or reamed, the I.D. will be too large and
the bearing pores will seal over.
4. DO NOT cross-drill bearings. Because the
bearing is so highly porous, oil from the wick
touching the outside bearing surface will bleed
through and provide adequate lubrication.
5. The middle bearing is a support bearing used to
prevent armature deflection during cranking.
The clearance between this bearing and the
armature shaft is large compared to the end
frame bearings.

Motor Assembly:
1. Install the end frame (with brushes) onto the
field frame as follows:
FIGURE 2-10. PINION CLEARANCE CHECK
a. Insert armature (45, Figure 2-6) into field CIRCUIT
frame (35). Pull the armature out of the field
frame just far enough to permit the brushes
to be placed over the commutator.
b. Place end frame (1) on the armature shaft.
Slide the end frame and armature into place 5. Using new gasket (72), install drive housing
against the field frame. (69) and secure it with screws (70).
c. Insert screws (34) and washers (33) and 6. Assemble field coil connector (42) to the sole-
tighten securely. noid.
2. Assemble lever (63) into lever housing (78) If 7. Adjust the pinion clearance per instructions on
removed. the following page.
3. Place washer (79) on the armature shaft and 8. After the pinion clearance has been adjusted,
install new O-ring (80). Position drive assembly install gasket (74) and plug (73).
(71) in lever (63) in the lever housing. Apply a
light coat of lubricant (Delco Remy Part No.
1960954) on washer (75) and install it over the
armature shaft. Align the lever housing with the
field frame and slide the assembly over the
armature shaft. Secure it with screws (76) and
washers (77).
4. Assemble and install the solenoid assembly
through the lever housing and attach it to the
field frame. Install nut (64), but do not tighten at
this time. Install brush inspection plugs (52).

D2-18 24VDC Electrical Supply System 12/11 D02033


MAGNETIC SWITCH
The magnetic switch is a sealed unit and not repair-
able.

FIGURE 2-11. CHECKING PINION CLEARANCE

FIGURE 2-12. MAGNETIC SWITCH ASSEMBLY

Pinion Clearance Removal


To adjust the pinion clearance, follow the steps listed 1. Remove battery power as described in Crank-
below. ing Motor Removal.
1. Make connections as shown in Figure 2-10. 2. Disconnect the cables from the switch terminals
and the wires from coil terminals (Figure 2-12).
2. Momentarily flash a jumper lead from terminal
“G” to terminal “MTR”. The drive will now shift NOTE: If the magnetic switch being removed has a
into cranking position and remain so until the diode across the coil terminals, mark the leads prior
batteries are disconnected. to removal to ensure correct polarity during
3. Push the pinion or drive back towards the com- installation.
mutator end to eliminate slack movement. 3. Remove the mounting cap screws and wash-
4. The distance between the drive pinion and ers. Remove the switch from the mounting
housing must be between 8.3 mm to 9.9 mm bracket.
(0.330 to 0.390 in.) as shown in Figure 2-11. 4. The switch coil circuit can be tested as
5. Adjust clearance by turning shaft nut (64, described on the next page.
Figure 2-6).
Installation
1. Attach the magnetic switch to the mounting
bracket using the cap screws and lockwashers
removed previously.
2. Inspect the cables and switch terminals. Clean
as required and install the cables.
3. Install the diode across the coil terminals.
Ensure that diode polarity is correct. Attach the
wires from the truck harness to the coil termi-
nals (See Figure 2-5).
4. Connect battery power as described in Crank-
ing Motor Installation.

D02033 12/11 24VDC Electrical Supply System D2-19


Coil Test
1. Using an ohmmeter, measure the coil resis-
tance across the coil terminals.
a. The coil must read approximately 28 at
22.2°C (72°F).
b. If the ohmmeter reads , the coil is open
and the switch must be replaced.
c. If the ohmmeter reads 0 , the coil is shorted
and the switch must be replaced.
2. Place one of the ohmmeter probes on a coil ter-
minal and another on the switch mounting
bracket. If the meter displays any resistance
reading, the coil is grounded and the switch
must be replaced.
3. The ohmmeter must display when the probes
are placed across the switch terminals.
NOTE: The switch terminals will show continuity
when 24VDC is applied to the coil terminals.
However, high resistance across the internal switch
contacts due to arcing, etc, could prevent the switch
from delivering adequate current to the cranking
motor. If the coil tests are satisfactory but the switch
is still suspect, it must be replaced with a new part.

D2-20 24VDC Electrical Supply System 12/11 D02033


SECTION D3
24VDC ELECTRICAL SYSTEM COMPONENTS
INDEX

TRUCK SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

BRAKE WARNING BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

AUXILIARY CONTROL CABINET COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

Power Distribution Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

Engine Starter Failure Delay Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3

5 Minute Idle Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Pulse Voltage Modulator (PVM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Auto Lube Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Control Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4

Diode Board - DB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6

Fuse Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7

Alarm Indicating Device (AID) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7

RELAY BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10

Relay Boards RB1, RB3, RB4, RB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10

Relay Boards RB6, RB7, RB8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11

Relay Board Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-13

BODY-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15

HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16

FUSE BLOCKS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-17

CIRCUIT BREAKERS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-18

D03035 10/08 24VDC Electrical System Components D3-1


NOTES

D3-2 24VDC Electrical System Components 10/08 D03035


24 VDC ELECTRICAL SYSTEM COMPONENTS
AUXILIARY CONTROL CABINET
COMPONENTS
The following 24VDC electrical system components
are located in the auxiliary control cabinet, which is
Do not attempt repairs until the truck is properly mounted on the left side of the main control cabinet
shut down. Dangerous voltage levels are present behind the cab. The auxiliary control cabinet houses
in the propulsion system while the engine is various components for the 24VDC circuits, engine
running and for a period of time after shutdown. related devices, and terminal strips that connect truck
Refer to the Index in Section D for additional wiring harnesses with the main control cabinet and
warnings. cab.
The following information describes the components
TRUCK SHUTDOWN PROCEDURE in the auxiliary control cabinet and their operation.
1. Reduce the engine speed to idle. Move the Additional detailed information for operation and
directional control lever in PARK. Make sure troubleshooting procedures not included below can
that the parking brake applied indicator light in be found in Section E, Electrical Propulsion System,
the overhead panel is illuminated. the engine manufacturer's service publications, and
the appropriate GE publications. The electrical
2. Place the drive system in the rest mode by
schematics in Section R should be used when
turning the rest switch on the instrument panel
troubleshooting problems with the following 24VDC
ON. Make sure that the rest mode indicator light
electrical system components.
is illuminated.
3. Shut down the engine using the key switch. If,
for some reason the engine does not shut
down, use the shutdown switch on the center
console. Power Distribution Terminals
4. Verify the link voltage lights on the electrical 24VDC terminal (1, Figure 3-1) and 12VDC terminal
cabinet and next to the DID panel in the cab are (2) are mounted on the left wall of the cabinet. These
OFF. If they remain on longer than 5 minutes terminals distribute battery voltage and 12VDC for
after shutdown, the propulsion system must be devices requiring reduced voltage. The 24VDC
inspected by a technician trained to investigate terminal is a convenient test point for measuring
the cause. battery voltage during troubleshooting procedures.
5. Place the GF cutout switch in the CUTOUT
position throughout test and troubleshooting
procedures.
Engine Starter Failure Delay Timer
6. Verify that the steering accumulators have bled
down by attempting to turn the steering wheel. Engine starter failure delay timer (3) is used in the
circuitry which detects a failure of one of the two
starter motors. This circuit provides a warning to the
operator if either starter does not energize for at least
BRAKE WARNING BUZZER 2 seconds when engine starting is first attempted, or
The brake warning buzzer provides an audible alarm if either starter stops operating during the engine
for the operator if a malfunction occurs in the starting process.
hydraulic service brake system. This buzzer is
located inside the radio module in the overhead
panel. Refer to Section J for additional details.

D03035 10/08 24VDC Electrical System Components D3-3


5 Minute Idle Timer Test the 5 minute idle timer circuits as follows:
5 minute idle timer (4) is activated when the operator 1. With the key switch ON, press the engine
presses the 5 minute idle timer engine shutdown shutdown switch firmly to the momentary
switch on the instrument panel. (This is a momentary position and release (switch will return to the
switch that also latches the 5 minute idle timer in the ON position).
energized position.) When the timer is energized, 2. Turn the key switch OFF and verify the
internal contacts close and energize the relay. following:
The 5 minute idle timer circuit automatically provides  Circuit 712 (to ground) remains 24 volts for
approximately five minutes of engine idle time before approximately 5 minutes. After 5 minutes,
actual engine shutdown occurs. This system allows the voltage drops to 0.
the engine cooling system to circulate coolant to
reduce and stabilize engine component  The 5 minute idle indicator lamp on the
overhead display is ON when circuit 712
temperatures, when engine power requirements are
reads 24 volts.
minimal, resulting in extended engine life.
3. Repeat Step 1. While monitoring voltage at
The circuit is controlled by a 3-position rocker switch. circuit 712, turn the key switch OFF. Turn the
Pressing the bottom of the switch will turn the circuit engine shutdown switch off.
OFF. The engine will shut down by use of the key
switch, console mounted engine shutdown switch, or  Verify that the voltage at circuit 712 drops to
0 when the shutdown switch is turned to
the ground level shutdown switch.
OFF.
With the rocker switch in the middle position, the
circuit is ON, but does not activate the 5 minute idle
timer circuit. The engine can be shut down
Pulse Voltage Modulator (PMV)
immediately using any one of the three switches
described above. The Pulse Voltage Modulator (6) receives a load
curve signal from the engine controls and converts it
When the top of the switch is depressed and held
to a 0 to 10 volt signal for use by a PSC card in the
momentarily, the idle timer circuit is activated. When
Integrated Control Panel (ICP).
released, the switch will return to the ON (middle)
position, and the 5 minute idle timer circuit is latched
on through the switch. The 5 minute idle timer
indicator lamp on the overhead display will also Control Power Relay
illuminate. The engine will not shut down with the key
switch. Moving the key switch to the OFF position, Control power relay (8) is energized when the control
will cause the engine to shut down after the 5 minute power switch, located in the main control cabinet, is
time delay is completed. The normal shutdown turned ON. This relay isolates the GE control power
sequence will then occur. from the truck circuits and provides power to non-
propulsion system 24VDC components.
However, if during the 5 minute idle timing sequence,
the 5 minute delay switch on the instrument panel is
pressed to the OFF position, the center console
engine shutdown switch is depressed, or the ground Auto Lube Timer
level shutdown switch is activated, the engine will
The automatic lubrication system lubrication interval
shut down immediately, followed by the normal
is controlled by auto lube timer (9). Lubrication cycle
shutdown of all systems.
frequency can be adjusted by removing the timer
cover and selecting one of five different timing
intervals available. System “on” time is automatically
determined by the timer and is not adjustable. Refer
to Section P for additional automatic lubrication
system details.

D3-4 24VDC Electrical System Components 10/08 D03035


FIGURE 3-1. AUXILIARY CONTROL CABINET - LEFT WALL
1. 24VDC Terminal 7. 12V Power Relay 13.Relay Board - RB5
2. 12VDC Terminal 8. Control Power Relay 14.Relay Board - RB6
3. Engine Starter Failure Delay Timer 9. Auto Lube Timer 15.Relay Board - RB7
4. 5 Minute Idle Timer 10.Relay Board - RB1 16.Relay Board - RB8
5. Key Switch Power Relay 11.Relay Board - RB3 17.Relay Board - RB9
6. Pulse Voltage Modulator (PVM) 12.Relay Board - RB4 18.Diode Board - DB1

NOTE: For more information about relay boards RB1 through RB9, refer to Relay Boards later in this section.

D03035 10/08 24VDC Electrical System Components D3-5


Diode Board - DB1 If a diode failure is suspected, remove and check the
diode as follows:
Diode board (18, Figure 3-1) contains 24 replaceable
diodes that are mounted on a plug-in connector for 1. Grasp the diode connector, compressing the
easy replacement. Some of the diodes are used in locking “ears” while pulling the connector off the
the coil circuit of various relays to suppress the board. Note the connector “key” used to ensure
resultant coil voltage spike when power is removed correct polarity.
from the circuit, preventing damage to other circuit NOTE: Some digital multimeters are designed to test
components (lamp filaments, etc.). Other diodes are diodes. If this type is used, follow the manufacturer's
used to control the flow of current in a circuit as instructions for proper test.
required. Resistors or diodes may also be installed in
sockets P7 through P12. 2. An analog ohmmeter can be used to test the
diode as follows:
Refer to the electrical schematic in Section R of this
a. Place the meter on the “X100” scale.
manual for specific circuits.
b. With the red meter lead (+) on the banded
end of the diode and the black lead (-) on the
other diode lead, the meter should read
between 1000 and 2000 ohms.
c. Reverse the meter leads and read infinite
resistance.
3. If no resistance is read on the meter, the diode
is open and must be replaced.
4. If the meter reads zero ohms, the diode is
shorted and must be replaced.
5. Orient the diode assembly for proper polarity
(“key” noted in step 1.) and insert connector
until locked in position on mating receptacle.
FIGURE 3-2. DIODE BOARD
1. Mounting Rail 5. Foam Block
2. Screw 6. Board
3. Nut 7. Diode
4. Mounting Plate

D3-6 24VDC Electrical System Components 10/08 D03035


Fuse Blocks Alarm Indicating Device (AID) System
Four fuse blocks (1, Figure 3-3) contain fuses that Alarm indicating device (AID) module (1, Figure 3-4
protect various circuits on the truck. Always replace a is connected to the electrical accessories circuits to
blown fuse with a new one of the same rating. For a provide the operator with a warning indication of a
listing of fuse sizes and circuits, refer to the Fuse malfunction. This system consists of up to eight
Blocks charts at the end of this section. printed circuit cards located in the auxiliary control
cabinet. The actual quantity of cards will depend on
the that are options installed on the truck.

FIGURE 3-3. AUXILIARY CONTROL CABINET -


FRONT VIEW FIGURE 3-4. AUXILIARY CONTROL CABINET -
1. Fuse Blocks RIGHT WALL
1. AID Module

D03035 10/08 24VDC Electrical System Components D3-7


The AID system enables the indicating lights to be The following briefly describe each card and its
flashing or constant. The AID also has the capability function. Refer to Section R, Schematics, for the
of operating an audible alarm along with the light. circuit components described below.
The eight printed circuit cards are:
Diode Matrix (With Sound)
• Diode Matrix (With Sound) Card (Slot 1)
• Diode Matrix (Without Sound) Card (Slot 2) The diode matrix with sound card works very much
like the other diode matrix card, except that it
• Hot Switch Inverter Card (Slot 3)
contains extra diodes to activate the alarm horn in
• Hot Switch Inverter Card (Slot 4) (Not Used) addition to the flasher. The circuits connected to
• Temperature Card (Slot 5) (Optional) terminals A1 through A8 operate in the same
• Oil Level Card (Slot 6) (Optional) manner.
• Temperature and Latch Card (Slot 7) All of the card circuits are connected to the lamp test
• Coolant Level and Flasher Card (Slot 8) switch on the overhead display area. In normal
operation, these circuits are open and not functional.
NOTE: Each card is identified with a number which When the operator pushes the lamp test switch, it
corresponds to a mating number on the housing. If activates all the indicator circuits by grounding them.
any cards are removed, make sure that the card This is used to verify that all lamps are functional.
numbers correspond with the housing numbers
during installation See Figure 3-5. Diode Matrix (Without Sound)
The diode matrix without sound card consists of a
series of diodes capable of working with eight
different indicator circuits. The indicator light can be a
flashing light by connecting it to the 12F circuit or a
steady light by connecting it to the 12M circuit. In
addition, some of the indicator light circuits are
routed through a dimmer module to allow the
operator to vary the intensity of the lamps. These
lamps are fed by circuits 12FD (flashing) and 12MD
(steady).
When an indicator circuit is not activated, there is no
ground circuit for the bulb. When the indicator
detecting switch activates the circuit, it grounds the
lamp and the flasher circuit through the diodes. Any
circuits connected to terminals C1 through C8 will
operate in the same manner. The alarm horn is not
activated by this card.

Hot Switch Inverter


The hot switch inverter card is used to operate and
test the service brake indicator light. In normal
conditions Q4 transistor is off and the Indicator Light
is off. When the stoplight switch is activated, 24 volts
is sent to pin “E” of the hot switch inverter card.
FIGURE 3-5. AID SYSTEM CARD ENCLOSURE Transistor Q4 is turned on by this voltage and, in
turn, grounds the service brake indicator light. There
1. Diode Matrix With Sound is no alarm horn operation with this card.
2. Diode Matrix Without Sound
3. Hot Switch Inverter A second circuit on this card is used to operate and
4. Hot Switch Inverter (Not Used) test the retard speed control indicator light. When
5. Temperature & Latch RSC is turned OFF, transistor Q7 is off and the
6. Coolant Level & Flasher indicator light is off. When RSC is turned on, 24 volts
is sent to pin “J” of the card. This voltage turns on
Q7, grounding the indicator light circuit.

D3-8 24VDC Electrical System Components 10/08 D03035


Hot Switch Inverter (Not Used) Coolant Level & Flasher
The optional oil level card is used to turn on the low The coolant level and flasher card contains two
oil level indicator light to warn the operator that the separate circuits. The flasher circuit at the top of the
engine oil/hydraulic tank oil level is below acceptable card has Q12 transistor biased to be saturated when
levels. The oil float is connected to a variable no malfunction is present, resulting in 24 volt positive
resistor. As the oil level decreases, the resistance output on pin “H” of the card and on wire 12F. When
goes down, causing Q3 to turn on and grounding the an indicating circuit is activated, the ground side of
indicator light and alarm horn. the circuit connected to card pin “K” is grounded.
Q12 will turn off initially and then after a delay,
The optional temperature card is used to turn on the adjusted by R20, will turn on and off to give the
high oil temperature indicator light. The indicator light intermittent 24 volt output.
tells the operator hydraulic tank oil temperature has
exceeded acceptable levels. Normal temperature The other half of the circuitry on the coolant level and
setting is 121°C (250°F). As the temperature goes flasher card operates the coolant level light. The
up, the resistance in the probe decreases providing a water level probe connected to terminal B11 grounds
ground path for the indicator light and alarm horn. the 31L circuit when the coolant in the radiator is
above the probe position. The coolant saturates the
Temperature and Latch probe and electrically grounds the circuit. When the
The temperature and latch card has two circuits to circuit is grounded, Q6 transistor is off, resulting in no
operate two different indicator lights. The indication. When the coolant level drops below the
temperature circuit is controlled by a coolant probe, 31L is no longer grounded and Q6 turns on to
temperature sensor which decreases electrical ground the flasher through D5, the coolant level light
resistance as its temperature increases. It will have a through terminal D11, and the alarm horn through
resistance of approximately 1000 ohms at 85°C D6. The light and alarm horn will operate
(185°F) and 500 ohms at 121°C (250°F). The normal intermittently as their 24 volt supply is from circuit
setting is 96°C (204°F). 12F, the flasher output.

When the temperature is low and the resistance is NOTE: Some electronic engine controls monitor
high, Q1 is off and no high temperature indication coolant level. If the engine controls monitor the
occurs. When the coolant temperature is excessive, circuit, a 2K resistor is installed to replace the probe
resistance decreases to a point where Q1 will turn on and disable the AID system circuit.
and ground the flasher through D8, the alarm horn
through D12, and the high temperature light through
terminal D8. R14 can adjust the temperature
(resistance) at which the circuit is activated.
NOTE: Some electronic engine controls monitor
coolant temperature. If the engine controls monitor
the circuit, a 2K ohm resistor is installed to replace
the temperature sensor and disable the AID system
circuit.
The latch circuit monitors the accumulator precharge
pressure switches. When one of the pressure
switches closes, Q5, which supplies power to the
gate of SCR Q7, will be turned off. With Q7 turned
on, Q9 will supply the ground path to turn on the low
accumulator precharge indicator light and sound the
alarm horn. The indicator light is connected to 12F
and will flash off and on. The SCR will remain on until
power is removed from the card by turning the key
switch OFF.

D03035 10/08 24VDC Electrical System Components D3-9


RELAY BOARDS Relay Boards RB1, RB3, RB4, RB5
The auxiliary control cabinet contains eight relay Each relay board of this type is equipped with four
boards to provide control for many of the 24VDC green lights (9, Figure 3-6) and one red “breaker
circuits. Two types of boards are used. One type of open” light (7). Each relay board has a fifth green (8)
board contains circuit breakers in addition to 24VDC light that has a different function on each board.
relays and a PC board for special functions. The Four green lights (9) are labeled K1, K2, K3, or K4.
second type of board contains relays only. These lights will be on only when that particular
All relays are interchangeable. The circuit breakers control circuit has been switched ON and the relay
are interchangeable, providing that the circuit coil is being energized. The light will not turn on if the
breaker capacity is the same. relay board does not receive the 24 volt signal to turn
on a component.
If illuminated, red “breaker open” light (7) indicates
that a circuit breaker on that relay board is in the OFF
position. A light on the overhead display panel will
Do not interchange or replace any circuit breaker
also illuminate, informing the operator that a circuit
with one of a different capacity than specified for
breaker is in the OFF position. The red “breaker
the circuit. Serious damage or a fire may result if
open” light will turn ON whenever there is a voltage
the wrong capacity breaker is used.
difference across the two terminals of a circuit
breaker.
The relay boards are identified as follows: If a control switch has been turned ON and a green
(K) light is on, but that component is not operating,
Relay Board Functions check the following on the relay board for that circuit:
RB1 Clearance/Turn Signal Lights  If a circuit breaker light is on, press all the
circuit breakers to make sure that they are
RB3 Stop, Retard, Backup Lights all on. There is no visual indication as to
RB4 Parking Brake, Horn, Body-Up, which circuit breaker has been tripped.
Engine Cranking Check the operation of the component. If it
trips again, check the wiring or component
RB5 Headlights (standard) for the cause of the overload.
RB6 Backup Horn, Start Relay, Engine  The contacts inside the relay may not be
Interlock, 5 Minute Idle Timer, Ether closing, or the contacts may be open,
Start preventing an electrical connection. Swap
RB7 Starter Relays, Bleeddown Power, relays and check again. Replace defective
Auto Lube Solenoid & Timer, relays. Relays may take one minute to trip
and 30 seconds before they can be reset.
Starter Failure Relays #1 and #2,
Headlights (HID)  Check the wiring and all of the connections
between the relay board and the
RB8 PLMIII Lights, Shutter Control, TCI component for an open circuit.
RB9 Engine Start, Start Lockout, Starter  The component may be defective. Replace
Failure Relays #3 and #4, Parking the component.
Brake OFF  There is a poor ground at the component.
Repair the ground connection.
Refer to Figure 3-1 for the location of each relay
board. Refer to the Circuit Breakers chart at the end
of this section for electrical circuit identification
numbers.

D3-10 24VDC Electrical System Components 10/08 D03035


1. Relay Board
2. Screw
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

FIGURE 3-6. TYPICAL RELAY BOARDS - RB1, RB3, RB4, RB5

To replace a relay:
NOTE: The relays are labelled to identify the
applicable circuits and components Also, refer to the
Fuse Blocks charts at the end of this section.
1. Remove one screw (10, Figure 3-6) holding the
crossbar in place and loosen the other screw.
2. Swing the crossbar away.
3. Gently wiggle and pull outward to remove relay
(11).
4. Line up the tabs and install a new relay.
5. Place the crossbar in its original position and
install screw (10). Tighten both screws.

D03035 10/08 24VDC Electrical System Components D3-11


To replace a circuit breaker: Relay Board RB6, RB7, RB8, RB9
NOTE: Always replace a circuit breaker with one of Relay boards 6, 7 and 8 (Figure 3-7) do not contain
the same amperage capacity as the one being circuit breakers or modular cards. Additional circuits
removed. may be added by utilizing a spare relay socket as
described below:
1. Activate the battery disconnect switches.
2. Unplug all wiring harnesses from the relay The control circuit for the relays are the “+” and “-”
board. Remove the four relay board mounting terminals:
screws. Remove the relay board from the truck. • “+” terminal is for positive voltage.
3. Remove four hold down screws (2, Figure 3-6) • “-” terminal is for grounding of the control circuit.
(one in each corner) in the circuit breaker cover • Either circuit can be switched “open” or “closed” to
plate. Remove two screws (6) and card (5). control the position of the relay.
4. Remove the nuts on the wire terminal leads on The terminals of the switched circuit from the relay
the circuit breaker to be replaced. Remove contacts are labeled as follows:
mounting screws on circuit breaker to be
• NC - Normally Closed
replaced.
• COM - Common
5. Lift out circuit breaker. Retain flat washers from
• NO - Normally Open
wire terminals.
6. Install new circuit breaker of the same capacity  COM terminal is for the voltage source
rating as the one removed. Install one nut and (protected by a circuit breaker) coming into
two flat washers for each wire connection to the the relay which will supply the electrical
power for the component being controlled.
new circuit breaker.
7. Install cover plate and all screws removed  NC terminal is connected (through the
during disassembly. relay) to the “COM” terminal when the relay
is not energized (when the control circuit
8. Carefully install card (5) with screws (6). terminals “+” & “-”) are not activated).
9. Install relay board in truck and connect all wiring
 NO terminal is connected (through the
harnesses. relay) to the “COM” terminal when the relay
is energized (by the control circuits “+” & “-”
being energized).
To replace a circuit panel card:
NOTE: DO NOT remove the small screws that hold
the cover plate to the circuit panel. Replace circuit
panel as a complete assembly.
1. Place battery disconnect switches in the OFF
position.
2. Remove the two mounting screws (6, Figure 3-
6) and carefully remove the circuit panel card
from the relay board.
3. Line up the new circuit panel in slots and with
the socket on the relay board and install
carefully.
4. Install two mounting screws (6).

FIGURE 3-7. AUXILIARY RELAY BOARD -


RB6, RB7, RB8, RB9
1. Circuit Board 5. Mounting Plate
2. Mounting Rail 6. Foam Block
3. Screw 7. Relay
4. Nut

D3-12 24VDC Electrical System Components 10/08 D03035


Relay Board Functions Relay Board 4 (RB4)
The following describes the components and 1 - Steering Pressure Bleed Down Timer Module
functions of each relay board. card
1 - Bleed Down Light (Green): This light is
illuminated when the bleeddown solenoid is
Relay Board 1 (RB1) being energized. The bleeddown timer will
1 - Flasher Power Light (Green): This light will be energize the solenoid for 90 seconds after the
illuminated when the turn signals or hazard key switch is turned OFF.
lights are activated. 3 - 12.5 amp circuit breakers (CB20, CB21, CB22)
 1 light will be illuminated during right turn 4 - Relays
signal operation
 Parking Brake Status Relay (K1)
 2 light will be illuminated during left turn
signal operation  Engine Cranking Oil Pressure Interlock
Relay (K2)
 3 light will be illuminated when clearance
lights are activated.  Horn Relay (K3)
 4 light will be flashing when the turn signals  Body-Up Relay (K4)
or hazard lights are in operation.
NOTE: If circuit breakers (CB13 & CB15) are in the
off position, no warning will be noticed until the Relay Board 5 (RB5)
clearance light switch is turned ON. 1 - Light Display Module card
1 - Flasher Module card 1 - Lights Control Light (Green): This light is
2 - 12.5 amp circuit breakers (CB13, CB15) illuminated when 24 volts is being supplied to
the battery terminal of the light switch.
4 - Relays
5 - 12.5 amp circuit breakers
 Left Turn Light Relay (K1) (CB23, CB24, CB25, CB26, CB27)
 Right Turn Light Relay (K2) 4 - Relays
 Clearance Lights Relay (K3)  Left Low Beam Relay (K1)
 Flasher Relay (K4)
 Right Low Beam Relay (K2)
 Left High Beam Relay (K3)
Relay Board 3 (RB3)  Right High Beam Relay (K4)
1 - Light Module Display card
1 - Rev Light (Green): This light is illuminated
whenever the directional control lever is in the
REVERSE position and the key switch is in the
ON position.
4 - 12.5 amp circuit breakers
(CB16, CB17, CB18, CB19)
4 - Relays
 Manual Backup Lights Relay (K1)
 Stop Lights Relay (K2)
 Retard Lights Relay (K3)

D03035 10/08 24VDC Electrical System Components D3-13


Relay Board 6 (RB6) Relay Board 8 (RB8)
The following relays are installed on RB6: The following relays are installed on RB8:
 Backup Horn Relay (K1)  70% Load Signal to PSC Relay (K1)
 Engine Interlock Relay (K2)  Full Load Signal to PSC Relay (K2)
 Engine Start Relay (K3)  Shutter Control Relay (K3)
 Spare Relay (K4)  PLMIII Lights Relay (K4)
 Ether Start Relay (K5)  A/C Shutter Control Relay (K5)
 5 Minute Idle System Relay (K6)  PLMIII Red Lights Relay (K6)
 5 Minute Idle System Relay (K7)  PLMIII Amber Lights Relay (K7)
 5 Minute Idle System Relay (K8)  PLMIII Green Lights Relay (K8)

Relay Board 7 (RB7) Relay Board 9 (RB9)


The following relays are installed on RB7: The following relays are installed on RB7:
 Starter Motor #2 Relay (K1)  Spare Relay (K1)
 Starter Motor Failure #1 Relay (K2)  Spare Relay (K2)
 Starter Motor Failure #2 Relay (K3)  Spare Relay (K3)
 Starter Motor #1 Relay (K4)  Park Brake Off Relay (K4)
 Auto Lube Solenoid Relay (K5)  Starter Motor Failure #3 Relay (K5)
 HID Headlights Relay (K6)  Engine Start Relay (K6)
 Bleeddown Power Supply Relay (K7)  Engine Start Lockout Relay (K7)
 Auto Lube Timer Relay (K8)  Starter Motor Failure #4 Relay (K8)

D3-14 24VDC Electrical System Components 10/08 D03035


BODY-UP SWITCH Adjustment
Body-up switch (3, Figure 3-8) is located inside the Before adjusting the body-up switch, inspect the
right frame rail near the front of the body. It must be body pads for wear and damage. Replace the body
adjusted to specifications to ensure that the proper pads if required. The body must be resting on the
electrical signal is obtained when the body is raised frame in the normal body down position when
or lowered. The body-up switch is designed to adjustments are made.
prevent propulsion in REVERSE when the dump 1. Loosen capscrews (2, Figure 3-8) and adjust
body is not resting on the frame rails. The switch also proximity switch bracket (3) to achieve an air
prevents forward propulsion with the body up unless gap (dimension “A”) of 12.7 to 15.9 mm (0.50 to
the override button is depressed and held. 0.62 in.) between the sensing area
(crosshatched area as marked on the switch)
Operation
and actuator arm (4). Tighten the capscrews
When the body is resting on the frame, actuator arm after the adjustment.
(4) causes the electrical contacts in the magnetically 2. If necessary, loosen actuator arm mounting
operated switch to close. When the body is raised, capscrews (5), and position arm until centered
the arm moves away from the switch, opening the over sensing area of switch. Vertical set up
contacts. The electrical signal is sent to the control dimension (“B”) should be 1.63 in. (41.5 mm).
system and the body-up relay. Tighten the capscrews.
The switch must be properly adjusted at all times.
Service
Improper adjustment or loose mounting bolts may
cause false signals or damage to the switch Keep the sensing area clean and free of metallic dust
assembly. and other debris that may damage or inhibit
operation of the switch. If the switch is damaged or
not functioning, the switch must be replaced.

1. Switch Mounting Bracket


2. Adjustment Capscrews
3. Proximity Switch
4. Actuator Arm
5. Adjustment Capscrews

FIGURE 3-8. BODY-UP SWITCH

D03035 10/08 24VDC Electrical System Components D3-15


HOIST LIMIT SWITCH
Hoist limit switch (5, Figure 3-9) is located inside the
right frame rail above the rear suspension, near the
body pivot pin. The hoist limit switch is designed to
stop the hoist cylinders before they reach full
extension, preventing possible damage to the dump
body or hoist cylinders.

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
contacts close, an electrical signal is sent to the
hoist-up limit solenoid valve, located in the hydraulic
brake 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
assembly.

Adjustment
1. Raise the body so that the hoist cylinders are
within 152 mm (6 in.) of maximum travel.
2. Adjust the hoist limit switch to achieve an air
gap (dimension “A”) of 12.70 to 14.30 mm (0.50
to 0.56 in.) between the sensing area and
actuator arm (3). Tighten the capscrews.

Service
Keep the sensing area clean and free of metallic dust
and other debris that may damage or inhibit
operation of the switch. If the switch is damaged or
not functioning, the switch must be replaced.
FIGURE 3-9. HOIST LIMIT SWITCH ADJUSTMENT

1. Body 4. Switch Mounting


2. Frame Plate
3. Actuator Arm 5. Hoist Limit Switch

D3-16 24VDC Electrical System Components 10/08 D03035


FUSES AND CIRCUIT BREAKERS

FUSE BLOCK #1
Location Amps Devices protected Circuit
1 15 A/C, Heater Blower Motor 12H
2 10 Windshield Washer / Wiper 63
3 5 Instrument Panel Gauges 712G
4 10 Key Switch Power 712P
5 10 Hoist Limit Switch 712H
6 15 Turn Signal / Clearance Lights 712T
7 10 Engine Options 712E
8 10 AID Module and Indicator Lights 12M
9 10 Engine Start Failure 712SF
10 10 Engine Shutters 712R
11 10 Auxiliary Control Cabinet Dome Lights 712A
13 10 Radio 12VREG
17 15 Key Switch Supplemental Power 11GP
18 15 Payload Meter Lights 39J
19 5 Payload Meter Module 39G
20 15 Ground Level Power 11GP

FUSE BLOCK #2
Location Amps Devices protected Circuit
1 15 Engine Service Lights 11SL
2 15 Cab Dome, Fog, Ladder Lights, Beacon, Hour Meter 11L
3 15 Hazard Lights 46
4 10 Interface Module 11INT
5 10 VHMS & Orbcomm Controllers Power 85
6 20 Modular Mining Hub 11M
7 10 Display Module 11DISP
8 15 HID Headlights 11IM2
9 15 Reserve Oil System Pump 11ORS
10 15 Reserve Oil System Control Module 11RCNT
11 20 Hydraulic Bleed Down Power 11BD
12 10 Engine Load Module Power 11EM
13 10 Key Switch Power 11KS
17 20 Engine ECM Power 11E1
18 20 Engine ECM Power 11E2
19 20 Engine ECM Power 11E3
20 20 Engine ECM Power 11E4

D03035 10/08 24VDC Electrical System Components D3-17


FUSE BLOCK #3
Location Amps Devices protected Circuit
1 15 Cab Drive System Power 71P
2 10 Auto Lube Pump Power 68ES
3 15 Interface Module (GE Power) 71IM
4 20 Operator Seat Power 71OS
13 10 Left Front Wheel Speed Sensor 15LWS
14 10 Right Front Wheel Speed Sensor 15RWS
17 10 12V Auxiliary Power Outlets 67C
18 20 R.H. Cab Window Switch 67R
19 20 L.H. Cab Window Switch 67P

FUSE BLOCK #4
Location Amps Devices protected Circuit
1 10 Brake Circuits 71BC
2 5 Payload Meter Controller 712PL
3 5 Interface Module 87
4 5 VHMS Controller 71VHM
5 5 Modular Mining Hub 712MM
6 5 Display Module 86
7 15 Hydraulic Bleed Down Power 71BD
8 10 Switch LED Power 71LS
9 1 Selector Switch Power 71SS
17 5 Gauge Voltage 15V
18 5 Pedal Voltage 15PV
19 5 Engine Interface 15VL

The following two fuses are located in the fusable link between the prelube timer solenoid and prelube pump.

Location Amps Devices protected Circuit


Fusable link 200 each Prelube Pump 11PL

D3-18 24VDC Electrical System Components 10/08 D03035


The following circuit breakers are located on the relay boards on the left inside wall of the auxiliary control cabinet.

Location Amps Devices protected Circuit


RB1 - CB13 12.5 Turn Signals / Clearance Lights 11CL
RB1 - CB14 12.5 Turn Signal Flasher 11Z
RB1 - CB15 12.5 Tail Lights 41T
RB3 - CB11 12.5 Backup Lights and Horn 79A
RB3 - CB16 12.5 Retard Lights 44D
RB3 - CB17 12.5 Manual Backup Lights 47B
RB3 - CB18 12.5 Stop Lights 44A
RB3 - CB19 12.5 Backup Lights and Horn 79A
RB4 - CB20 5 Parking Brake Failure Relay 439E
RB4 - CB21 12.5 Service Lights, Forward Horn 11A
RB4 - CB22 5 Engine Control Power 23D
RB5 - CB23 12.5 Headlights, Left Low Beam 11DL
RB5 - CB24 12.5 Headlights, Right Low Beam 11DR
RB5 - CB25 12.5 Headlights, Left High Beam 11HL
RB5 - CB26 12.5 Headlights, Right High Beam 11HR
RB5 - CB27 12.5 Headlights and Dash Lights 11D

The following circuit breaker is located in the battery control box at the front of the truck.

Location Amps Devices protected Circuit


CB60 50 24V to 12V Converter 11B1

D03035 10/08 24VDC Electrical System Components D3-19


NOTES

D3-20 24VDC Electrical System Components 10/08 D03035


SECTION D10
BATTERY CHARGING ALTERNATOR
INDEX

BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

CHARGE VOLT AND AMP VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Undercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Overcharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Acid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Non-Use or Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6

Freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-7

BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8

Terminal Identification and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Battery Positive (B+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Battery Negative (B-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

DC Output (D+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

AC Output (R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Regulator Harness Plug Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9

Battery/Alternator Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-10

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-12

D10003 07/06 Battery Charging Alternator D10-1


DIMENSIONS AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-13

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Troubleshooting Alternator (On-Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14

Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-16

Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17

REGULATOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-18

Regulator Bypass Test (No Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-18

Regulator Bypass Test (Amp Rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-19

BENCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Identification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Advanced Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Bench Test 1: No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20

Bench Test 2: Full Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-21

Bench Test 3: Regulator Bypass Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-21

STATIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Identification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Regulator Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Check For Shorted Power Transistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-22

Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-23

FIELD COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24

Field Coil Test 1: Check for Open or Shorted Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24

Field Coil Test 2: Check For Grounded Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-24

STATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-25

Stator Test 1: Check For Stator-To-Stator Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-25

D10-2 Battery Charging Alternator D10003 07/06


Stator Test 2: Check For Grounded Stators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-26

THERMAL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-26

Initial Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-26

Verifying a Faulty Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-27

TROUBLESHOOTING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-28

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32

ALTERNATOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-32

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-34

Special Tools and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-34

Epoxy Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-35

Liquid Threadlockers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-35

Elastoplastic Silicone Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-35

ALTERNATOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-38

ALTERNATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-40

Regulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-40

Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-41

Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-42

Anti-Drive End Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-42

Anti-Drive End Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-44

Drive End Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-46

Drive End Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-52

Field Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-53

Drive End and/or Anti-Drive End Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-55

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-57

ALTERNATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-57

Anti-Drive End Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-57

Drive End Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-59

Field Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-62

Drive End Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-64

D10003 07/06 Battery Charging Alternator D10-3


Drive End Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-66

Rotor and Rotor Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-66

Drive End Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-67

Anti-Drive End Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-71

Anti-Drive End Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-72

Regulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-75

THERMAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-76

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-76

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-78

SUPPORT STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-78

D10-4 Battery Charging Alternator D10003 07/06


BATTERY CHARGING SYSTEM

BATTERY CHARGING SYSTEM


ELECTRICAL SYSTEM DESCRIPTION
The Komatsu truck utilizes a 24VDC electrical sys-
tem which supplies power for all non-propulsion elec- Lead-acid storage batteries contain sulfuric acid,
trical components. The 24VDC power is supplied by which if handled improperly, may cause serious
two pairs of 12-Volt storage batteries wired in series. burns on the skin or other serious injuries. Wear
The batteries are a lead-acid type, each containing protective gloves, aprons, and eye protection
six 2-Volt cells. With the key switch on and the when handling and servicing lead-acid storage
engine off, power is supplied by the batteries. When batteries. See the precautions in General Informa-
the engine is operating, the electrical power (non- tion, Section A, of this manual to ensure proper
propulsion) is supplied by a 28-Volt alternator. Refer handling of the batteries and/or accidents involv-
to Schematics, Section R, for specific electrical hook- ing sulfuric acid.
up information.
Maintenance and Service
CHARGE VOLT AND AMP VALUES
Check the electrolyte level of each cell at the interval
The volt and amp levels are a function of the battery specified in Lubrication and Service, Section P. Add
state-of-charge. If the batteries are in a state of dis- water, if necessary. The proper electrolyte level is 10
charge, as after extended cranking time to start the to 13 mm (0.375 - 0.50 in.) to above the plates. To
engine, system voltage, when measured after the ensure maximum battery life, use only distilled water
engine is started, will be lower than the regulator set or water recommended by the battery manufacturer.
point. The system amperage will also be high. This is After adding water in freezing temperature, operate
a normal condition for the charging system. The the engine for at least 30 minutes to thoroughly mix
measured values of system Volts and amps will the electrolyte.
depend on the level of battery discharge. In other
words, the greater the battery discharge level, the
lower the system Volts and the higher the system
amperage will be. The Volt and amp readings will
change; system Volts reading will increase up to the DO NOT smoke or allow a flame around a dead
regulator set point and the system amperage will battery or during recharging. The expelled gas
decrease to a low level (depending on other loads) from a dead battery cell or a charging battery is
as the batteries recover and become fully charged. extremely explosive and can cause serious
bodily injury.
BATTERY Excessive consumption of water indicates leakage or
During operation, the storage batteries function as an overcharging. Normal water usage for a truck operat-
electrochemical device for converting chemical ing eight hours per day is about 30-60 ml (1-2 oz) per
energy into the electrical energy required for operat- cell, per month. For heavy-duty operation (24 hours
ing the accessories when the engine is off. per day), normal consumption is about 30-60 ml (1-2
oz) per cell, per week. Any appreciable increase in
water consumption is considered a danger signal. No
water consumption may indicate undercharging or
sulfated battery plates.

D10003 07/06 Battery Charging Alternator D10-5


Troubleshooting NOTE: When washing the batteries, ensure the cell
caps are tight, preventing any cleaning solution from
The two most common problems that occur in the
entering the battery cells.
charging system are undercharging and overcharg-
ing of the truck's batteries. Acid Levels
Undercharging The addition of acid will be necessary if considerable
electrolyte has been lost through spillage. Before
An undercharged battery is incapable of providing
adding acid, ensure the battery is fully charged. This
sufficient power to the truck's electrical system.
is accomplished by putting the battery on a battery
Some possible causes for an undercharged battery charger and taking hourly specific gravity readings on
are: each cell. When all the cells are charged (gassing
freely) and three successive hourly readings show no
 Sulfated battery plates
rise in specific gravity, the battery is considered fully
 Loose or corroded battery connections charged. Additional acid may now be added. Con-
 Defective wire in the electrical system tinue charging for another hour and again check the
specific gravity. Repeat the above process until all
 Loose alternator drive belt cells indicate a specific gravity of 1.260 to 1.265 cor-
 Defective alternator or regulator rected to 27°C (80°F).
 Defective battery equalizer NOTE: Use 1.400 strength sulfuric acid when making
specific gravity adjustments. Acid of higher strength
Overcharging will attack the plates and separators before it has a
Overcharging, which causes battery overheating, is chance to diffuse into the solution.
first indicated by excessive use of water. If allowed to If the temperature of the electrolyte is not reasonably
continue, the cell covers will push up at the positive close to 27°C (80°F) when the specific gravity is
ends of the battery case. In extreme situations, the taken, the temperature factor must be corrected to
battery container will become distorted and cracked. 27°C (80°F):
Leakage can be detected by continual wetness of the • For every 5°C (10°F) below 27°C (80°F), subtract
battery or excessive corrosion of the terminals, bat- 0.004 from the specific gravity reading.
tery carrier, and surrounding area. A slight amount of
• For every 5°C (10°F) above 27°C (80°F), add
corrosion is normal in lead-acid batteries. Inspect the
0.004 to the reading.
case, covers, and sealing compound for holes,
cracks, or other signs of damage. Check the battery Non-Use or Storage
hold-down connections to ensure they are not over-
tightened, which could cause a crack in the battery. If Remove idle batteries (unused for more than two
the battery connections are too loose, it could allow weeks) from the truck and place in a cool, dry place.
vibration, causing the battery case seams to break Periodically check and charge, when necessary.
open. A leaking battery must be replaced. Remember, all lead-acid batteries discharge slowly
when not in use. This self-discharge takes place even
Corrosion though the battery is not connected in a circuit and is
more pronounced in warmer weather than in cold.
Corrosion creates resistance in the charging circuit,
which causes undercharging and gradual starvation of The rate of self-discharge of a battery kept at 38°C
the battery. (100°F) is about six times faster than that of a battery
kept at 19°C (50°F). Self-discharge of a battery kept
To remove corrosion, clean the battery with a solution at 27°C (80°F) is about four times faster than that of
of ordinary baking soda and a stiff, non-wire brush. one at 10°C (50°F). Over a thirty day period, the
Then rinse the battery with clean water. DO NOT allow average self-discharge is about 0.002 specific gravity
the baking soda solution into the battery cells. Dry the per day at 27°C (80°F).
battery and ensure the battery terminal connections
are clean and tight. Clean terminals are very important
in a voltage regulated system.

D10-6 Battery Charging Alternator D10003 07/06


To offset the results of self-discharge, booster-charge
idle batteries (not a quick charge) at least once every
thirty days. Batteries not used for long periods in a
discharged condition are attacked by a crystallization
of the lead sulfate on the plates. Such batteries are
called sulfated and are, in the majority of cases,
irreparably damaged. In less severe cases, the sul-
fated battery may be restored to limited service by
prolonged charging at a low rate (approximately 1/2
normal rate).

Freezing
An undercharged battery is extremely susceptible to
freezing when stored in cold weather.
The electrolyte of a battery in various stages of
charge will start to freeze at temperatures indicated
in Table 10-1.
The temperatures in Table 10-1 indicate the points at
which the first ice crystals appear. Lower tempera-
tures must be reached for a solid freeze. Solid freez-
ing of the electrolyte may crack the battery case and
damage the positive plates. A battery with at least a
75% charge is in no danger of freezing, especially
during winter weather.

Table 10-1: OPERATING TEMPERATURES


Specific Gravity Freezing
Corrected to 27°C Temperature
(80°F) Degrees
1.280 -70°C (-90°F)
1.250 -54°C (-60°F)
1.200 -27°C (-16°F)
1.150 -15°C (+5°F)
1.100 -7°C (+19°F)

NOTE: If the temperature of the electrolyte is not rea-


sonably close to 27°C (80°F) when the specific grav-
ity is taken, adjust the temperature factor to 27°C
(80°F).

D10003 07/06 Battery Charging Alternator D10-7


BATTERY CHARGING ALTERNATOR This is a basic dual stator alternator constructed from
shell assembly (8) containing one stator at each end
GENERAL INFORMATION and a field coil between the stators.

General Description Drive end housing (9) and anti-drive end housing (6)
each contain a bearing to support drive and rotor
The Niehoff model C653A 28-Volt (260 Amp) alterna- shaft (1). They are attached to each end of the shell
tor is self-rectifying. All windings and current-trans- assembly by long threaded studs.
mitting components are non-moving, so there are no
brushes or slip rings to wear out. Drive end housing assembly (9) has an area called
control housing (2), containing all the required inter-
When controlled by voltage regulator (5), these alter- nal electrical connections for the alternator. It also
nators become self-energizing through an internal contains a thermal switch used to protect the B+ ter-
dual diode trio. A residual magnetic field induces a minal.
small voltage in the stator and energizes the field
coil. The field coil continues receiving incremental Battery positive terminal (4) is located on the face of
voltage until full voltage is achieved. Alternating cur- control housing (2) for connection to the truck’s bat-
rent (AC) is rectified into a direct current (DC) output tery positive circuit. The ground circuit cable can be
through the diodes. The regulator controls voltage attached to either of two ground terminals (10)
output and has a D+ terminal to provide a DC output located on the front housing. Fan guard (7) protects
signal to the truck’s electrical system, confirming maintenance personnel from the rotating fan when
alternator operation. An R terminal provides optional the engine is operating.
AC output. Identification plate (3) contains general alternator infor-
mation, including model number and serial number.
.

FIGURE 10-1. ALTERNATOR EXTERIOR

1. Drive Shaft with Woodruff Key 6. Anti-Drive End Housing


2. Control Housing 7. Fan Guard and Cooling Fan Assembly
3. Identification Plate 8. Shell Assembly
4. Battery Positive Terminal (B+) 9. Drive End Housing
5. Voltage Regulator 10. Ground Terminals (B-)

D10-8 Battery Charging Alternator D10003 07/06


Terminal Identification and Location Regulator Harness Plug Identification

FIGURE 10-3. PIN CONNECTION IDENTIFICATION

Alternator Specifications
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28VDC
Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Negative
Regulator Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 10-2. TERMINAL LOCATIONS
Regulator Settings . . . . . . . . . . . . . . . . . . . . . . . 27.5
B+. Battery Positive D+. DC Output ...................................... 28.5
B-. Battery Negative R. AC Output ...................................... 28.0
...................................... 29.0
Battery Positive (B+)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 29 kg (65 lbs)
Main positive power terminal on the alternator.
Located on the control housing. Performance Curve

Battery Negative (B-) Measurements listed on the curves are for a stabi-
lized machine at maximum output at temperatures
Main negative power terminal (ground) on the alter- indicated for each curve.
nator. Located on the drive end housing.

DC Output (D+)
Positive DC voltage output from the alternator. May
be used for specific control circuit. Located on the
regulator. Limited to one or two amp output.

AC Output (R)
Relay terminal. AC current output terminal for the
tachometer or for relay use. Located on the regulator.

FIGURE 10-4. ALTERNATOR PERFORMANCE


CURVE

D10003 07/06 Battery Charging Alternator D10-9


Battery/Alternator Terminology Diode Trio: Assembly of three diodes, one diode
connected to each stator phase tap. Used typically to
NOTE: Charge voltage and amp rates vary from
operate as a signaling source, once the alternator is
battery type to battery type, based on battery
rotating, to tell the regulator to turn on (self-energiz-
construction technology and physical size of the
ing signal), or to provide current for the field coil oper-
battery.
ation.
AC: Alternating current (AC) output of the alternator.
Diode Trios: Dual use of two diode trios, one trio per
Alternator: General term for a vehicle generator stator, on dual stator alternators.
using solid-state devices to rectify output power and
DMM: Digital Multimeter. A handheld test instrument
provide DC output.
to digitally display test values. The preferred test
Amps, Low: A minimum or lowest charging system meter has high impedance value (10 Meg-ohms).
amp value required to maintain the battery state of
Drive End: End of the alternator is equipped to
charge, obtained when testing the charging system
receive mechanical power from the primary power
with a fully charged battery and no other loads
source via the pulley or drive coupling.
applied. This value will vary with battery type.
Fan: Fan located at the anti-drive end of the alterna-
Amps, Medium: A system amp value which can
tor.
cause the battery temperature to rise above the ade-
quate charging temperature within 4-8 hours of Ground: Return path of electrical circuit. May be
charge time. To prevent battery damage, the charge separate wire, component housing, or vehicle chas-
amps must be reduced when the battery temperature sis. (B-) is considered the ground on modern vehicle
rises. Check the battery manufacturer’s recommen- systems.
dations for proper rates of charge amps.
Harness: Enclosed bundle of wires used to connect
Amps, High: A system amp value which can cause electrical devices.
the battery temperature to rise above adequate
Phase: Single output winding of an alternator. Most
charging temperature within 2-3 hours of charge
dual stator alternators have six phases, three phases
time. To prevent battery damage, the charge amps
per stator.
must be reduced when the battery temperature rises.
Check the battery manufacturer’s recommendations Polarity: Distinguishes between positive (+) and
for proper rates of charge amps. negative (-) in an electrical circuit.
Anti-Drive End: End of alternator farthest from drive Rectifier Assemblies: Assembly of power diodes
end (drive pulley). that convert AC current output of the alternator stator
phases to DC current output. Rectifier assemblies
Charge Voltage: Nominal value to which the regula-
are modular designed. Rectifier modules are
tor is set. The actual charge voltage level is deter-
grouped in single blocks mounted in an end housing.
mined by the battery type and the system duty cycle
Modular rectifier blocks can be replaced individually.
and may vary slightly.
Self-energized: The alternator turns itself on and
Control Housing: Part of the housing assembly con-
begins to produce electricity at predetermined rotor
taining internal electrical connections of the alterna-
speed through special circuits designed into the reg-
tor and mounting area for the control unit.
ulator or the alternator.
DC: Direct current (DC) output of the alternator.

D10-10 Battery Charging Alternator D10003 07/06


Set Point: The voltage value to which the regulator is
set. The voltage value is established by the battery
type and the vehicle duty cycle. There are four val-
ues available on the regulator. The set point valve
may be fixed (flat compensation) or variable, based
on operating temperature (negative temperature
compensation).
Significant Magnetism: A change in the strength or
intensity of a magnetic field present in the alternator
rotor shaft when the field coil is energized. The mag-
netic field strength when the field coil is energized
must feel stronger than when the field is not ener-
gized.
Surface Charge: A higher than normal battery volt-
age occurring when the battery is removed from a
battery charger. The surface charge must be
removed to determine true battery voltage and state
of charge.
Voltage B+: A voltage value obtained when measur-
ing voltage at the battery positive terminal or alterna-
tor (B+) terminal.
Voltage, Battery: The steady-state voltage value as
measured with the battery in an open circuit with no
battery load. This value relates to the battery state of
charge.
Voltage, Charge: A voltage value obtained when the
charging system is operating. This value will be
higher than the battery voltage and must never
exceed the regulator voltage set point.
Voltage Droop or Sag: A normal condition which
occurs when the load demand on the alternator is
greater than rated alternator output at a given rotor
shaft rpm.
Voltage Regulator (also Regulator): Device to con-
trol the alternator output voltage. Modern regulators
are solid-state devices. The regulator is mounted on
the alternator. Some regulators have several voltage
set points available for different operating conditions
or battery types.

D10003 07/06 Battery Charging Alternator D10-11


WIRING DIAGRAM

FIGURE 10-5. WIRING DIAGRAM

D10-12 Battery Charging Alternator D10003 07/06


DIMENSIONS AND TORQUE VALUES

FIGURE 10-6. TORQUE SPECIFICATIONS AND OVERALL DIMENSIONS

TORQUE SPECIFICATIONS
Item Description Metric SAE
1 Ground Bolt (B-), M10 X 1.5 15 N·m 11 ft lbs
2 Pulley Nut, M20 X 1.5 163 N·m 120 ft lbs
3 Output Bolt (B+), M12 X 1.75 32 N·m 24 ft lbs
4 Fan Nut, M16 X 1.5 67 N·m 50 ft lbs
5 Regulator Hold Down Screw, M5 X 0.8 8.5 N·m 75 in. lbs
6 Regulator Terminal (R), M6 X 1 4.5 N·m 40 in. lbs
7 Regulator Terminal (D+), M5 X 0.8 4.5 N·m 40 in. lbs
DIMENSIONS
A Housing Diameter 203.2 mm 8.0 in.
B Overall Length Minus Drive Shaft 292.0 mm 11.5 in.
C Shaft Diameter 22.22 mm 0.875 in.
D Height (Centerline to Top) 142.0 mm 5.59 in.
E Height (Centerline to Bottom) 135.6 mm 5.34 in.
F Width (Centerline to Regulator) 139.2 mm 5.48 in.

D10003 07/06 Battery Charging Alternator D10-13


PERIODIC MAINTENANCE TESTING
Alternator performance depends on the condition of
the components in the charging system. The most GENERAL INFORMATION
important components in the charging system are the
Troubleshooting Alternator (On-Truck)
alternator drive belt, battery, and related cables and
connections. A loose drive belt, weak battery, or cor- Most 24-Volt charging system problems can be diag-
roded cables and connections can cause the alterna- nosed with the alternator installed on the truck, oper-
tor to work extra hard, leading to overheating and a ating under normal conditions. Many problems can
reduction in performance. When performing any be attributed to loose or corroded cable connectors.
scheduled maintenance on your vehicle, ensure It is essential that all battery charging cables are in
these components are working properly. The alterna- satisfactory condition and all connections are clean
tor itself requires little maintenance. and securely tightened.
1. The most important maintenance requirement Equipment Required
for an alternator is to keep the air cooling pas-
sages free of dirt and obstruction. • Voltmeter, 0-40 Volt range (Digital type preferred)
2. To ensure that air cooling passages are clean, • Ammeter, 0-400 amp range (Digital, inductive
the alternator can be washed using a garden type preferred)
hose. • Jumper wires
3. During washing, avoid spraying high pressure
water directly on the regulator and regulator Preliminary Checks
connector. This can cause moisture to get past Ensure that an undercharged battery condition has
the seals in the connector and cause perfor- not been caused by accessories having been left on
mance problems. for extended periods.
4. After washing, dry the alternator by operating
1. Check the alternator drive belt.
the engine and alternator a few minutes. Main-
tenance requirements for internal components, 2. Ensure the automatic belt tensioner is working
such as alternator bearings, depend on the correctly.
application, usage, and environment. 3. If a battery defect is suspected, check the bat-
tery.
4. Inspect the wiring for defects. Check all connec-
tions for tightness and cleanliness. Remove and
clean the battery cables.
5. The truck is equipped with a battery equalizer
system. Verify the proper operation of the
equalizer and the individual battery voltages.
Refer to Battery Equalizer, Section D, 24VDC
Electrical Supply System.
6. Check the (B-) cable, (B+) cable, and alterna-
tor-to-regulator wiring harness connections.
Repair or replace any damaged component
before troubleshooting.
7. Ensure the thermal switch is functioning properly.
Refer to the Thermal Switch section in this chap-
ter for additional information.

D10-14 Battery Charging Alternator D10003 07/06


8. Check the battery. The batteries must be in NOTE: Until electrical system component
good condition and fully charged. If any battery temperatures stabilize, the conditions listed here may
condition is marginal, replace it with one known be observed during cold start voltage tests.
to be in good condition. a. Maintenance-type batteries display the fol-
For split battery pack, dual voltage systems, lowing characteristics.
battery rest voltages with 0.3 V. When the 12V 1). Immediately after engine start, the sys-
battery voltage is more than 0.3 V lower than tem Volts are lower than regulator set
24V battery voltage, check the 12V battery cir- point with medium amps.
cuit to verify adequate charge. 2).Three to five minutes into the charge
Polarity of the battery and the alternator must cycle, higher system Volts and reduced
agree; reverse polarity will damage the alterna- amps.
tor. The alternator is negative ground. 3). Five to ten minutes into the charge cycle,
9. Check the voltage output and use the informa- system Volts are at, or nearly at, the regu-
tion below to determine possible cause. lator set point, and the amps are reduced
a. Causes of low voltage to a minimum.
1). Loose or broken drive belt b. Low maintenance-type batteries display the
2). Batteries low state of charge same characteristics as maintenance-type
3). Current load on system greater than batteries, except cycle times may be longer.
the alternator can produce
c. Maintenance free-type batteries display the
4). Defective wiring or poor ground path
following characteristics.
5). Low regulator set point
1). Immediately after engine start, the sys-
6). Defective voltage regulator
tem Volts are lower than the regulator set
7). Defective alternator
point with low charging amps.
8). Lost residual magnetism
2). Fifteen to thirty minutes into the charge
b. Causes of high voltage cycle, still low Volts and low amps.
1). Wrong regulator 3). Fifteen to thirty minutes into the charge
2). High regulator set point cycle, Volts increase several tenths, amps
3). Defective regulator increase gradually, then increase quickly
4). Defective alternator to medium to high amps.
c. Causes of no voltage output. See 4). Twenty to thirty-five minutes into the
Regulator Bypass Test (No Output) for charge cycle, Volts increase to the set
additional testing information. point and amps decrease.
1). No drive belt d. High-cycle, maintenance-free type batteries
2). No battery (B+) voltage at alterna- display the following characteristics.
tor's (B+) terminal 1). These batteries respond much better than
3). Defective regulator the standard maintenance-free batteries.
4). Defective alternator 2). The charge acceptance of these batteries
5). Lost residual magnetism may display characteristics similar to stan-
10. Check the condition of the battery and the dard, maintenance-type batteries.
charge voltage reactions.

D10003 07/06 Battery Charging Alternator D10-15


Test Set-up
1. Discharge the battery as follows:
a. Disable the fuel system.
b. Turn all lights and accessories on. Crank the
engine for 10-15 seconds to discharge the
battery.
c. Turn all lights and accessories off.
d. Enable the fuel system.
2. Determine which set point is used on the regu-
lator (27.5, 28.0, 28.5, 29.0). The set point of
the alternator is 28V. Normal range is within ±
0.3V of set point, as shown in Table 10-2.

Table 10-2: VOLTAGE REGULATOR


System Factory Normal
Voltage Setting Range
27.5 27.2 - 27.8
28.0 27.7 - 28.3
24
28.5 28.2 - 28.8
29.0 28.7 - 29.3
FIGURE 10-7. TROUBLESHOOTING
Refer to Figure 10-7 for the following steps. Install 1. Alternator Under 4. Alternator (B+)
meters directly at the alternator, as shown, to elimi- Test Terminal
nate variations in readings due to cable lengths, etc. 2. 0 to 400 AMP 5. Alternator (B-)
Ammeter Ground Terminal
3. Open the battery disconnect switch. Remove 3. 0 to 40VDC 6. Truck Batteries
the battery cable from the alternator (B+) termi- Voltmeter
nal. 4. Attach the meters as indicated by Figure 10-7.
Measure the voltage and amperage at the alter-
nator, not at the batteries or an intermediate
point.
a. Connect the ammeter negative lead to the
end of the cable removed in Step 3. Connect
the ammeter positive lead to the alternator
(B+) terminal.
b. Connect the red lead of a voltmeter to the
alternator (B+) terminal, and the black lead
of the voltmeter to the (B-) terminal on the
alternator.
5. Secure all the test equipment leads to prevent
damage or short circuits when the engine is
started.
6. Reconnect the battery disconnect switch.

D10-16 Battery Charging Alternator D10003 07/06


Test Procedure 2. Watch the meter reading(s). If the battery is suf-
ficiently discharged, the amps must be high
within ± 10% of the output specified by the per-
formance curve. Volts must be within or below
the normal range as the battery approaches full
The following tests require working near the charge. Amps must fall as the voltage rises.
engine when it is on. Use caution when working When the amps and Volts stabilize, note the
near the engine fan, alternator fan, and fan belts. readings and refer to Table 10-3.

Table 10-3: AMP/VOLTAGE READINGS


1. Start the engine and accelerate to high idle.
Amps Volts Diagnosis
HIGH LOW Charging system is good. Battery
is not yet fully charged. Wait for
charging system to bring to full
charge: Amps must decrease and
Volts must stabilize within normal
If the charge voltage is above 33-Volts, immedi- range.
ately shut the engine off. Electrical system dam-
HIGH NORMAL Watch until amps fall, or Volts
age may occur if the charging system is allowed
exceed normal range. If amps
to operate at high voltage. decrease and Volts remain normal,
charging system is good. If Volts
exceed normal, regulator and/or
field coil must be replaced. Go to
Static Tests.
HIGH HIGH Stop the test. Regulator and/or
field coil replaced. Go to Static
Tests.
LOW LOW Ensure voltmeter leads are
attached at the alternator. If the
connections are good, the alterna-
tor and/or regulator must be
repaired or replaced. Go to Bench
Test 3.
LOW NORMAL Regulator is good. Go to Bench
Test 2.
LOW HIGH Stop the test. If battery and voltme-
ter check good, the regulator and/
or field coil must be replaced.

3. The batteries are considered fully charged if the


charge voltage is at the regulator set point, and
the charge amps remain at the lowest value for
10 minutes.
4. If the charging system is not performing prop-
erly, go to the Regulator Bypass test in the next
section.

D10003 07/06 Battery Charging Alternator D10-17


REGULATOR TESTING 3. If the shaft is still not magnetized, remove the
jumper from the alternator (D+) terminal on the
Regulator Bypass Test (No Output) regulator and go to Step 4.
If the Troubleshooting Alternator test procedure indi- 4. If the shaft is not magnetized:
cates low or no output, perform the following test to a. If connected, unplug the alternator-to-regula-
determine if the voltage regulator is defective or if the tor wiring harness connection.
alternator is defective.
b. Install a jumper wire from the alternator (B+)
1. A self-energized alternator may have lost its terminal to pin F in the wiring harness plug.
magnetism.
c. Momentarily (1 second), connect a jumper
a. Touch a steel tool to the shaft on the anti- wire from pin A to the alternator (B-) terminal.
drive end to detect any magnetism.
d. Touch the shaft with the steel tool to detect
b. If the shaft is magnetized, proceed to Step 5. significant magnetism.
c. If the shaft is not magnetized, proceed to e. If the shaft is not magnetized, the alternator
Step 2. is defective.
2. If the shaft is not magnetized:
f. If the shaft is magnetized, the regulator is
a. Momentarily (1 second), connect a jumper defective.
wire from the regulator (D+) terminal to the
alternator (B+) terminal.
b. Touch the shaft with the steel tool to detect
significant magnetism.
c. If the shaft is magnetized, proceed to Step 5;
otherwise go to Step 3.

FIGURE 10-9. WIRING HARNESS PLUG JUMPER


WIRE CONNECTION
1. Wiring Harness Plug 2. Regulator

5. Connect a voltmeter across pin D and pin C in


the wiring harness plug. Does battery voltage
FIGURE 10-8. JUMPER WIRE CONNECTION exist?
a. If no voltage, the alternator is defective.
1. Plug 2. Regulator
b. If voltage is present, proceed to Step 6.

D10-18 Battery Charging Alternator D10003 07/06


6. Set the voltmeter to the diode test scale.
a. Connect the black lead of the voltmeter to
pin E in the wiring harness plug.
b. Connect the red lead to the (B-) terminal on
the alternator. Limit the time the terminal is connected to a few
seconds. Doing so can protect the charging sys-
c. The voltmeter must read a voltage drop.
tem from excessive voltage increase.
d. Reverse the leads. The voltmeter must read
OL.
e. If there is no voltage drop, the alternator is Table 10-4: REGULATOR BYPASS TEST
defective.
Connect Disconnect Diagnosis
f. If there is a voltage drop, proceed to Step 7.
Amps increase Amps Alternator is good.
7. Install a jumper from the alternator (B+) terminal decrease Replace the regula-
to pin F in the wiring harness plug. tor only if low amps/
low Volts are indi-
a. Momentarily (1 second), connect a jumper cated by Bench Test
wire from pin A to the alternator (B-) terminal. 1 or 2.
b. Again, touch the shaft with a steel tool to No change No change The alternator must
detect significant magnetism. Is the shaft be repaired. Go to
magnetized? Static Tests.
c. If the shaft is not magnetized, the alternator
is defective.
d. If the shaft is magnetized, the regulator is
defective.

Regulator Bypass Test (Amp Rating)


1. Disconnect alternator-to-regulator wiring har-
ness plug (1, Figure 10-9).
2. Connect a jumper wire from pin F (F+ terminal)
in the alternator-to-regulator harness plug to the
alternator (B+) terminal.
3. Start the engine and accelerate to high idle.
4. Momentarily touch pin A (F- terminal) wiring
harness plug to the alternator ground terminal
(B-). Observe whether the amps increase or
decrease.
a. If the amps increase to within ± 10% of the
rated output when connecting (F-) to ground
(B-), the alternator is good. Refer to Table
10-4.
b. If the amps decrease when disconnecting
pin A (F-) from alternator ground (B-), the
alternator is good. Refer to Table 10-4.

D10003 07/06 Battery Charging Alternator D10-19


BENCH TESTING Bench Test 1: No-Load Test
1. With the battery connected and no electrical
load, operate the alternator at 5000 rpm.
2. Compare the test results to the No Load Test,
Perform the following on-bench tests when: Table 10-5, and take the appropriate action, as
stated in the table.
• On-vehicle test results are not available.
• Confirming on-vehicle test results. Table 10-5: NO LOAD TEST
Amps Volts Diagnosis
Equipment
HIGH LOW Test bench battery is discharged
• Voltmeter, 0-40 Volt range (Digital type preferred) or defective. Allow to charge or
replace.
• Ammeter, 0-400 ampere range (Digital, Inductive
type preferred.) HIGH NORMAL Allow time to stabilize while moni-
toring the Volts. If the Volts
• Test bench with 30-40 hp motor able to drive the increase above the normal range,
alternator to 8000 rpm. Mount the alternator on the regulator and/or field coil must
the test bench per the bench manufacturer’s be replaced. If the amps
instructions. Ensure the test bench batteries are decrease, the charging system is
at 95% or higher state of charge. good.

Identification Record HIGH HIGH The regulator and/or field coil


must be replaced. Go to Static
List the following items for troubleshooting: Testing.
 Alternator model number ______________ LOW LOW The alternator and/or regulator
must be repaired or replaced. Go
 Regulator model number ______________ to Bench Test 3.
 Set point(s) listed on regulator __________ LOW NORMAL The regulator is good. Go to
Bench Test 2.
Advanced Troubleshooting
LOW HIGH Stop the test. The alternator is
a. A voltage reading at the regulator set point of defective, bench is not working
± 0.2 Volts is considered normal. properly, or the alternator is wired
improperly to the bench.
b. The alternator rated output (listed on the
nameplate) within ± 10% is determined at
5000 rpm.

D10-20 Battery Charging Alternator D10003 07/06


Bench Test 2: Full Load Test 2. Set up the load on the alternator the same as
Bench Test 2.
1. With the load set to the rated output (listed on
the nameplate) ± 10%, operate the alternator at 3. Note whether the amps increased to within ±
5000 rpm. 10% of the rated output when connecting pin A
(F-) to alternator ground (B-.)
2. Compare the test results to Table 10-6, and take
the appropriate action, as stated in the table. 4. Note whether the amps decrease when discon-
necting pin A (F-) from the alternator ground.
Table 10-6: FULL LOAD TEST Compare the test results to Table 10-7, and take
the appropriate action, as stated in the table.
Amps Volts Diagnosis
HIGH LOW The test bench battery is dis-
charged or defective. Allow the
battery to charge or replace the
battery. Limit the time the terminal is connected to a few
HIGH NORMAL The charging system is good. seconds. Doing so can protect the charging sys-
HIGH HIGH Stop the test. The regulator and/ tem from excessive voltage increase.
or field coil replaced. Go to Static
Testing. Table 10-7: REGULATOR BYPASS TEST
LOW LOW The alternator and/or regulator Connect Disconnect Diagnosis
must be repaired or replaced. Go
to Bench Test 3. Amps increase Amps decrease The alternator is
good. Replace the
LOW HIGH Stop the test. The alternator is regulator only if low
defective, the bench is not work- amps/low Volts are
ing properly, or the alternator is indicated by Bench
wired improperly to the bench. Test 1 or 2.
No change No change The alternator must
Bench Test 3: Regulator Bypass Test be repaired. Go to
Static Testing.
Perform this test only when directed by other tests.
1. Bypass the regulator by installing a jumper
between pin A (F-) and pin F (F+).

FIGURE 10-10. PIN CONNECTION


IDENTIFICATION

D10003 07/06 Battery Charging Alternator D10-21


STATIC TESTING Check For Shorted Power Transistor
1. Set the DMM to the diode test scale and zero
the meter.

Static tests must confirm on-vehicle and bench


tests. For best results, disassemble the alterna-
tor, as needed, to access the parts.

Equipment
• Digital Multimeter (DMM)
• Ammeter (digital, inductive)
• Regulator tester
FIGURE 10-11. PIN CONNECTION
Identification Record IDENTIFICATION
 Alternator model number ______________ 2. Connect one meter lead to pin A (F-, Figure 10-
 Regulator model number ______________ 11) connector socket in the regulator, and con-
nect the other lead to pin C (B-) connector
 Set point(s) listed on regulator __________
socket in the regulator. Observe the meter read-
Regulator Tester ing.
3. Reverse the leads and observe the meter reading.
A regulator tester can test all regulator functions. If a
regulator tester is used, follow the regulator tester 4. In one direction, the DMM must register a tone.
manufacturer’s instructions. In the other direction, the DMM must show OL
(out of limits).
If a regulator tester is not available, the regulator can
5. If the DMM shows zero in both directions, the
only be tested for a shorted power transistor.
power transistor is shorted and the regulator
must be replaced.

NOTE: If regulator failure is indicated, field coil failure


must also be suspected.

D10-22 Battery Charging Alternator D10003 07/06


Circuit Tests 3. The expected reading listed for each test must
be obtained.
1. Before testing, check for visible signs of dam-
aged components. 4. Replace any component that fails.
2. Conduct the tests described in Alternator Pin- 5. Remove wiring harness (1, Figure 10-12)
to-Pin Tests, Table 10-8. before any test.

Table 10-8: ALTERNATOR PIN-TO-PIN TESTS


Test Meter Meter (+) Lead Meter (-) Lead Expected
No. Scale Connection Connection Tested Circuit Reading
1 Ohms Pin C Alt. B- Terminal Regulator ground circuit 0 ohms
2 Ohms* Pin A Pin F Field coil resistance 1.5 ± 0.2 ohms
3 Ohms Pin F Alt. B- Terminal Insulated OL (out of limits)
4 Ohms Pin A Alt. B- Terminal Insulated OL (out of limits)
5 Diode Test Pin B Alt. B+ Terminal Phase winding and diode <0.7 Volts (flow)**
6 Diode Test Alt. B+ Terminal Pin B Phase winding and diode OL (blocking)**
7 Diode Test Pin B Alt. B- Terminal Phase winding and diode OL (blocking)*
8 Diode Test Alt. B- Terminal Pin B Phase winding and diode <0.7 Volts (flow)**
9 Ohms Pin D Alt. B+ Terminal Regulator power circuit 0 ohms
10 Diode Test Alt. B+ Terminal Alt. B- Terminal All diodes in parallel OL (blocking)
11 Diode Test Alt. B- Terminal Alt. B+ Terminal All diodes in parallel <0.8 Volts (flow)
12 Diode Test Alt. B- Terminal Pin E Dual diode trio <0.7 Volts (flow)
13 Diode Test Pin E Alt. B- Terminal Dual diode trio OL (blocking)

* Applies only when the field coil is attached to the


rectifier/housing assembly.
** If the expected reading is not achieved, check the
thermal switch inside the rectifier/housing assem-
bly and test the switch for continuity.

D10003 07/06 Battery Charging Alternator D10-23


FIELD COIL TESTS
This test is used to check for an open or shorted field
coil.

Field Coil Test 1: Check for Open or Shorted Field


Coil
1. Set the digital multimeter DMM to x1 scale.
Ensure the DMM is zeroed.
2. Connect the meter leads from pin A (F-, Figure
10-13) and pin F (F+) in the regulator harness
plug. The DMM must show 1.2 ± 0.2 ohms.
a. If the meter shows more than 1.5 ohms, the
field coil is open.
b. If the meter shows less than 0.5 ohm, the
field coil is shortened. Replace the field coil.

FIGURE 10-12. WIRING HARNESS PLUG JUMPER


WIRE CONNECTION
1. Wiring Harness Plug 2. Regulator

FIGURE 10-13. PIN CONNECTION


IDENTIFICATION

Field Coil Test 2: Check For Grounded Field Coil


1. Set the digital multimeter (DMM) to x10K scale.
Ensure the DMM is zeroed.
2. Connect one meter lead to pin A (F-, Figure 10-
14) in the regulator harness plug. Connect the
other lead to the alternator ground (B-) terminal.
The DMM must show a very high resistance. If
the DMM reads less than 100K ohms, the field
coil is grounded. Replace the field coil.

D10-24 Battery Charging Alternator D10003 07/06


3. Move the drive lead from pin A (F-) to pin F (F+) STATOR TESTS
in the harness plug. The DMM must show a
These alternators have delta-wound stators. Test 1
very high resistance. If the ohmmeter shows
will show the condition of the phase lead from the
less than 100K ohms, the field coil is grounded.
ring terminal at the diode end of the lead to the sol-
Replace the field coil.
dered connection at the phase winding. Test the
phase coil windings on a bench stator tester, follow-
ing the tester’s instructions.
Before performing tests:
1. Check the stator for signs of damage, such as
burnt insulation or a loose coil.
2. Disconnect the phase lead wire from the mount-
ing terminals.

FIGURE 10-14. WIRING HARNESS PLUG JUMPER


WIRE CONNECTION
1. Wiring Harness Plug 2. Regulator

FIGURE 10-15. PHASE LEAD LOCATIONS

Stator Test 1: Check For Stator-To-Stator Conti-


nuity
1. Set the DMM to the ohms scale and zero the
meter.
2. Connect one meter lead to phase lead P1 (Fig-
ure 10-15), connect other meter lead (one at a
time) to each phase lead P4, P5, and P6.
Repeat for P2 and P3.
3. The DMM must show OL (out of limits) each
time. If the DMM shows a value, replace the
stator.

D10003 07/06 Battery Charging Alternator D10-25


Stator Test 2: Check For Grounded Stators Initial Test
1. Set the DMM to the ohms scale and zero the 1. Disconnect the wiring harness plug from the
meter. regulator.
2. Connect one DMM lead to the (B-) terminal on 2. If necessary, remove the cover from the drive
the alternator, and connect the other meter lead end housing.
to each phase lead P1, P2, and P3 (Figure 10- 3. Check for continuity between pin B (phase 1) of
15). the wiring harness plug and the phase lead
3. If the resistance reading is other than OL (out of (diode) connection (2), shown in Figure 10-16.
limits) at any connection, the stator is grounded This connection is just left of the 11 O'clock
to the shell. Replace the stator. position when looking at the alternator from the
4. Connect one DMM lead to the (B-) terminal on drive end.
the alternator, and connect the other DMM lead a. If continuity exists, there is a problem with
to each phase lead P4, P5, and P6. the alternator and not with the thermal
5. If the resistance reading is other than OL (out of switch.
limits) at any connection, the stator is grounded b. If there is no continuity, the thermal switch is
to the shell. Replace the stator. probably faulty.

THERMAL SWITCH TEST


If the alternator is not operating properly, check the
thermal switch. This switch is a normally closed (NC)
switch which must have continuity between the wires
from the switch.

FIGURE 10-16.

1. Pin B (Phase) 2. Phase Lead


Connection

D10-26 Battery Charging Alternator D10003 07/06


Verifying a Faulty Thermal Switch
1. Remove the cover from the control box on the
drive end housing.
2. Locate the thermal switch inside the control
box.
3. Test the two wires from the thermal switch for
continuity.
a. If there is no continuity, the switch is faulty.
b. If there is continuity, there may be a problem
with either the alternator or the wiring har-
ness.

D10003 07/06 Battery Charging Alternator D10-27


TROUBLESHOOTING TIPS
PROBLEM CAUSE/SOLUTION
1. Installed the alternator and connected the A self-energizing type alternator can lose its residual magne-
tism and not work properly. Residual magnetism is the small
cables (B+/B-(GND)) but the alternator has no
output. What could be wrong? amount of magnetic field that remains in the alternator when
there is no field current present. This residual magnetism is
Refer to the Regulator Bypass test (No Output)
necessary to start the alternator. Once established, the resid-
section for additional testing information.
ual magnetism slowly declines over time when the alternator
is not used. In practical terms, this time period is months. To
test for the presence of residual magnetism, touch a steel
wrench or screwdriver to the rotor shaft on the anti-drive end
of the alternator. If a light magnetic attraction is present, the
residual magnetism is present. If there is no attraction, the
residual magnetism is lost and must be restored or the alter-
nator may not self-energize. See 2. Self-energizing alternator
loses residual magnetism.
2. Self-energizing alternator loses residual Once an alternator is magnetized at the factory, it must hold
magnetism. its residual magnetic field for the duration of its life. In rare
instances, residual magnetism can be lost either during an
Refer to the Regulator Bypass test (No Output)
extended period of inactivity (shelf time) or if the alternator
section for additional testing information.
was exposed to a strong external magnetic field.
Momentarily (1 second), connect a jumper wire from the
jumper (D+) terminal on the regulator to the (B+) alternator
output terminal. The alternator must operate normally. If not,
further troubleshooting is required.

3. How can voltage regulators be tested? Voltage regulators can be tested using several methods.
Refer to the Regulator Bypass test (No Output) 1. The first method is to remove the suspect regulator and
section for additional testing information. substitute a known good regulator and then conduct the
alternator output test. If the alternator performs properly,
the suspect regulator is confirmed defective and must
be replaced.
2. The second method, incorporating the process of elimi-
nation, is to follow a diagnostic sequence and test the
individual alternator component functions to determine if
the components are good or bad. After systematically
eliminating the alternator components as the cause of
the problem, most likely, the regulator is defective.
Replace the regulator.
3. The third method involves utilizing a direct regulator
tester which is commercially available. When using a
tester to test a regulator, follow the instructions supplied
by the tester manufacturer and service manual for
proper terminal connections. If the regulator is not prop-
erly connected, the tester or the regulator may be dam-
aged. Refer to the regulator tester manufacturer's
instructions to determine if the regulator is defective.

D10-28 Battery Charging Alternator D10003 07/06


PROBLEM CAUSE/SOLUTION
4. The regulator has four different voltage settings The voltage regulator is equipped with a selectable voltage
from 27.0V to 29.5V on the 28.0V systems. set point. This feature allows the choice of the regulated volt-
Which is used? age output of the alternator according to the type of batteries
in use on the truck.
Refer to the Regulator Removal procedure in the
Alternator Disassembly section for additional infor- The lower voltage settings are used for maintenance-type
mation. batteries. The maintenance-type batteries require slightly
lower charge voltage to maintain performance. Excessive
voltage settings on the maintenance-type batteries will lead to
overcharging and premature failure of the batteries.
The higher voltage settings are used for maintenance-free
batteries. In general, a vehicle equipped with maintenance-
free batteries must have the regulator charge voltage set
point adjusted to one of the two higher settings on the regula-
tor. If the voltage setting is set too low for the maintenance-
free batteries, the insufficient charge voltage will keep the
battery from reaching full charge. Over time, this can lead to a
no start condition and reduce the battery life. An incorrectly
adjusted regulator voltage set point will result in either a con-
tinuous overcharging or undercharging condition, which can
affect battery performance and shorten the battery life.
The highest regulator voltage setting can be used only on
vehicles equipped with battery isolators. The battery isolators
are generally used on vehicles with two or more batteries.
The isolator set-up allows for independent discharge of one
battery, while the other battery remains fully charged for
engine restart. Due to the design nature of the isolator, the
alternator voltage setting must be increased to overcome a
voltage drop that occurs as the current flows through the iso-
lator. This voltage drop can be as high as one Volt. If the volt-
age is set lower than the battery type requires, it will lead to
an undercharge condition, a no start situation, and will reduce
the battery life.
If regulator replacement is necessary, set the new regulator
charge voltage set point to the same voltage setting as on the
regulator being replaced. Confirm that this is the correct set-
ting for the type of battery being used. The ambient tempera-
ture may also play a role in determining the correct regulator
charge voltage set point. When the vehicle is operated contin-
uously in cold climates, and the battery is not maintaining a
state of full charge, the regulator voltage set point may be
adjusted to the next higher set point appropriate for the given
battery type.

D10003 07/06 Battery Charging Alternator D10-29


PROBLEM CAUSE/SOLUTION
5. What is an alternator field coil, and how can the coil be The alternator field coil acts as an electromagnet
tested? when field current is applied. The stronger the mag-
netic field, the higher the alternator output when the
Refer to the Field Coil tests section for additional testing
shaft is turned. The strength of the magnetic field is
information.
dependent on the resistance of the field coil winding
(which determines the amperes of current the field
coil draws) and the number of wire turns in the field
coil. The most common symptoms associated with
alternator field coil failure are a no output condition,
reduced output, and sometimes an over-charge con-
dition.
The field coil can be tested for resistance value or
short to ground using an ordinary multi-meter. To test
the alternator's field coil resistance, refer to the Field
Coil Tests for additional testing information.
6. What is the function of the R terminal on the regulator The R terminal represents a tap or direct connection
and what can be measured there? to the alternator stator that has electric power only
when the alternator is turning and producing power.
The terminal output is utilized on some applications
for rpm or tachometer function. This requires a cali-
bration circuit that relates the alternator shaft speed
to the engine speed. The output at the R terminal is
AC voltage. The average voltage output can be mea-
sured with an ordinary multi-meter. The R terminal
output, depending on the electrical load, will be equiv-
alent to approximately one-half of the alternator regu-
lated voltage output. In other words, on the 28-Volt
system, the average voltage reading will be about 14-
Volts.

7. An alternator is being tested on a test bench and it does The maximum alternator output is dependent on the
not reach its full-rated output. What could be wrong? alternator shaft speed. If the test bench motor is not
properly rated, the alternator shaft will turn too slowly.
The alternator will not reach its rated output. When
testing an alternator on a test bench, ensure the test
bench motor is powerful enough to drive the alterna-
tor shaft at full load. To properly test the alternator
rated at 28-Volts and more than 200 amps, a bench
motor rated at 30 hp is required. Testing an alternator
using an underrated bench motor can lead to misdi-
agnosis and unnecessary component replacement.

D10-30 Battery Charging Alternator D10003 07/06


PROBLEM CAUSE/SOLUTION
8. When the alternator voltage is measured at the alterna- When there is a difference in voltage measured
tor (B+) terminal, it is considerably higher than alterna- between two places in the same circuit, the most
tor voltage measured at the battery (B+) terminal. What likely cause is excessive resistance in that circuit.
could be wrong? This difference, as measured between two points, is
called a voltage drop. The excessive resistance in the
circuit can be a result of poor connections at the ter-
minals or undersize gauge of the connecting cable.
All connecting cables in any electrical system must
be of sufficient gauge for the length of the cable to be
able to carry the necessary current within the circuit.
If the gauge is too small, the resulting voltage drop
will impair electrical system performance. This is a
critical issue for the charging system because exces-
sive voltage drops in the system, on the positive or
the negative side, can prevent the batteries from
recharging properly. The maximum difference
between the measurements must not exceed 0.8-
Volts for the 28-Volts system. To maintain accuracy
when testing the charging system, measure the volt-
age drop with the alternator at no load and at maxi-
mum load to check how the load current can affect
the voltage. Undersized cables also heat up when
conducting electrical current. This causes the insula-
tion to either soften or get brittle, and represents a
safety hazard in the system.

D10003 07/06 Battery Charging Alternator D10-31


ALTERNATOR
ALTERNATOR REPAIR

The alternator weighs approximately 32 kg (70


lbs). To prevent personal injury, it is recom-
The charging system is capable of causing phys- mended that a sling and overhead lifting device
ical harm. Use caution during the removal/instal- be used when removing the alternator.
lation procedures to protect personnel from 1. Disconnect the battery power:
injury.
a. If the truck is equipped with a battery equal-
izer, open the battery disconnect switch to
remove power from the system.
b. Remove the battery cables using the follow-
ing sequence:
1). Remove the battery positive (+) cables
first.
2). Remove the negative (-) cables last.
2. Securely attach a sling around the alternator,
and hook the sling to an overhead lifting device.
3. Remove battery cable (1, Figure 10-18) from
the (B+) terminal on alternator (2).

FIGURE 10-17. BATTERY CHARGING


ALTERNATOR
1. Alternator 2. Radiator

Removal
The following instructions cover the removal of alter-
nator (1, Figure 10-17) from a Komatsu engine. Radi-
ator (2) has been removed from the truck in some
pictures to clearly show the removal process. How-
ever, the radiator does not need to be removed to
remove the alternator.

FIGURE 10-18. REMOVE BATTERY CABLE


1. Battery Cable (B+) 2. Alternator
Terminal
To prevent shorting of the electrical system, dis-
connect the positive battery cable from the bat-
tery before starting this procedure.

D10-32 Battery Charging Alternator D10003 07/06


4. Remove ground strap (1, Figure 10-19) from 5. Remove eight lock nuts (1, Figure 10-21) from
the alternator by removing cap screw (1, Figure the front cover of the belt guard assembly.
10-20). It is not necessary to completely remove 6. Remove cover (2).
the ground cable unless it is damaged and must
be replaced.

FIGURE 10-21. BELT GUARD ASSEMBLY

1. Lock Nuts 2. Cover


FIGURE 10-19. GROUND STRAP
1. Ground Strap 2. Sub Frame 7. Use a ¾ inch square drive breaker bar to
release the tension on automatic belt tensioner
(1, Figure. 10-22.)
8. Remove belt (2). Replace the belt if signs of
wear or damage are found.

FIGURE 10-20. GROUND STRAP CONNECTION


1. Ground Strap 2. Cap Screw

FIGURE 10-22. AUTOMATIC BELT TENSIONER


ASSEMBLY

1. Automatic Belt 2. Belt


Tensioner

D10003 07/06 Battery Charging Alternator D10-33


9. Remove outer alternator bracket half (1, Figure 4. Use a ¾ inch square drive breaker bar to
10-23) by removing four lock nuts (2). release the tension on automatic belt tensioner
(1, Figure 10-22) and install belt (2).
10. Remove the alternator from the inner bracket
half. 5. Install cover (2, Figure 10-21) using eight lock
nuts (1).
6. Install ground strap (1, Figure 10-19) to the
alternator. Tighten ground cable cap screw (2,
Figure 10-20) to 15 N·m (11 ft lbs). If the ground
strap cable was removed from the frame, reat-
tach it.
7. Install battery cable (B+) to the terminal on
alternator (2, Figure 10-18). Tighten the nut to
32 N·m (24 ft lbs).
8. Connect the battery cable to the battery.
a. If the truck is equipped with a battery equal-
izer, close the battery disconnect switch.
b. If the truck is not equipped with a battery
equalizer, install the negative cable to the
negative battery post. Then, install the posi-
FIGURE 10-23. MOUNTING BRACKET tive cable to the positive battery post.
1. Alternator Bracket 2. Lock Nut Special Tools and Lubricants
(Top Half) Table 10-9: REQUIRED LUBRICANTS AND
SEALANTS
For additional information on disassembling the alter-
nator, see the Alternator Disassembly procedure in Komatsu Description Use
this chapter. Part #
XA3401 Grease Lubricate spiral rings
Installation
— Liquid Thread lock screws
Threadlockers
— Elastoplastic Insulate electrical
Silicone Resin connections
The alternator weighs approximately 32 kg (70
lbs). To prevent personal injury, it is recom- — Epoxy Install new stator
mended that a sling and overhead lifting device Adhesive wedges
be used when removing the alternator.
1. Securely attach a sling around the alternator
and hook the sling to an overhead lifting device.
2. Place the alternator on the inner bracket half.
3. Install outer alternate bracket half (1, Figure 10-
23). Install four lock nuts (2) and tighten to stan-
dard torque.

D10-34 Battery Charging Alternator D10003 07/06


Epoxy Adhesive Elastoplastic Silicone Resin
Master Bond, Inc. Dow Corning 1-2577 Low VOC RTV is a one-part
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Room Temp Cure Time = 60 minutes;
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excess of 22753 kPa (3,300 psi) and forms rigid and
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Liquid Threadlockers
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Phone: 860-571-5100
Internet: www.loctite.com

D10003 07/06 Battery Charging Alternator D10-35


Table 10-10: REQUIRED TOOLING
XA3320 Field Coil Removal/Installation Tool
XA3322 Stator Installation Tool
Customer-supplied dealer manufactured support stand
Three jaw gear puller (rotor removal, anti-drive end
housing, and anti-drive end shaft bearing)
Air impact wrench (pulley nut and fan nut)
Air chisel with a rounded point hammer bit (to loosen
rust from rotor, item 47)
Torque wrench (inch pounds)
Torque wrench (foot pounds)
FIGURE 10-25. XA3322 STATOR INSTALLATION
Torx bit T15 (field coil screws, item 53)
TOOL
Torx bit T20 (drive end cover plates and control unit
cover plates, item 6)
Torx bit T25 (rotor screws, item 46)
Allen socket wrench 3 mm (fan guard, item 69)
Deep well socket 6 mm (nut, item 54)
Socket 8 mm (voltage regulator screws, item 38)
Socket 9 mm (drive end and anti-drive end housings
lock flange nuts, item 14)
Socket 11 mm (stator wire hex jam nut, item 11)
Socket 24 mm (fan nut, item 67)
Socket 30 mm (pulley nut, item 1)
Small screwdriver (to release sockets in electrical plug,
item 30)
Expandable pliers (studs, item 61, and pulley bushing,
item 4) FIGURE 10-26. CUSTOMER-SUPPLIED DEALER
Internal heavy-duty snap ring pliers (items 8, 10) MANUFACTURED SUPPORT STAND
Hydraulic Press

FIGURE 10-27. THREE JAW GEAR PULLER


FIGURE 10-24. XA3320 FIELD COIL
REMOVAL/INSTALLATION TOOL

D10-36 Battery Charging Alternator D10003 07/06


ALTERNATOR EXPLODED VIEW

FIGURE 10-28. ALTERNATOR

D10003 07/06 Battery Charging Alternator D10-37


1. Lock Nut 36. Harness, Wiring
2. Flat Washer 37. Regulator
3. Pulley (supplied with engine) 38. Screw, Hex
4. Bushing, Pulley
39. Washer, Stainless Steel Bellville
5. Ring, Spiral
40. Washer, Bellville
6. Screw, Pan
41. Lock Nut
7. Plate, Cover
8. Ring, Beveled Retainer 42. Nut
9. Bearing, Front 43. Washer, Bellville
10. Ring, Flat Retainer 44. Bushing, Pulley
11. Nut, Hex Jam 45. Shaft and Core, Rotor Assembly
12. Flat Washer 46. Screw, Torx
13. Insulator 47. Rotor Assembly
14. Nut, Lock Flange 48. Rotor Shaft and Core Assembly
15. Flat Washer 49. Key, Woodruff
16. Cap Screw, Stainless Steel 50. Ring, Spiral
17. Lock Washer 51. Ring, Carrier
18. Lock Washer, Stainless Steel 52. Coil and Stator Assembly, Field
19. Cap Screw 53. Screw, Torx
20. Housing, Drive End 54. Nut
21. Cover, Control Unit 55. Wedge, Stator (attached to stator with epoxy
glue)
22. Switch, Thermal
56. Stator, Drive End
23. Cap Screw, Hex Head
57. Bushing, Tension (not used in mounting)
24. Lock Washer, Stainless Steel
58. Shell
25. Flat Washer
59. Stator, Anti-Drive End
26. Cover Plate, Stud Assembly
60. Coil, Field
27. Cap Screw, Stainless Steel
61. Stud
28. Lock Washer
62. Bearing, Anti-Drive End
29. Flat Washer
63. O-Ring
30. Shell Connector (Plug)
64. Housing, Anti-Drive End
31. Pin Connector, Female
65. Fan
32. Plug, Wedge Lock
66. Washer, Bellville
33. Shell Connector (Receptacle)
67. Nut
34. Receptacle, Wedge Lock
68. Guard, Fan
35. Pin Connector, Male
69. Screw, Pan
70. Grommet

D10-38 Battery Charging Alternator D10003 07/06


Regulator Removal
1. Remove voltage regulator (37).
a. Disconnect wiring harness (36) from voltage
regulator (37).
Wedges must be reinstalled and sealed in place
b. Remove and save four screws (38) and four
correctly to prevent damage to the internal parts
Bellville washers (39) using an 8 mm socket.
during operation.

ALTERNATOR DISASSEMBLY
NOTE: Disassemble the alternator only as far as
necessary to replace any defective part(s).

The alternator weighs approximately 32 kg (70


lbs). Be careful when moving or positioning the
alternator to prevent personal injury.

FIGURE 10-29.
36. Wiring Harness 37. Voltage Regulator
The following replacement parts are mandatory:
spiral rings (5, 50), O-rings (63), lock nuts (14),
bearings (9, 62), and all lock washers. All small
hardware is included in a kit. Refer to the Parts
book.

FIGURE 10-30.
38. Screw 39. Bellville Washer

D10003 07/06 Battery Charging Alternator D10-39


2. If replacement of the voltage regulator is neces- NOTE: DO NOT lose the metal portion of grommet
sary, record the setting of the selectable voltage washers (70).
set point switch on the back side of the voltage 2. Remove fan (65) by removing nut (67) using an
regulator. When installing a new voltage regula- air impact wrench and a 24 mm socket. Also,
tor, set the selectable voltage set point switch to remove Bellville washer (66).
the same switch position as the faulty regulator.

FIGURE 10-33.
FIGURE 10-31.
65. Fan 67. Nut
NOTE: The setting of this switch can depend on the 66. Bellville Washer
type of battery being used. Refer to the Battery
section for additional information.

Fan Removal
1. Remove fan guard (68) by removing six Allen
head screws (69) using a 3 mm Allen wrench. When removing nut (67), the use of an air impact
wrench is recommended.

FIGURE 10-32.
FIGURE 10-34.
68. Fan Guard 70. Grommet Washer
69. Allen Head Screw

D10-40 Battery Charging Alternator D10003 07/06


3. Remove and discard spiral ring (50) from fan Anti-Drive End Housing Removal
(65).
1. Scribe a single mark on side of shell (58) and
drive end housing (20). Scribe a double mark on
the side of shell (58) and anti-drive end housing
(64). This will ensure the proper reassembly of
the end housings.

FIGURE 10-35.

50. Spiral Ring 65. Fan

Pulley Removal
1. Remove pulley (3, Figure 10-24) from the drive
end by removing nut (1) using an air impact
wrench and a 30 mm socket. Also, remove
washer (2) and woodruff key (49).

FIGURE 10-37.
20. Drive End Housing 64. Anti-Drive End
58. Shell Housing

FIGURE 10-36.
1. Nut 49. Woodruff Key
2. Washer

NOTE: Removal of the pulley may require a three


jaw gear puller.

D10003 07/06 Battery Charging Alternator D10-41


NOTE: Disassembly of the alternator can be made 3. Remove and discard nine lock flange nuts (14)
easier by using a support stand, as shown. The from anti-drive end housing (64) using a 9 mm
Support Stand section in this chapter provides socket.
dimensions to manufacture the stand.

FIGURE 10-40.
FIGURE 10-38.
14. Lock Flange Nuts 64. Anti-Drive End
Housing

4. Remove anti-drive end housing (64) from shell


(58).

The alternator weighs approximately 32 kg (70 NOTE: Removal may require the use of a three jaw
lbs). Be careful when moving or positioning the gear puller.
alternator to prevent personal injury.

2. Position the alternator in the support stand with


the anti-drive end facing up.

FIGURE 10-41.
58. Shell 74. Three Jaw
64. Anti-Drive End Gear Puller
Housing
FIGURE 10-39.

D10-42 Battery Charging Alternator D10003 07/06


5. Remove and discard two O-rings (63) from 7. Remove and discard spiral ring (50) from carrier
inside diameter of anti-drive end housing (64). ring (51).
.

FIGURE 10-42. FIGURE 10-44.


63. O-Rings 64. Anti-Drive End
Housing 50. Spiral Ring 51. Carrier Ring

6. Remove bearing (62) from rotor shaft (48) along


Anti-Drive End Rotor Removal
with ring carrier (51) using a three jaw gear puller.
1. Remove one Torx screw (46) using a number
T25 Torx bit. Scribe a mark on the face of the
rotor at the center of the screw hole. This will be
used to correctly position the rotor during
assembly.

FIGURE 10-43.
48. Rotor Shaft 62. Bearing
51. Ring Carrier

FIGURE 10-45.

46. Screw 47. Rotor

D10003 07/06 Battery Charging Alternator D10-43


NOTE: If necessary to loosen rust, use an air chisel
with a rounded-point hammer bit to vibrate the area
between screw holes on the rotor face.
4. Thread three screws (46) into the puller holes.
Tighten the screws evenly to start removing
The rotor retaining screws have been installed
rotor (47) from rotor shaft (48).
with a thread lock compound (Loctite). DO NOT
use air impact tools to remove screws (46). Use .
only hand tools to carefully remove these
screws. Using air tools can cause the screws to
break, resulting in damage.

FIGURE 10-48.
46. Screw 48. Rotor Shaft
47. Rotor
FIGURE 10-46.

46. Screw 47. Rotor


2. Remove remaining five Torx screws (46) using
a number T25 Torx bit.
3. Clean out three threaded puller holes in top of Threaded screws (46) may not be long enough to
rotor (47). completely remove rotor (47) from the rotor shaft. If
necessary, use a three jaw gear puller to completely
remove the rotor. Using the three jaw gear puller
may damage the rotor if it is rusted to the rotor shaft.

FIGURE 10-47.

46. Screw 47. Rotor


FIGURE 10-49.
47. Rotor. 74. Three Jaw
Gear Puller

D10-44 Battery Charging Alternator D10003 07/06


5. Remove the rotor from the rotor shaft. 2. Place the alternator in the support stand with
the drive end facing up.

FIGURE 10-50.
FIGURE 10-52.

Drive End Housing Removal


3. Remove cover plate (7) by removing six Torx
screws (6) using a number T20 Torx bit.

Ensure the single mark has been scribed


between drive end housing (20) and shell (58).
This mark will be used during the assembly pro-
cess to correctly align the two parts.

1. Position the support stand so the large diameter


hole is facing up.

FIGURE 10-53.

6. Screw 7. Cover Plate

FIGURE 10-51.

D10003 07/06 Battery Charging Alternator D10-45


4. Remove six hex jam nuts (11, Figure 10-54) 5. Mark the location of the six phase leads for
using an 11 mm socket. Remove the phase proper reassembly. Place a different identifica-
leads from the terminals. If necessary, remove tion mark on both the housing and each phase
flat washers (12, Figure 10-55) and insulators lead terminal.
(13).

FIGURE 10-56.
FIGURE 10-54.
11. Hex Jam Nuts 20. Drive End Housing
6. Remove and discard nine lock flange nuts (14)
using a 9 mm socket.

FIGURE 10-55. FIGURE 10-57.


12. Flat Washers 13. Insulators
14. Lock Flange Nuts 20. Drive End Housing

D10-46 Battery Charging Alternator D10003 07/06


7. Remove the sealing compound from the face of 9. Carefully pull out and disconnect plug (30) from
the drive end housing where the field coil leads receptacle (33) by releasing the lock and dis-
enter the control unit connecting the gray plug assembly.
.

FIGURE 10-58. FIGURE 10-60.


8. Remove five Torx screws (6) from control unit 30. Plug 33. Receptacle
cover (21) using a T20 Torx bit. Remove control
unit cover (21).
10. Remove orange wedge lock (32).

FIGURE 10-61.

30. Plug 32. Wedge Lock

FIGURE 10-59.
6. Screw 21. Control Unit Cover

D10003 07/06 Battery Charging Alternator D10-47


11. Using a small flat-blade screwdriver, release the 13. Pull the field coil leads through the opening in
female pin connectors from the plug assembly. the drive end housing.

FIGURE 10-62. FIGURE 10-64.

12. Remove the two field coil leads from plug (30), 14. Lift drive end housing (20), along with rotor (47)
and remove the orange seal from the field coil and rotor shaft (48), off of shell assembly (58).
leads. This may require two people; one to lift the
housing, and the other to guide the phase leads
out of the housing.

FIGURE 10-63.
20. Drive End Housing 30. Plug
FIGURE 10-65.
20. Drive End Housing 48. Rotor Shaft
47. Rotor 58. Shell Assembly

D10-48 Battery Charging Alternator D10003 07/06


15. Remove pulley bushing (4). 16. Remove spiral ring (5) from pulley bushing (4)
and discard.

FIGURE 10-66.
4. Pulley Bushing 20. Drive End Housing FIGURE 10-68.
4. Bushing 5. Spiral Ring

NOTE: Use a pair of expandable pliers and gently


wiggle (move side-to-side) the pulley bushing out of 17. Place drive end housing (20) into a hydraulic
the housing. press with the outer surface of the housing sup-
ported by the press table.

FIGURE 10-67.
4. Pulley Bushing 75. Expandable Pliers FIGURE 10-69.
20. Drive End Housing 77. Hydraulic Press

D10003 07/06 Battery Charging Alternator D10-49


18. Press rotor shaft (48) out of front bearing (9). 20. Remove flat retainer ring (10) using heavy-duty
internal snap ring pliers. Save the ring.

FIGURE 10-70.
FIGURE 10-72.
9. Front Bearing 48. Rotor Shaft
10. Flat Retainer Ring 9. Front Bearing

19. Remove beveled retainer ring (8) using heavy-


duty internal snap ring pliers. Save the retainer 21. Place the drive end housing face down on a
ring. hydraulic press with the outer surface of the
housing supported by the press table.

FIGURE 10-71.
FIGURE 10-73.
8. Beveled Retainer 9. Front Bearing
Ring

D10-50 Battery Charging Alternator D10003 07/06


2. Remove one Torx screw (46) using a number
T25 Torx bit. Scribe a mark on the face of the
rotor at the center of the screw hole. This will be
used to correctly position the rotor during
assembly.
Use a bearing driver with a slightly smaller diam-
eter than the outer race of the bearing. Pressing
against the inner race of the bearing will cause
bearing damage.
22. Use a bearing driver to remove the bearing from
the housing. Discard the bearing.

FIGURE 10-76.
46. Screw 47. Rotor

FIGURE 10-74.
The rotor retaining screws have been installed
Drive End Rotor Removal with a thread lock compound (Loctite). DO NOT
1. If necessary, remove drive end rotor (47) from use air impact tools to remove screws (46). Use
rotor shaft (48), using the following steps. only hand tools to carefully remove these
screws. Using air tools can cause the screws to
break, resulting in damage.

3. Remove remaining five Torx screws (46) using


a number T25 Torx bit.
4. Place rotor (47) and rotor shaft (48) into a
hydraulic press and remove the shaft. Ensure
the rotor is fully supported by the press table.

FIGURE 10-75.

47. Drive End Rotor 48. Rotor Shaft

D10003 07/06 Battery Charging Alternator D10-51


Field Coil Removal 4. Reposition the alternator in the support stand
with the drive end facing up.

DO NOT damage or bend studs (61).


1. Position the alternator in the support stand with
the anti-drive end facing up.
2. Permanently mark the letters ADE on the sur-
face of field coil (60) in the location of the miss-
ing screw.
3. Remove eight Torx screws (53) using a number
T15 Torx bit.

FIGURE 10-78.

5. Permanently mark the letters DE on the surface


of field coil (60) in the location of the missing
screw.
6. Remove eight Torx screws (53) using a number
T15 Torx bit.

FIGURE 10-77.
53. Screws 60. Field Coil

Field coil retaining screws (53) have been


installed with a thread lock compound (Loctite).
DO NOT use air impact tools to remove screws. FIGURE 10-79.
Use only hand tools to carefully remove these
screws. Using air tools can cause the screws to 53. Screws 60. Field Coil
break, resulting in damage.

D10-52 Battery Charging Alternator D10003 07/06


7. Place XA3320 field coil removal/installation tool
on top of the field coil.

DO NOT damage the field coil leads during the


removal process.
NOTE: If a new field coil will be installed, mark the
letters (in the same location and orientation) from
Steps 2 and 5 on the new replacement field coil.

9. Carefully remove the field coil from the stator.


The clearance between the field coil and stator
is minimal. Use caution during the removal pro-
cess. As the field coil is removed, ensure the
two field coil leads are removed without dam-
FIGURE 10-80. age.

8. Engage the recessed areas of the tool with the NOTE: In some instances, removal of the field coil
field coil bobbin ears. Rotate the tool clockwise may be easier by placing the anti-drive end of the
approximately five degrees to release the field alternator in an upward position and pulling the field
coil from the stator tabs. coil out of the stator.

FIGURE 10-82.

FIGURE 10-81.

D10003 07/06 Battery Charging Alternator D10-53


Drive End and/or Anti-Drive End Stator Removal 4. Permanently scribe or etch a single mark
aligned with the center of two stud holes, across
the top surface of anti-drive end stator (59) and
end of shell (58). Repeat at an adjacent hole.

Remove and replace one faulty stator at a time.


This process will ensure the alignment of stators
(56, 59) to shell (58). Refer to the appropriate
Installation section for specific installation
instructions.
1. Position the alternator in the support stand with
the drive end facing up.
2. Permanently scribe or etch a single mark,
aligned with the center of a stud hole, across
the top surface of drive end stator (56) and end
of shell (58).

FIGURE 10-84.

58. Shell 59. Anti-Drive End


Stator

A single scribe mark identifies the stator as the


drive end stator. The double mark identifies the
stator as the anti-drive end stator. It is critical
FIGURE 10-83. that these marks be precisely aligned during
assembly. If the marks are not precisely aligned,
56. Drive End Stator 58. Shell the phase leads, field coil leads, and the mount-
ing holes will not properly align. If a new stator is
3. Reposition the alternator in the support stand being installed, it is critical to precisely transfer
with the anti-drive end facing up. the location of the mark(s) to the new part.

D10-54 Battery Charging Alternator D10003 07/06


5. Remove the shell assembly from the support 8. Position the shell in the support stand with the
stand. Remove hex head nuts (54) from studs faulty stator in a downward position. Place sta-
(61) using a deep well 6 mm socket. Discard tor installation/removal tool XA3320 on top of
nuts (54). Use expandable pliers to hold the the tabs of the stator being removed. Ensure
enlarged portion of the stud. the recessed portion of the tool is fully engaged
with the stator tabs

Ensure the stator installation/removal tool is


engaged with the stator tabs of the part being
removed and not the stator in the upper position.
The shell assembly is manufactured with a raised
area in the center of the shell. The stators can
only be removed by pushing them out through
the end of the shell.

9. Place the shell assembly into a hydraulic press


and remove the faulty stator. Figure 10-86
FIGURE 10-85. shows the drive end stator being removed.
54. Hex Head Nuts 61. Studs

NOTE: Hex head nuts (54) have been installed using


a thread locking compound. Use care when
removing.

6. Remove and save nine studs (61) from the sta-


tors.
7. If a stator needs to be replaced, remove only
the faulty stator.
a. If removing the anti-drive end stator, place a
mark on the drive end stator where each
anti-drive end phase lead is located. Cut the
three terminals off the anti-drive end phase
FIGURE 10-86.
leads and discard.
b. If removing the drive end stator, break out NOTE: The tabs of the stator may bend slightly
the six glued in wedges on the drive end sta- downward during the removal process. Continued
tor with the anti-drive end phase leads downward pressure will push the stator out of the
behind them. shell.

D10003 07/06 Battery Charging Alternator D10-55


10. Carefully pull the three anti-drive end stator CLEANING AND INSPECTION
phase leads through the spaces between the 1. Ensure all parts being reused are thoroughly
stator windings. clean.
2. Ensure all parts being reused are in good condi-
tion. Replace any damaged parts.

ALTERNATOR ASSEMBLY
Before starting the installation procedure, ensure all
the parts are available and in good condition.
Replace any damaged parts before assembly.

All electrical wiring connections are coated with


a Dow Corning® 1-2577 low VOC RTV coating or
FIGURE 10-87. equivalent. DO NOT use a coating containing
acetic acid (vinegar smell) on any electrical com-
11. If it is necessary to remove the other stator, first ponents. Using any other coating will cause part
reinstall a new stator in place of the removed damage.
stator. Then, reposition the shell in the hydraulic
press with the remaining stator in a downward
position.

The following replacement parts are mandatory:


spiral rings (5, 50), O-rings (63), lock nuts (14),
bearings (9, 62), and all lock washers. All small
hardware is included in a kit. Refer to the Parts
book.

Anti-Drive End Stator Installation


This procedure assumes the drive end stator is
already installed in the shell, and a new anti-drive
end stator is being installed.
NOTE: New stators do not have terminals on the
phase leads. The leads must be cut to length,
FIGURE 10-88. insulation sleeves installed, and terminals soldered
onto the wires during final assembly.
12. Place the shell assembly into a hydraulic press
and remove the other faulty stator (56 or 59).
1. Precisely transfer the two scribed assembly
marks from faulty anti-drive end stator (59) to
the replacement stator.
2. Place the stator in the opening of shell (58).

D10-56 Battery Charging Alternator D10003 07/06


NOTE: If the drive end stator will not be replaced, 4. Insert six alignment studs through the holes in
route the phase leads from the replacement anti- anti-drive end stator (59) aligning them with the
drive end stator through the corresponding spaces holes in drive end stator (56).
(marked in Step 7a of the Disassembly procedure,
.
page 55) between the drive end stator windings. New
insulation sleeves and terminals will be installed on
the phase leads during final assembly.

FIGURE 10-91.

56. Drive End Stator 59. Anti-Drive End


Stator
FIGURE 10-89. 5. Place the shell with the stator into a hydraulic
press. Place stator installation tool XA3322 on
top of the stator.
3. Align the two scribed marks on the stator with
the scribed marks on shell (58). It is critical that
these scribed marks be carefully aligned. If the
marks are not precisely aligned, the wiring and
the mounting holes will not properly align.

FIGURE 10-92.

FIGURE 10-90.

D10003 07/06 Battery Charging Alternator D10-57


8. If the drive end stator needs to be replaced, fol-
low the steps in the next section. If the drive end
stator does not need replacement, go to the
Field Coil Installation section in this manual.

Ensure the shell is supported in a hydraulic Drive End Stator Installation


press so the alignment studs are not damaged by
This procedure assumes the anti-drive end stator is
the supports.
already installed in the shell, and a new drive end
6. Press the stator into the shell. The top surface stator is being installed.
of stator (59) will be flush with the end of shell
(58) when fully installed. 1. Precisely transfer the scribed assembly mark
from faulty drive end stator (56) to the replace-
. ment stator.
2. Place the stator in the opening of the shell.
3. Route three anti-drive end stator phase leads
through the corresponding spaces between the
drive end stator windings.
NOTE: There are two methods for routing the anti-
drive end phase leads. Follow either Step 3a or 3b.

a. Primary method (recommended): Break out


the six wedges on the replacement drive end
stator. Route the phase leads through the
corresponding spaces between the drive end
stator windings. Glue the six replacement
FIGURE 10-93. wedges in place using the recommended
58. Shell 59. Stator epoxy adhesive after the drive end stator is
pressed in place.
7. Remove the shell and stator assembly from the
press. Remove the installation tool. Remove the
six alignment studs.

FIGURE 10-95.

FIGURE 10-94.

D10-58 Battery Charging Alternator D10003 07/06


b. Alternative method: Remove the insulation 4. Place the stator in the opening of the shell. Pre-
sleeves from the three anti-drive end phase cisely align the scribed mark. It is critical that
leads. DO NOT damage the insulation this scribed mark be carefully aligned. If the
sleeves during removal. Carefully feed the mark is not precisely aligned, the wiring and the
terminal ends up through the corresponding mounting holes will not properly align.
spaces between the drive end windings. Use
a pick tool to pull the terminals though the
windings. Reinstall insulation sleeves after
the drive end stator is pressed in place.

FIGURE 10-97.

5. Insert six alignment studs through the holes in


the drive end stator aligning them with the holes
FIGURE 10-96. in the anti-drive end stator.

If the insulation sleeves are damaged or not


installed properly, excessive damage can be
caused to the alternator when current is pro-
duced during operation.

FIGURE 10-98.

D10003 07/06 Battery Charging Alternator D10-59


6. Place the shell with the stator in a hydraulic 8. Remove the shell and stator assembly from the
press. Place stator installation tool XA3322 on press. Remove the installation tool. Remove the
top of the stator. Position the studs in the open- six alignment studs.
ings of the tool.

FIGURE 10-101.
FIGURE 10-99.
NOTE: Precisely align the alignment marks on both
stators and the shell. If they are not aligned, remove
the stator(s) and reinstall.

9. Install nine studs (61) through stators (56 and


Position the shell in a hydraulic press so the 59). Install the studs from the anti-drive end of
alignment studs are not damaged by the sup- the alternator with the enlarged portion of the
ports. stud on the anti-drive end.

7. Press the stator into the shell. The top surface


of drive end stator (56) will be flush with end of
shell (58) when fully installed.

FIGURE 10-102.

56. Drive End Stators 61. Studs


59. Anti-Drive End
Stators
FIGURE 10-100.
56. Drive End Stator 58. Shell

D10-60 Battery Charging Alternator D10003 07/06


10. Install hex head nuts (54) onto the studs. Use a 2. Align the letters ADE on the field coil with the
suitable thread lock compound such as Loctite non-tabbed portion of the stator, and route the
222. Tighten the nuts to 3 N·m (30 in. lb) in an two field coil leads through the corresponding
alternating pattern. space between the stator windings.

Field Coil Installation


NOTE: If a new field coil is being installed, transfer
the letters ADE (anti-drive end) and DE (drive end)
from the faulty field coil to the corresponding
locations on the replacement field coil.

1. Position shell (58) on the support stand with the


drive end facing down.

FIGURE 10-104.

NOTE: New field coils do not have terminal pins


installed on the leads. The leads must be cut to
length and the new terminal pins crimped on during
final assembly.

FIGURE 10-103.

58. Shell 73. Support Stand

D10003 07/06 Battery Charging Alternator D10-61


3. Carefully push the field coil downward through 5. Engage the recessed areas of the tool with the
stator tabs (59). The clearance between the field coil bobbin ears. Rotate the tool clockwise
field coil and stator is minimal and will require approximately five degrees to engage the field
care during the installation process. As the field coil with the stator tabs. Ensure the letters ADE
coil is installed, ensure the two wires are not are now aligned with the non-tabbed area of the
damaged. Push the field coil downward until the stator.
mating surfaces between the field coil bobbin
ears and the stator tabs are vertically aligned.

FIGURE 10-107.

FIGURE 10-105.
6. Install eight field coil screws coated with a
59. Stator Tabs 60. Field Coil thread locking compound (such as Loctite 222
or equivalent). Tighten the screws to 2 N·m (20
in. lb).
4. Place field coil removal/installation tool XA3320
on top of the field coil.

FIGURE 10-108.

FIGURE 10-106.

D10-62 Battery Charging Alternator D10003 07/06


DO NOT install a screw in the marked hole DO NOT install a screw in the marked hole
because there is no corresponding stator tab. If because there is no corresponding stator tab. If
installed, the screw will fall into the stator cavity, installed, the screw will fall into the stator cavity,
damaging internal parts during operation. damaging internal parts during operation.

Drive End Bearing Installation


7. Reposition the shell assembly in the support
1. Install flat retainer ring (10) into the drive end
stand with the drive end facing up.
housing, as shown, using heavy-duty, internal
snap ring pliers.

FIGURE 10-109.
FIGURE 10-111.

8. Install eight field coil screws coated with a 10. Flat Retainer Ring 76. Snap Ring Pliers
thread locking compound (such as Loctite 222
or equivalent). Tighten the screws to 2 N·m (20
in. lb).

Fully support the housing before pressing the


bearing into the housing. Position the diameter of
the bearing driver against the outer bearing race.
Pressing on the inner race of the bearing will result
in bearing damage.

FIGURE 10-110.

D10003 07/06 Battery Charging Alternator D10-63


2. Place drive end housing (20) and front bearing 4. Lubricate the spiral ring with Komatsu grease
(9) in a hydraulic press. Press the bearing into XA3401. Wind new spiral ring (5) into the
the bore until completely seated against the flat groove around pulley bushing (44).
retainer ring.

FIGURE 10-114.
FIGURE 10-112.
5. Spiral Ring 44. Pulley Bushing
9. Front Bearing 20. Drive End Housing

5. Compress spiral ring (5) and install pulley bush-


3. Install beveled retainer ring (8) using heavy- ing assembly into the inside bore of the drive
duty, internal snap ring pliers. Position the bev- end housing. Position the thickest flange of the
eled portion of the retaining ring facing up. pulley bushing facing up (towards the inside of
the alternator).

FIGURE 10-113.
FIGURE 10-115.
8. Beveled Retainer 76. Snap Ring Pliers
Ring 5. Spiral Ring 20. Drive End Housing

D10-64 Battery Charging Alternator D10003 07/06


Drive End Rotor Installation Rotor and Rotor Shaft Installation
1. If removed, install drive end rotor (47) onto shaft 1. Press rotor and rotor shaft assembly (47, 48)
assembly (48). into drive end housing (20).
a. Place the rotor and rotor shaft assembly into
a hydraulic press with the rotor shaft fully
supported.
b. Place drive end housing (20) onto rotor shaft
(48).
c. Press the drive end housing onto the rotor
shaft. Press the housing onto the shaft using
a bearing driver, which will press against the
inner bearing race.

FIGURE 10-116.

47. Drive End Rotor 48. Shaft Assembly

2. Center the screw hole in rotor shaft (48) with


the slot in rotor (47).

FIGURE 10-118.

20. Drive End Housing 48. Rotor Shaft


47. Rotor Assembly Assembly

When installing the drive end housing, press


only on the inner race of the bearing. Pressing on
any other surface will result in bearing damage.
FIGURE 10-117.

47. Drive End Rotor 48. Shaft Assembly


2. Rotate the shaft to verify the bearing moves
3. Install five Torx screws (46) using a T25 Torx bit. freely.
Apply thread lock compound (Loctite 222) and
tighten to 7 N·m (65 in. lb). DO NOT install a
screw in the marked hole at this time.
4. Ensure the screw hole has remained centered
in the slot on the face of the rotor. Apply thread
lock compound (Loctite 222) and install the
screw. Tighten to 7 N·m (65 in. lb).

D10003 07/06 Battery Charging Alternator D10-65


Drive End Housing Installation 3. As the drive end housing is installed, guide the
two field coil leads and the six stator phase
1. Place shell assembly (58) into the support
leads through the proper openings in the drive
stand with the drive end facing up.
end housing.
NOTE: If necessary, install new terminal ends on the
wires. On the stator phase leads cut the wires to
length, strip the correct amount of wire insulation,
install insulating sleeves over the wires, and solder
on the new terminal ends. On the new field coil leads,
cut the wires to length, strip the correct amount of
wire insulation, and crimp on the new terminal pins.

FIGURE 10-119.
58. Shell Assembly 73. Support Stand

DO NOT damage the stator windings or studs FIGURE 10-121.


while repositioning the alternator.

2. Align the scribed marks on the drive end hous-


ing and the shell. Install the rotor shaft and
housing assembly onto the shell. A rod can be
used to verify the mounting tabs on the shell
and the drive end housing are properly aligned.

FIGURE 10-120.

D10-66 Battery Charging Alternator D10003 07/06


4. Install nine new lock flange nuts (14) onto studs 6. Place the stator phase leads onto the stator
(61). Tighten the nuts to 5 N·m (45 in. lb) using phase lead studs and install new hex jam nuts
an alternating pattern. (11). Tighten the nuts to 3 N·m (30 in. lb).

FIGURE 10-122. FIGURE 10-124.

14. Lock Flange Nuts 61. Studs 11. Jam Nuts 20. Drive End Housing

5. Install insulator (13) and then flat washer (12)


on the stator phase lead studs.

Position the insulation sleeves on the stator


phase leads over the arm of each terminal ring to
avoid a possible short circuit.

FIGURE 10-123.

12. Flat Washer 13. Insulator

D10003 07/06 Battery Charging Alternator D10-67


7. Lubricate the spiral ring with Komatsu grease 9. Guide the two field coil leads through the open-
XA3401. Wind new spiral ring (5) into the ing in the drive end housing and into the control
groove around pulley bushing (4). housing.

FIGURE 10-125. FIGURE 10-127.

4. Pulley Bushing 5. Spiral Ring

8. Compress spiral ring (5) and install pulley bush-


ing assembly (4) into the outside of drive end
housing (20). Position the thickest flange of the
pulley bushing facing up (towards the outside of
the alternator).

FIGURE 10-126.

4. Pulley Bushing 20. Drive End Housing


Assembly
5. Spiral Ring

D10-68 Battery Charging Alternator D10003 07/06


10. Install the orange wire seal over the field coil 11. Connect plug assembly (30) with receptacle
leads. Install the two terminal sockets into plug assembly (33).
assembly (30). Install orange wedge (32) to lock
the sockets into the plug.

FIGURE 10-129.

30. Plug Assembly 33. Receptacle


Assembly

12. Apply Dow Corning® 1-2577 low VOC RTV, or


equivalent, onto all electrical connections. Also,
seal the opening where the field coil leads enter
the control unit.

FIGURE 10-128.

30. Plug Assembly 32. Wedge

NOTE: Ensure the brown wire in the plug assembly


corresponds to the white wire in the receptacle
assembly. Ensure the red wire corresponds with the
black wire.

FIGURE 10-130.

D10003 07/06 Battery Charging Alternator D10-69


13. Install cover plate (7). Apply thread lock com- Anti-Drive End Rotor Installation
pound (Loctite) and install six Torx screws (6) 1. Reposition the alternator in the support stand
using a T20 Torx bit. Tighten the screws to 3 N·m with the anti-drive end facing up.
(30 in. lb).

FIGURE 10-133.
FIGURE 10-131.
6. Screws 7. Cover Plate
2. Install anti-drive end rotor (47) onto shaft
assembly (48). Align the previously-scribed
14. Apply Dow Corning® 1-2577 low VOC RTV, or mark on the face of the rotor with the center of
equivalent, onto the cover before installing. the screw hole.
Install control unit cover (21). Apply thread lock
compound (Loctite) with five Torx screws (6)
using a T20 Torx bit. Tighten to 3 N·m (30 in.
lb).

FIGURE 10-134.
47. Anti-Drive End Rotor 48. Shaft Assembly

FIGURE 10-132.
6. Screws 21. Control Unit Cover

D10-70 Battery Charging Alternator D10003 07/06


3. Apply thread lock compound (Loctite) and Anti-Drive End Housing Installation
install five Torx screws (46) using a T25 Torx bit. 1. Lubricate the spiral ring with Komatsu grease
DO NOT install a screw in the scribed hole at XA3401. Wind new spiral ring (50) into the
this time. Tighten the five screws to 7 N·m (65 groove of carrier ring (51).
in. lb).

FIGURE 10-137.
FIGURE 10-135.
46. Screw 47. Rotor 50. Spiral Ring 51. Carrier Ring

2. Install two new O-rings (63) in anti-drive end


4. Ensure the alignment mark has remained cen- housing (64).
tered with the screw hole. Apply thread lock
compound (Loctite), install the screw. Tighten to
7 N·m (65 in. lb).

FIGURE 10-138.
63. O-Rings 64. Anti-Drive End
FIGURE 10-136. Housing
46. Screw 47. Rotor

D10003 07/06 Battery Charging Alternator D10-71


3. Compress spiral ring (50) and install carrier ring 5. Apply thread lock compound (Loctite 222) and
assembly (51) into the anti-drive end housing, install nine new lock flange nuts (14). Tighten to
(towards the inside of the alternator). This part 5 N·m (45 in. lb) in an alternating pattern.
can be installed in either direction.

FIGURE 10-141.
FIGURE 10-139.
14. Lock Flange Nuts 64. Anti-Drive End
50. Spiral Ring 51. Carrier Ring Housing
Assembly

6. Install anti-drive end bearing (62) over the rotor


4. Align the installation scribe marks on shell (58) shaft. Place the shell assembly into a hydraulic
and anti-drive end housing (64). Install the anti- press. Press the bearing into the bore of anti-
drive end housing over rotor shaft (48) and nine drive end housing (64) until it is completely
studs (61). seated against the pulley bushing.

FIGURE 10-140. FIGURE 10-142.


48. Rotor Shaft 61. Studs
62. Bearing 64. Anti-Drive End
58. Shell 64. Anti Drive-End
Housing
Housing

D10-72 Battery Charging Alternator D10003 07/06


10. Install fan guard (68). Apply thread lock com-
pound (Loctite). Install Allen head screws (69)
using a 3 mm Allen socket wrench. Tighten the
screws to 7 N·m (65 in. lb).

When installing the anti-drive end bearing, press


only on the inner race of the bearing. Pressing on
any other surface will result in bearing damage.

7. Rotate the shaft to verify the bearing moves freely.


8. Lubricate the spiral ring with Komatsu grease
XA3401. Wind new spiral ring (50) into the
groove around fan (65).

FIGURE 10-143.
50. Spiral Ring 65. Fan

FIGURE 10-145.
9. Install the fan onto the rotor shaft with Bellville
washer (66) and nut (67). Use an air impact 68. Fan Guard 70. Grommets
wrench and a 24 mm impact socket to tighten 69. Allen Head Screws
the nut to 6 N·m (50 ft lb).
.
NOTE: Verify the metal grommet washers are still in
grommets (70).

FIGURE 10-144.

D10003 07/06 Battery Charging Alternator D10-73


11. Remove the alternator from the support stand. NOTE: The setting of this switch can depend on the
Install woodruff key (49) in the rotor shaft. type of battery being used. Refer to Battery in this
Install pulley (3) with flat washer (2) and nut (1). chapter for additional information.
Use an air impact wrench and a 30 mm impact
socket to tighten the nut to 163 N·m (120 ft lb).
2. Place the regulator on the alternator. Install four
screws (38) with Bellville washers (39) using an
8 mm socket. Tighten the screws to 8 N·m (70
in. lb).

FIGURE 10-146.
1. Lock Nut 49. Woodruff Key
2. Flat Washer
FIGURE 10-148.
Regulator Installation
38. Screws 39. Bellville Washers
1. Set the selectable voltage set point switch on
the back side of the regulator to the correct
position.
3. Connect wiring harness (36) to voltage regula-
tor (37).

FIGURE 10-147.

FIGURE 10-149.
36. Wiring Harness 37. Voltage Regulator

D10-74 Battery Charging Alternator D10003 07/06


THERMAL SWITCH 3. Remove the plastic tie strap securing the wires
together.
Removal
1. Disconnect wiring harness plug (36) from volt-
age regulator (37).

FIGURE 10-152.

FIGURE 10-150. 4. Remove all the sealant from around thermal


switch (22).
36. Wiring Harness Plug 37. Voltage Regulator

2. Remove nine Torx screws (6) using a T20 Torx


bit. Remove covers (21, 26).

FIGURE 10-153.
22. Thermal Switch

FIGURE 10-151.
6. Screws 26. Stud Assembly
21. Control Unit Cover

NOTE: If desired, disconnect field coil plug (30) from


receptacle (35). This will provide additional clearance
when removing the thermal switch.

D10003 07/06 Battery Charging Alternator D10-75


5. Remove hex head bolt (23) using a 13 mm 7. Remove thermal switch (22).
socket. Also, remove Bellville washer (24) and a. Reposition the two insulation sleeves to
flat washer (25). expose the wiring connections.
b. Remove the heat shrink insulation from both
wiring connections.
c. Unsolder each wire from the wiring terminal
sleeves.

FIGURE 10-154.
23. Hex Head Bolt 25. Flat Washer
24. Bellville Washer

6. Identify and mark the wiring terminals for proper FIGURE 10-156.
reassembly. These terminals must be reinstalled
in the same location as they were removed.
The order of the connections from top to bottom is:
rectifier terminal (1)
rectifier terminal (1),
B+/sense terminal (2),
thermal switch terminal (3),
flat washer,
Bellville washer, and
bolt

FIGURE 10-157.

FIGURE 10-155.

D10-76 Battery Charging Alternator D10003 07/06


Installation SUPPORT STAND
1. Place the appropriate diameter heat shrink Disassembly of the alternator can be made easier by
insulation onto the thermal switch wires. using a support stand, as shown. This drawing pro-
2. Solder the new thermal switch wires into the vides the dimensions to manufacture the stand.
wiring terminal sleeves.
3. Position the heat shrink insulation over each
wiring connection and apply heat to seal the
connection.
4. Reposition the insulation sleeve over each wir-
ing connection.
5. Place the wiring terminal connections in the cor-
rect order. Refer to Step 6, Removal, for the
proper installation order. Install hex head bolt
(23) with lock washer (24) and flat washer (25).
Tighten the bolt to 28 N·m (20 ft lb).

The thermal switch connection is coated with a


Dow Corning® 1-2577 low VOC RTV coating, or FIGURE 10-158.
equivalent. DO NOT use a coating containing
acetic acid (vinegar smell) on any electrical com-
ponents. Using any other coating will cause part
damage.

6. Coat the thermal switch connection with Dow


Corning® 1-2577 low VOC RTV coating, or
equivalent.
7. Secure the wires together using a plastic tie
strap.
8. Apply Dow Corning® 1-2577 low VOC RTV
coating, or equivalent, onto the cover plates
before installing. Install control unit cover plates
(21, 26). Apply a thread lock compound (Loc-
tite) to the screws with nine Torx screws (6)
using a T20 Torx bit. Tighten to 3 N·m (30 in.
lb).
9. Connect wiring harness (36) to voltage regula-
tor (37).

D10003 07/06 Battery Charging Alternator D10-77


NOTES

D10-78 Battery Charging Alternator D10003 07/06


SECTION D11
KOMTRAX PLUS
INDEX

KOMTRAX PLUS BASIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3


Gather Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3
Convert and Record Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3
Communicate Data to Off-Board Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-4

USING KOMTRAX PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5


Turning KOMTRAX PLUS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5
Normal KOMTRAX PLUS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5
Turning KOMTRAX PLUS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-6
Downloading from the KOMTRAX Plus Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-6

KOMTRAX PLUS DATA ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7


Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7
Machine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7
KOMTRAX Plus History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7
Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-8
Manual Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-8
Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-10
Histogram (Load Map) Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-10
Haul Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D11-11
Alarm and Snapshot Triggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-12
Satellite Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-12

KOMTRAX PLUS DIAGNOSTIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14


Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14
LED Digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14

KOMTRAX PLUS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-15

KOMTRAX PLUS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-16


VHMS Tool Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-16
VHMS Setting Tool Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-16

KOMTRAX PLUS INITIALIZATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17


Controller Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17
Snapshot Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-20
Download Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-21
FTP Upload Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-22
Initialization Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-23

D11010 12/11 KOMTRAX Plus D11-1


WHEN REPLACING A KOMTRAX PLUS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-24

KOMTRAX PLUS CONTROLLER CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-29


Necessary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-29
Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-29
KOMTRAX Plus Controller Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-30

ORBCOMM CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32

D11-2 KOMTRAX Plus 12/11 D11010


KOMTRAX PLUS
KOMTRAX PLUS BASIC FEATURES Convert and Record Data
The center of KOMTRAX Plus is the KOMTRAX Plus KOMTRAX Plus controller (2, Figure 11-1) processes
controller, which gathers data about the operation of data received from external controllers and stores the
the truck from sensors and other controllers installed following data in internal memory:
on the truck. Refer to Figure 11-1 for an overview of
• Fault codes from the engine, Interface Module,
the KOMTRAX Plus components. and PLM III
For instructions on how to use KOMTRAX Plus • Snapshots of data when specific fault codes
software programs, refer to KOMTRAX Plus occur
Software elsewhere in this section. For error codes,
• Trends of specific engine and chassis
checkout and troubleshooting procedures, refer to parameters
KOMTRAX Plus Troubleshooting and Checkout
Procedures elsewhere in this section. • Load map and other measures of engine and
chassis usage
• Haul cycle summary information, including
payload, distance traveled, and travel times
Gather Data
In addition to data gathered from external controllers,
The KOMTRAX Plus controller gathers data from
KOMTRAX Plus records information about the
three sources. Real-time and alarm data from each
vehicle and KOMTRAX Plus usage, including:
controller is gathered continually. In addition, haul
cycle summary data from the PLM III is requested by • Key ON and engine ON record
the controller one time per day. • KOMTRAX Plus configuration changes.
The system performs three primary functions:
1. Gathers data from on-board sources:
• PLM III controller
• Interface Module (IM)
• Engine controllers
2. Converts data into usable formats and records it
into permanent memory.
3. Communicates data to off-board systems:
• Satellite (Orbcomm)
• PC download
NOTE: The electric drive system does provide a
limited number of faults to the interface module.
Refer to KOMTRAX Plus Troubleshooting later in this
section for a complete listing of fault codes that are
generated by the drive system.

FIGURE 11-1. KOMTRAX PLUS COMPONENTS


1. Orbcomm Controller 3. Interface Module
2. KOMTRAX Plus 4. Red LED Digits
Controller 5. Green LED Light

D11010 12/11 KOMTRAX Plus D11-3


FIGURE 11-2. KOMTRAX PLUS COMPONENT FLOW CHART

Communicate Data to Off-Board Systems Communication to a laptop PC occurs whenever a


user connects a laptop PC to the KOMTRAX Plus
KOMTRAX Plus has two methods to communicate
controller and requests a data download. All
data to off-board systems:
KOMTRAX Plus data is available for download to a
• Via satellite to the WebCARE database laptop PC. Once downloaded to a laptop PC, the
• Download to a laptop PC running the VHMS information is then sent to Komatsu via FTP. This
Technical Analysis Tool Box software data is then compiled at the Komatsu computer
server. Based on this information, the local Komatsu
Communication to the satellite (using Orbcomm) distributor will suggest improvements and provide
occurs automatically, but only sends critical data information aimed at reducing machine repair costs
items. Orbcomm controller (1, Figure 11-1) is located and downtime.
inside the auxiliary control cabinet. Orbcomm
antenna (1, Figure 11-3) is mounted on the front left
corner of the cab by magnetic mount (2). In order to collect all the necessary machine data, a
NOTE: The Orbcomm controller installed at the preventive maintenance (PM) snapshot needs to be
factory on all new trucks may not be approved for recorded every 500 hours of operation. The snapshot
use in certain countries of the world. Local regulation and other data is then downloaded into a laptop PC.
may prohibit the use of the Orbcomm controller/ This data is to be sent to Komatsu via the FTP
satellite communicator. The controller and antenna program which is a part of the VHMS Technical
may be disconnected and/or removed. Analysis Tool Box program. Refer to the check-out
procedure for more detailed information regarding a
PM snapshot.

D11-4 KOMTRAX Plus 12/11 D11010


Turning KOMTRAX Plus ON
The KOMTRAX Plus controller is turned on by the
truck key switch (circuit 712). Immediately after
receiving input from the key switch signal, the
controller begins its power-up initialization sequence.
This sequence takes about three seconds, during
which time red LED digits (4, Figure 11-1) on the top
of the controller will display a circular sequence of
flashing LED segments. The controller will not
support a connection from a laptop PC or a manual
snapshot during this initialization time.
The KOMTRAX Plus controller is connected directly
to the battery circuit, which provides a constant 24
volt signal from the truck batteries. However, the
controller has the ability to turn itself off and will do so
automatically within three minutes after the key
switch is turned off.

The battery disconnect switch, located at the


truck battery box, will remove 24 volt power from
FIGURE 11-3. ORBCOMM ANTENNA the KOMTRAX Plus controller and cause the
controller to lose all data gathered since the key
1. Orbcomm Antenna 2. Magnetic Mount switch was last turned on. DO NOT disconnect
the batteries until the controller has completed
its shutdown operations and has turned off its
LED digits.

USING KOMTRAX PLUS


The primary tool for configuring, downloading, and Normal KOMTRAX Plus Operation
viewing KOMTRAX Plus data is the VHMS Technical The red LED digits on the top of the KOMTRAX Plus
Analysis Tool Box software. Use of this software controller indicate the current condition of the
requires: system. The possible conditions are shown in Table
• A laptop PC running Windows 95/98/2000/ME/ 1.
XP operating system.
• A serial cable to connect the laptop PC to the Table 1: KOMTRAX Plus Status
KOMTRAX Plus controller.
LED DISPLAY DESCRIPTION
Refer to the VHMS Technical Analysis Tool Box Flashing LED segments
instruction manual for additional information about Power-on initialization
in circular sequence
using this software.
Numeric display, counting
NOTE: It is recommended that the engine be OFF 00 - 99 at rate of 10 Normal Operation
when downloading or configuring the KOMTRAX numbers per second
Plus controller.
Normal operation, but
Flashing Fault Codes
a fault code is active

NOTE: Only a limited number of fault codes are


displayed on the LED display. Most fault conditions
are recorded internally in the KOMTRAX Plus
controller, but are not indicated on the LED digits.

D11010 12/11 KOMTRAX Plus D11-5


Turning KOMTRAX Plus OFF Downloading from the KOMTRAX Plus Controller
The KOMTRAX Plus controller is connected directly Downloading data requires a laptop PC running
to the truck batteries, but will remain in normal Windows 95/98/2000/ME/XP operating system, the
operation only if the truck key switch input (circuit VHMS Technical Analysis Tool Box software, and a
712) is on. When the controller senses that the truck serial cable to connect the laptop PC to the
key switch has been turned off, it finishes its internal KOMTRAX Plus controller. Refer to the VHMS
processing and then saves recent data into Technical Analysis Tool Box instruction manual for
permanent memory. This process can take up to additional information about using this software.
three minutes.
When a download to a laptop PC is performed,
If 24 volt power is removed from the KOMTRAX Plus certain files are generated to store data. A listing of
controller before it has time to save data to the file types and data is shown in Table 2.
permanent memory, data loss or corruption may
KOMTRAX Plus diagnostic port (2, Figure 11-4),
occur.
located on the DID panel at the rear of the operator
The controller will turn off the red LED digits when it cab, is used to download from the KOMTRAX Plus
is off. controller.

Do not remove 24 volt power from the KOMTRAX


Plus controller unless the red LED digits on the
controller are off!

FIGURE 11-4. DIAGNOSTIC PORTS


1. IM Diagnostic Port
2. KOMTRAX Plus Diagnostic Port

D11-6 KOMTRAX Plus 12/11 D11010


Table 2: File Types of Download Data
File Name Data Type Description
cyc_int0 Cycle Interval Changes in engine speed
csvdata_3f.csv Temporary Brake Load Map
Fault0.csv Fault History Records all faults
index00.csv Index Lists all common data files
loadm1.csv Temporary Load Map
mcn_his0.csv Machine History Key On, Key Off
m_area0.csv Running Area Map Records engine operation distribution
m_drct0.csv Running Direction Map Records engine performance movement
snap00.csv Snapshot Records snapshot data over time period
vhmshis0.csv KOMTRAX Plus History Records changes to KOMTRAX Plus
*.k Zipped File Contains all data files

KOMTRAX PLUS DATA ITEMS Machine History

Fault Codes The KOMTRAX Plus controller maintains a history of


the most recent 400 Key ON and Engine ON
The KOMTRAX Plus controller maintains a history of conditions.
the most recent 600 fault codes. For each fault code,
the controller records the following information:
• Fault Code Number KOMTRAX Plus History
• SMR (service meter reading) when the fault The KOMTRAX Plus controller maintains a history of
occurred the most recent 400 KOMTRAX Plus configuration
• Time/Date when the fault occurred changes. The controller will record a history entry
• SMR (service meter reading) when the fault each time one of the following configuration changes
cleared occurs:
• Time/Date when the fault cleared • Changing the date or time of the KOMTRAX
Plus controller
• Changing the Orbcomm satellite settings
If a fault occurs more than once within 30 minutes,
• Performing a KOMTRAX Plus memory clear
the KOMTRAX Plus controller will only maintain a
operation
single fault entry, but it will count the number of times
the fault occurred and was cleared. This feature
prevents an intermittent fault that occurs repeatedly
from filling up the fault memory.
Serious fault conditions will be sent to WebCARE via
the Orbcomm satellite network (if equipped) as well
as being recorded in permanent memory. Some fault
codes are configured to generate a snapshot when
they occur. Refer to Table 6 for detailed information
showing which fault codes will send data to
WebCARE and which ones trigger a snapshot.

D11010 12/11 KOMTRAX Plus D11-7


Snapshots Manual Snapshots
A snapshot is a time history of real-time data that is A manual snapshot is taken by pressing the data
recorded before and after the instant that a fault code store button (1, Figure 11-5), located at the rear of
occurs. The KOMTRAX Plus controller is continually the center console. When the 7.5 minute snapshot is
recording real-time data for various engine data being recorded by the KOMTRAX Plus controller,
items. This allows the controller to record data for the snapshot in progress light (2) will be illuminated.
time period before and after a fault code occurred. During the first five minutes, the LED will be on
continuously. During the next two minutes, the LED
Only certain fault codes generate snapshots. When a
will flash slowly. During the last 30 seconds, the LED
snapshot enabled fault code occurs, the KOMTRAX
will flash rapidly.
Plus controller will record data for 330 seconds (5.5
minutes) before the fault to 120 seconds (2 minutes) Manual snapshots are used to record current
after the fault. machine data that can then be downloaded and
stored on a laptop PC. These snapshots can be used
In order to conserve storage memory, the KOMTRAX
to observe current conditions on a machine. Over
Plus controller records snapshot data at two different
time, these snapshots can be compared and trends
sample rates. Each data item is recorded at a rate of
can be monitored. During the snapshot recording
one sample every 10 seconds up until 30 seconds
period, the machine should be driven over a variety
prior to the fault occurrence. Each data item is then
of conditions so useful data can be collected.
recorded at a rate of one sample per second from 30
seconds prior to 120 seconds after the fault
occurrence.
If a snapshot enabled fault condition occurs more
than one time, the KOMTRAX Plus controller will
record the snapshot for the first (earliest) fault
occurrence. The only exception is the manual
snapshot button, in which case the controller will
record the latest (most recent) snapshot.
Refer to Table 3 for all the items that are recorded in
each snapshot.

FIGURE 11-5. REAR OF CENTER CONSOLE


1. Data Store Button
2. Snapshot In Progress Light

D11-8 KOMTRAX Plus 12/11 D11010


Table 3: Snapshot Data

Data Item Data Source


Engine Coolant Temperature Cummins QUANTUM Controller

Engine Oil Pressure Cummins QUANTUM Controller

Accelerator Position% Cummins QUANTUM Controller

Engine Speed Cummins QUANTUM Controller

Exhaust Gas Temperature (Left Front) Cummins CENSE Controller

Exhaust Gas Temperature (Left Rear) Cummins CENSE Controller

Exhaust Gas Temperature (Right Front) Cummins CENSE Controller

Exhaust Gas Temperature (Right Rear) Cummins CENSE Controller

Engine Oil Temperature Cummins CENSE Controller

Fuel Rate Cummins QUANTUM Controller

Boost Pressure Cummins QUANTUM Controller

Blow-by Pressure Cummins QUANTUM Controller

Vehicle Speed PLM III

Sprung Weight PLM III

haul cycle State PLM III

Brake Pressure Interface Module

Hoist Pressure 1 Interface Module

Hoist Pressure 2 Interface Module

Steering Pressure Interface Module

Front Left Brake Oil Temperature Interface Module

Front Right Brake Oil Temperature Interface Module

Rear Left Brake Oil Temperature Interface Module

Rear Right Brake Oil Temperature Interface Module

Ambient Temperature Interface Module

D11010 12/11 KOMTRAX Plus D11-9


Trends The KOMTRAX Plus controller maintains an engine
speed vs. fuel rate histogram called the Engine Load
The KOMTRAX Plus controller develops trends by
Map, and a brake pressure vs. speed histogram.
monitoring real-time data and reducing the data into
20 hour statistical values. For each trended data The Engine Load Map histogram shows time-at-level
item, the controller can determine the maximum for specific engine speed and fuel rate combinations.
value, minimum value, and average value during the
The Brake Pressure vs. Speed histogram shows
preceding 20 hour period. Table 4 shows the type of
time-at-level for specific brake pressure and vehicle
statistical data recorded for each item.
speed combinations.
NOTE: Trend data is only collected when the engine
Two engine load maps are maintained in the
is running.
KOMTRAX Plus controller. The Permanent Load
Histogram (Load Map) Data Map contains load map data for the life of the engine.
The Temporary Load Map contains load map data
The KOMTRAX Plus controller develops histograms since the most recent memory clear action.
by sampling data every 100ms while the engine is
running. The data is presented as a two dimensional Although the engine data is sampled every 100ms
histogram showing time-at-level for various internally, the histograms are only updated every two
combinations of the two input data items. hours.

Table 4: Trend Data

Data Item Data Source MAX AVG MIN


Engine Coolant Temperature QUANTUM Controller X X

Engine Oil Pressure QUANTUM Controller X X

Engine Speed QUANTUM Controller X

Atmospheric Pressure QUANTUM Controller X

Exhaust Gas Temperature CENSE Controller X

Engine Oil Temperature CENSE Controller X

Fuel Rate QUANTUM Controller X

Boost Pressure QUANTUM Controller X

Blow-by Pressure QUANTUM Controller X

Brake Pressure Interface Module X X

Hoist Pressure 1 Interface Module X

Hoist Pressure 2 Interface Module X

Steering Pressure Interface Module X

Front Left Brake Oil Temperature Interface Module X X

Front Right Brake Oil Temperature Interface Module X X

Rear Left Brake Oil Temperature Interface Module X X

Rear Right Brake Oil Temperature Interface Module X X

Ambient Temperature Interface Module X X X

D11-10 KOMTRAX Plus 12/11 D11010


Haul Cycle Data NOTE: The haul cycle summary statistics exclude
haul cycles that the Payload Meter III controller has
The KOMTRAX Plus controller downloads haul cycle
marked as 'not trusted'. The total number of haul
data from Payload Meter III one time every 24 hours,
cycles that occurred during the summary period, but
at a time specified by the VHMS Setting Tool
were excluded from the summary, are indicated in
software. The data consists of a summary report of
the 'Total Excluded Cycles' field. See the Payload
all haul cycles completed in the past 24 hours. The
Meter III coverage in Section M, Options, for more
summary data items are listed in Table 5.
information on excluded cycles.
After receiving the haul cycle summary data from
Payload Meter III, the KOMTRAX Plus controller
immediately attempts to send the data to WebCARE
via the Orbcomm satellite (if equipped). The haul
cycle summary data is also stored in controller
internal memory. The controller maintains a record of
the payload summary data from the past 100 daily
transmissions to Orbcomm.

Table 5: Haul Cycle Data


Summary Data Item Description
Summary Start Time Start time of first haul cycle in summary
Summary End Time Start time of last haul cycle in summary
Total Cycles Total haul cycles included in this summary
Total Excluded Cycles Total haul cycles occurring during summary period, but excluded from the statistics
Average Carried Load Average Gross Payload
Standard Deviation of Carried Load Standard Deviation of Gross Payload
Number of Loads Over Rated Number of haul cycles with carried load > rated payload for this truck.
Number of Loads Over 110% Number of haul cycles with carried load > 110% of rated payload for this truck.
Number of Loads over 120% Number of haul cycles with carried load > 120% of rated payload for this truck.
Maximum Carried Load Maximum carried load during this summary
Maximum Speed EMPTY Maximum truck speed while truck was empty
Average Speed EMPTY Average truck speed while truck was empty
Maximum Speed LOADED Maximum truck speed while truck was loaded
Average Speed LOADED Average truck speed while truck was loaded
Maximum Sprung Load Maximum instantaneous sprung weight recorded during this summary
Average Maximum Sprung Load Average of all 'Maximum Sprung Load' values recorded in each haul cycle
Maximum Frame Torque Maximum instantaneous frame torque recorded during this summary
Average Maximum Frame Torque Average of all 'Maximum Frame Torque' values recorded in each haul cycle.
Right Front Tire TKPH Total tire ton kilometer per hour recorded for the right front tire.
Left Front Tire TKPH Total tire ton kilometer per hour recorded for the left front tire
Rear Tires TKPH Total tire ton kilometer per hour recorded for the rear tires
Relative Application Severity Total frame damage recorded during this summary
Reserved_1 Future Use
Reserved_2 Future Use
Reserved_3 Future Use

D11010 12/11 KOMTRAX Plus D11-11


Alarm and Snapshot Triggers Satellite Features
Serious fault conditions will be sent to WebCARE via The KOMTRAX Plus controller sends data to
the Orbcomm satellite network(if equipped), as well WebCARE via the Orbcomm satellite network (if
as being recorded in permanent memory. Some fault equipped) in the following conditions:
codes are configured to generate a snapshot when • A fault code occurs that has been configured
they occur. for transmission via Orbcomm.
Table 6 shows which fault codes trigger a snapshot • A periodic event occurs, such as reception of
and which fault codes will be sent to WebCARE via daily PLM III summary data or a 20 hour trend.
satellite. • A remote request for data is received via the
satellite network.

Table 6: Alarm and Snapshot Triggers


Sent via Snapshot
Fault Code Fault Description Source
Orbcomm Trigger
#A018 RR Flat Cylinder Warning PLM III X
#A019 LR Flat Cylinder Warning PLM III X
#A101 Pump Filter Switches IM X
#A107 Propel System Caution IM X
#A108 Propel System Temp Caution IM X
#A109 Propel System Reduced Level IM X
#A115 Low Steering Precharge IM X
#A124 No Propel / Retard IM X
#A125 No Propel IM X
#A126 Hydraulic Tank Level IM X
#A127 IM Sensor +5V Low IM X
#A128 IM Sensor +5V High IM X
#A190 Auto Lube Switch IM X
#A194 High FL Brake Oil Temp IM X X
#A195 High FR Brake Oil Temp IM X X
#A196 High RL Brake Oil Temp IM X X
#A197 High RR Brake Oil Temp IM X X
MFA0 Manual Trigger Manual X X
C00115 Speed Signal Lost Engine X X
C00135 Oil Pressure Circuit Failed High Engine X X

D11-12 KOMTRAX Plus 12/11 D11010


Table 6: Alarm and Sna