Shop Manual 930E-2 A30296, A30297, A30300

CEBM012200
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS
A30296, A30297, A30300
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
personnel who will come into contact with it.
This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written authorization from KAC.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The
Company reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication.
Customers should contact their local Komatsu distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. Wash hands after handling.
NOTES
FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician become fully
knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational
checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing 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, at times, typical of the component shown and may not necessarily depict
a specific model.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to "Right",
"Left", "Front", or "Rear" are made with respect to the operator's normal seated position, unless specifically stated
otherwise.
Standard torque requirements are shown in torque charts in the general information section and individual torques
are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have
10% tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
(Gross Vehicle Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers
represent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an
Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
(GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the
GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often
as practical.
Exceeding the allowable payload will reduce expected life of truck components.
A00017 03/01
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 readers attention to avoid unsafe
or improper practices which may result in damage to the
A-2
Introduction
03/01 A00017
TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
ELECTRIC PROPULSION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
DRIVE AXLE, SPINDLES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
HYDRAIR II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
A00017 03/01
Introduction
A-3
KOMATSU MODEL 930E DUMP TRUCK
A-4
Introduction
03/01 A00017
SECTION A
GENERAL INFORMATION
INDEX
TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1
GENERAL SAFETY AND TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1
WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1
CHARTS AND TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1
STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-1
A01001 02/94
Index
A1-1
NOTES
A1-2
Index
02/94 A01001
MAJOR COMPONENT DESCRIPTION

Truck And Engine
Operator's Cab
The 930E Dump Truck is an off-highway, rear dump

truck with AC Electric Drive. The gross vehicle weight
is 1,100,000 lbs. (498 960 kg). The engine is a
Komatsu SSDA16V160 rated @ 2700 HP (2014 kW).
The operator cab has been engineered for operator

comfort and to allow for efficient and safe operation
of the truck. The cab provides wide visibility, with an
integral 4-post ROPS/FOPS structure, and an
advanced analog operator environment. It includes a
tinted safety-glass windshield and power-operated
side windows, a deluxe interior with a fully adjustable
seat with lumbar support, a fully adjustable/tilt steering wheel, controls mounted within easy reach of the
operator, and an analog instrument panel which provides the operator with all instruments and gauges
which are necessary to control and/or monitor the
truck's operating systems.
Alternator (GE-GTA42)
The diesel engine drives an in-line alternator at
engine speed. The alternator produces AC current
which is rectified to DC within the main control cabinet. The rectified DC power is converted back to AC
by groups of devices called "inverters", also within
the main control cabinet. Each inverter consists of six
"phase modules" under the control of a "gate drive
unit" (GDU). The GDU controls the operation of each
phase module.
Each phase module contains an air-cooled solidstate switch referred to as a "gate turn-off thyristor"
(GTO). The GTO cycles on and off at varying frequencies to create an AC power signal from the DC
supply.
The AC power signal produced by each inverter is a
variable-voltage, variable-frequency signal (VVVF).
Frequency and voltage are changed to suit the operating conditions.
AC Induction Traction Motorized Wheels

The alternator output supplies electrical energy to the
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction
motors with full-wave AC power.
The two wheel motors convert electrical energy back
to mechanical energy through built-in gear trains
within the wheel motor assembly. The direction of the
wheel motors is controlled by a forward or reverse
hand selector switch located on the center console.
Blower
Both the inverters and the wheel motors produce
heat while in operation and must be cooled. Cooling
air is provided by a dual impeller in-line blower
mounted on the alternator.
Suspension
HYDRAIRII suspension cylinders located at each
wheel provide a smooth and comfortable ride for the
operator and dampens shock loads to the chassis
during loading and operation.
A02064
Power Steering
The truck is equipped with a full time power steering
system which provides positive steering control with
minimum operator effort. The system includes nitrogen-charged accumulators which automatically provide emergency power if the steering hydraulic
pressure is reduced below an established minimum.
Dynamic Retarding
The dynamic retarding is used to slow the truck during normal operation or control speed coming down a
grade. The dynamic retarding ability of the electric
system is controlled by the operator through the activation of the retarder pedal (or by operating a lever
on the steering wheel) in the operators cab and by
setting the RSC (Retarder Speed Control). Dynamic
Retarding is automatically activated, if the truck
speed goes to a preset overspeed setting.
Brake System
Service brakes at each wheel are oil-cooled multiple
disc brakes applied by an all-hydraulic actuation system. Depressing the brake pedal actuates both front
and rear brakes, after first applying the retarder. All
wheel brakes will be applied automatically, if system
pressure decreases below a preset minimum.
The parking brake is a dry disc type, mounted
inboard on each rear wheel motor, and is springapplied and hydraulically-released with wheel speed
application protection (will not apply with truck moving).
Major Component Description
A2-1
930E MAJOR COMPONENTS

A2-2
A02064
SPECIFICATIONS
These specifications are for the standard Komatsu
930E truck. Customer options may change this listing.
ENGINE
SERVICE CAPACITIES
Komatsu SSDA16V160
. . . . . . . . . . . . . . . . . . . . . . U.S. Gallons . . . . (Liters)

Crankcase * . . . . . . . . . . . . . . . . 74 . . . . . . . . . . . .280
No. of Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating Cycle . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 rpm
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1910 rpm
Full Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Rated Brake HP . . . 2700 HP (2014 kW) @ 1900 RPM
Flywheel HP . . . . . . 2550 HP (1902 kW) @ 1900 RPM
Weight* (Dry). . . . . . . . . . . . . 21,182 pounds (9608 kg)
* Weight does not include Radiator, Sub-frame, or Alternator
AC ELECTRIC DRIVE SYSTEM

(AC/DC Current)
Alternator . . . . . . . . . . . . . . . General Electric GTA - 42
Dual Impeller, In-Line Blower 12,000 cfm (340 m/min)
Motorized Wheels . . . . GDY106 AC Induction Traction
Motors
. . . . . . . . . . . . . . . . . . . . . . . . Wheel Slip/Slide Control
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . 32.62:1
Maximum Speed . . . . . . . . . . . . . . 40 MPH (64.5 km/h)
*NOTE: Wheel motor application depends upon GVW, haul road
grade and length, rolling resistance, and other parameters. Komatsu
& G.E. must analyze each job condition to assure 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 . . . . . . . . . . . . . . . . . . . . . . .bumper mounted
. . 4 x 8D & 2 x 30H 12 Volt Batteries in Series/Parallel
. . . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity
. . . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch
Alternator . . . . . . . . . . . . . 26 Volt, 260 Ampere Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt
Starters (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
A02064
* Includes Lube Oil Filters
Cooling System . . . . . . . . . . . . . 157. . . . . . . . . . . .594

Fuel . . . . . . . . . . . . . . . . . . . . . 1200 . . . . . . . . . .4542
Hydraulic System . . . . . . . . . . . . 350. . . . . . . . . . 1325
Wheel Motor Gear Box. . . . . .25/Wheel . . . . 95/Wheel
HYDRAULIC SYSTEMS
Hoist & Brake Cooling Pump:. . . . . . . . . Tandem Gear
Rated @ . . . . . . . . 246 GPM (931 l/min.) @ 1900 RPM
. . . . . . . . . . . . . . . . . . . . . . .and 2500 psi (17 237 kPa)
Steering/Brake Pump: . Pressure Compensated Piston
Rated @ . . . . . . . . . 65 GPM (246 l/min.) @ 1900 RPM
. . . . . . . . . . . . . . . . . . . . . . .and 2750 psi (18 961 kPa)
Relief Pressure-Hoist . . . . . . . . . . 2500 psi (17.2 MPa)
Relief Pressure-Steering/Brake . . 4000 psi (27.6 MPa)
Hoist Cylinders (2) . . . . . . . . . . . . . . 3-Stage Hydraulic
Tank (Vertical/Cylindrical). . . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . . . 250 US Gal. (947 Liters)
Filtration . . . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Hoist & Steering Filters. . . . . . . . . .Beta 12 Rating =200
. . . . . . . . . . . . . . . . . . . . . Dual In-Line, High Pressure
SERVICE BRAKES
All Hydraulic Actuation . . . . . . . . . with Traction System
. . . . . . . . . . . . . . . . . . . . . . . Wheel Slip / Slide Control
Front & Rear Oil-Cooled Multiple Discs- . . .each wheel
Total Friction Area / Brake . . . . 15,038 in (97 019 cm)
Maximum Apply Pressure . . . . . 2500 psi (17 238 kPa)
STEERING
Turning Circle (SAE) . . . . . . . . . . . 97 ft. 7 in. (30.4 m)
Twin hydraulic cylinders with accumulator assist to provide constant rate steering.
Emergency power steering automatically provided by
accumulators.
A2-3
STANDARD DUMP BODY CAPACITIES

AND DIMENSIONS
WEIGHT DISTRIBUTION
Capacity,
Heaped @ 2:1 (SAE) . . . . . . . . . 276 yd3 (211 m3)
Struck . . . . . . . . . . . . . . . . . . . . . 224 yd3 (171 m3)
Width (Inside) . . . . . . . . . . . . . . . .26 ft. 9 in. (8.15 m)
Depth . . . . . . . . . . . . . . . . . . . . . . .10 ft. 7 in. (3.2 m)
Loading Height . . . . . . . . . . . . . . . . . . 23 ft. (7.01 m)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Empty Vehicle . . . . . . . . . Pounds . . . (Kilograms)

Front Axle (49.3%) . . . . . . 226,699 . . . . . (102 830)
Rear Axle (50.7%) . . . . . . . 233,137 . . . . . (105 750)
Total (50% Fuel) . . . . . . . . 459,836 . . . . . (208 580)
TIRES
*Not to exceed 1,100,000 lbs. (498 957 kg) including options, fuel,
and payload. Weights in excess of this amount require factory
approval.
Radial Tires (standard) . . . . . . . . . . . . . . . 53/80 R63

. . . . . . . . . . . . . . . . . . . . . . . Rock Service, Tubeless
Rims . . . . . . . . . . . . . . . . . . . (patented Phase I rims)
A2-4
Loaded Vehicle . . . . . . . . Pounds . . . (Kilograms)

Front Axle (33.9%) . . . . . . 363,000 . . . . . (164 656)
Rear Axle (66.1%) . . . . . . . 737,000 . . . . . (334 301)
Total * . . . . . . . . . . . . . . . 1,100,000 . . . . (498 957)
A02064
SECTION A3
GENERAL SAFETY AND OPERATING INSTRUCTIONS
INDEX
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Leaving The Operators Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Precautions When Handling At High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Prevention Of Injury By Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions When Using ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Safety At The Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Ventilation For Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
In Operators Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Check When Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Ensure Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Operate Carefully On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Avoid Damage To Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
When Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
A03017 11/02
General Safety and Operating Instructions
A3-1
Stopping The Engine Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13

Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Keep The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Rules To Follow When Adding Fuel Or Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Radiator Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Handling High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Precautions With High Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Precautions When Performing Maintenance At High Temperature Or High Pressure . . . . . . A3-16
Rotating Fan And Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
Handling Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
Storing Tires After Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
Preliminary Procedures before Welding or Performing Maintenance . . . . . . . . . . . . . . . . . . . A3-20
Normal Engine Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
Engine Shutdown Procedure before Welding or Performing Maintenance . . . . . . . . . . . . . . A3-21
TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
At The Truck - Ground Level Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27
AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
MACHINE OPERATION ON THE HAUL ROAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
DYNAMIC RETARDING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
Dynamic Retarder Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
Dynamic Retarder/Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
Starting On A Grade With A Loaded Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
NORMAL ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
DELAYED ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
A3-2
11/02 A03017
GENERAL SAFETY
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority.
The following safety rules are provided as a guide for 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 can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
When working with another operator or a person on work site traffic duty, be sure all personnel understand all
hand signals that are to be used.
Safety Features
Ensure all guards and covers are in their proper position. Have any damaged guards and covers repaired. (See
Walk-Around Inspection, Operating Instructions - Section 3)
Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
Never remove any safety features. Always keep them in good operating condition.
Improper use of safety features could result in serious bodily injury or death.
Clothing And Personal Items
Avoid loose clothing, jewelry, and loose long hair. They can catch on
controls or in moving parts and cause serious injury or death.
Additionally, never wear oily clothes as they are flammable.
Wear a hard hat, safety glasses, safety shoes, mask and gloves when
operating or maintaining a machine. Always wear safety goggles, hard
hat and heavy gloves if your job involves scattering metal chips or minute
materials--particularly when driving pins with a hammer or when cleaning
air cleaner elements with compressed air. Also, ensure that the work area
is free from other personnel during such tasks.
Unauthorized Modification
Any modification made to this vehicle without authorization from Komatsu America Corp. can possibly create
hazards.
Before making any modification, consult the authorized regional Komatsu America Corp. distributor. Komatsu
will not be responsible for any injury or damage caused by any unauthorized modification.
A03017 11/02
A3-3
Leaving The Operators Seat
When preparing to leave the operator's seat, do not touch any control lever that is not locked. To prevent
accidental operations from occurring, always perform the following:
Move the shift control lever to NEUTRAL and apply the parking brake.
Lower the dump body, set the dump lever to the FLOAT position.
Stop the engine. When exiting the machine, always lock compartments, and take the keys with you. If the
machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or
death.
Mounting And Dismounting
Never jump on or off the machine. Never climb on or off a machine while it is moving.
When climbing on or off a machine, face the machine and use the hand-hold and steps.
Never hold any control levers when getting on or off a machine.
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.
Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
Fire Prevention For Fuel And Oil
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is extremely flammable and can be hazardous.
Keep flames away from flammable fluids.
Stop the engine and never smoke when refueling.
Tighten all fuel and oil tank caps securely.
Refueling and oiling should be done in well ventilated areas.
Keep oil and fuel in a designated location and do not allow unauthorized persons to enter.
A3-4
11/02 A03017
Precautions When Handling At High Temperatures
Immediately after machine operation, engine coolant, engine oil, and hydraulic oil are at high temperatures and
are pressurized. If the cap is removed, the fluids drained, the filters are replaced, etc., there is danger of
serious burns. Allow the heat and pressure to dissipate before performing such tasks and follow proper
procedures as outlined in the service manual.
To prevent hot coolant from spraying:

1) Stop the engine.
2) Wait for the coolant temperature to decrease.
3) Turn the radiator cap slowly to release the pressure before removing.
To prevent hot engine oil spray:

1) Stop the engine.
2) Wait for the oil temperature to cool down.
3) Turn the cap slowly to release the pressure before removing the cap.
Asbestos Dust Hazard Prevention

Asbestos dust is hazardous to your health when inhaled. If you handle materials containing
asbestos fibers, follow the guidelines below:
Never use compressed air for cleaning.
Use water for cleaning to control dust.
Operate the machine or perform tasks with the wind to your back, whenever possible.
Use an approved respirator when necessary.
Prevention Of Injury By Work Equipment
Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body, chassis or cylinders. If the work equipment is operated, clearances will change and may lead to serious
bodily injury or death.
Fire Extinguisher And First Aid Kit
Ensure fire extinguishers are accessible and proper usage techniques are known.
Provide a first aid kit at the storage point.
Know what to do in the event of a fire.
Keep the phone numbers of persons you should contact in case of an emergency on
hand.
A03017 11/02
A3-5
Precautions When Using ROPS
The Rollover Protection Structure (ROPS) must be properly installed for machine operation.
The ROPS is intended to protect the operator if the machine should roll over. It is designed not only to support
the load of the machine, but also to absorb the energy of the impact.
ROPS structures installed on equipment manufactured and designed by Komatsu America Corp. fulfills all of
the regulations and standards for all countries. If it is modified or repaired without authorization from Komatsu,
or is damaged when the machine rolls over, the strength of the structure will be compromised and will not be
able to fulfill its intended purpose. Optimum strength of the structure can only be achieved if it is repaired or
modified as specified by Komatsu.
When modifying or repairing the ROPS, always consult your nearest Komatsu distributor.
Even with the ROPS installed, the operator must always use the seat belt when operating the machine.
Precautions For Attachments
When installing and using optional equipment, read the instruction manual for the attachment and the
information related to attachments in this manual.
Do not use attachments that are not authorized by Komatsu America Corp., or the authorized regional Komatsu
distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper
operation and useful life of the machine.
Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the
responsibility of Komatsu America Corp., or the authorized regional Komatsu distributor.
A3-6
11/02 A03017
PRECAUTIONS DURING OPERATION

Safety Is Thinking Ahead
Prevention is the best safety program. Prevent a potential accident by knowing the employer's safety requirements and all necessary job site regulations. In addition, know the proper use and care of all the safety equipment
on the truck. Only qualified operators or technicians should attempt to operate or maintain a Komatsu machine.
Safe practices start before the operator gets to the equipment!
Safety At The Worksite
When walking to and from a truck, maintain a safe distance from all machines even when the operator is
visible.
Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
Examine the road surface at the job site and determine the best and safest method of operation.
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 position, the roads to be used, and 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 which exceeds the permissible water depth.
Fire Prevention
Thoroughly remove wood chips, leaves, paper and other flammable items
accumulated in the engine compartment, as they could cause a fire.
Check fuel, lubrication, and hydraulic systems for leaks. Repair any leaks.
Wipe up any excess oil, fuel or other flammable fluids, and dispose of properly.
Ensure a fire extinguisher is present and in proper working condition.
Do not operate the machine near open flames.
Preparing For Operation
Always mount and dismount while facing the truck. Never attempt to mount or dismount the truck while it is in
motion. Always use handrails and ladders when mounting or dismounting the truck.
Check the deck areas for debris, loose hardware, and tools. Check for people and objects that might be in the
way.
Become familiar with and use all protective equipment devices on the truck and ensure that these items (antiskid material, grab bars, seat belts, etc.) are securely in place.
Ventilation For Enclosed Areas
If it is necessary to start the engine within an enclosed area, provide adequate

ventilation. Exhaust fumes from the engine can kill.
A03017 11/02
A3-7
In Operators Cab - Before Starting The Engine
Do not leave tools or spare parts lying around or 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.
Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always
use the seat belts when operating a machine.
Read and understand the contents of this manual. Read Section 3 pertaining to safety and operating
instructions with special attention. 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.
Ensure the steering wheel, horn, controls and pedals are free of any oil, grease or mud.
Check operation of the windshield wiper, condition of wiper blades, and check the washer fluid reservoir level.
Be familiar with all steering and brake system controls, warning devices, road speeds and loading capabilities,
before operating the truck.
Mirrors, Windows, And Lights
Remove any dirt from the surface of the windshield, cab windows, mirrors and lights. Good visibility may
prevent an accident.
Adjust the rear view mirror to a position where the operator can see best from the operator's seat. If any glass
or light should break, replace it with a new part.
Ensure headlights, work lights and taillights are in proper working order. Ensure that the machine is equipped
with the proper work lamps needed for the operating conditions.
OPERATING THE MACHINE

When Starting The Engine
Never start the engine if a warning tag has been attached to the controls.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated in the operators seat.
Do not allow any unauthorized persons in the operator's compartment or any other place on the machine.
Truck Operation - General
Wear seat belt at all times.
Only authorized persons are allowed to ride in the truck. Riders must be in the cab and belted in the passenger
seat.
Do not allow anyone to ride on the decks or steps of truck.
Do not allow anyone to get on or off truck while it is in motion.
Do not move the truck in or out of a building without a signal person present.
Know and obey the hand signal communications between operator and spotter. When other machines and
personnel are present, the operator should move in and out of buildings, loading areas and through traffic,
under the direction of a signal person. Courtesy at all times is a safety precaution!
Immediately report any adverse conditions on haul road, pit or dump area that may cause an operating hazard.
A3-8
11/02 A03017
Check for flat tires periodically during a shift. If the truck has been run on a flat, it must not be parked in a
building until the tire cools. If the tire must be changed, do not stand in front of the rim and locking ring when
inflating a tire mounted on the machine. Observers should not be permitted in the area and should be kept
away from the side of such tires.
The tire and rim assembly may explode if subjected to excessive heat. Personnel should move to a remote
or protected location if sensing excessively hot brakes, smell of burning rubber or evidence of fire near
tire and wheel area.
If the truck must be approached, such as to fight a fire, those personnel should do so only while facing the
tread area of the tire (front or back), unless protected by use of large heavy equipment as a shield. Stay at
least 50 ft. (15 m) from the tread of the tire.
In the event of fire in the tire and wheel area (including brake fires), stay away from the truck for at least 8
hours or until the tire and wheel are cool.
Keep serviceable fire fighting equipment on hand. Report used extinguishers for replacement or refilling.
Always have parking brake applied when the truck is parked and unattended. DO NOT leave the truck
unattended while the engine is running.
Park the truck a safe distance away from other vehicles as determined by the supervisor.
Stay alert at all times! In the event of an emergency, be prepared to react quickly and avoid accidents. If an
emergency arises, know where to get prompt assistance.
Check When Traveling In Reverse

Before operating the machine or work equipment, do as follows:
Sound the horn to warn people in the area. For machines equipped with a
back-up alarm, ensure the alarm works properly.
Check for personnel near the machine. Be particularly careful to check

behind the machine.
When necessary, designate a person to watch the area for the truck
operator. This is particularly necessary when traveling in reverse.
When operating in areas that may be hazardous or have poor visibility, designate a person to direct work site
traffic.
Do not allow any one to enter the line of travel of the machine. This rule must be strictly observed even with
machines equipped with a back-up alarm or rear view mirror.
Traveling
When traveling on rough ground, travel at low speeds. When changing direction, avoid turning suddenly.
Lower the dump body and set the dump lever to the FLOAT position when traveling.
If the engine should stop when the machine is in motion, the emergency steering system will be activated.
Apply the brakes immediately and stop the machine as quickly and safely as possible (off of the haul road, if
possible).
A03017 11/02
A3-9
Traveling On Slopes
Traveling on slopes could result in the machine tipping over or slipping.
Do not change direction on slopes. To ensure safety, drive to level ground before turning.
Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Avoid traveling sideways, and always keep travel speed low.
When traveling downhill, use the retarder to reduce speed. Do not turn the steering wheel suddenly. Do not use
the foot brake except in an emergency.
If the engine should stop on a slope, apply the service brakes fully and stop the machine. Apply the parking
brake after the machine has stopped.
Ensure Good Visibility
When working in dark places, install work lamps and head lamps. Set up extra lighting in the work area if
necessary.
Discontinue operations if visibility is poor, such as in mist, snow, or rain. Wait for the weather to
improve to allow the operation to be performed safely.
Operate Carefully On Snow
When working on snowy or icy roads, there is danger that the machine may slip to the side on even the
slightest slope. Always travel slowly and avoid sudden starting, turning, or stopping in these conditions.
Be extremely careful when clearing snow. The road shoulder and other objects are buried in the snow and
cannot be seen. When traveling on snow-covered roads, always install tire chains.
Avoid Damage To Dump Body
When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits, always use extreme caution. The dump body must be completely lowered before
driving the machine.
Driving Near High Voltage Cables
Driving near high-voltage cables can cause electric shock. Always maintain the safe distances between the
machine and the electric cable as listed below.
Voltage
Minimum Safety Distance
6.6 kV
3m
10 ft.
33.0 kV
4m
14 ft.
66.0 kV
5m
17 ft.
154.0 kV
8m
27 ft.
275.0 kV
10 m
33 ft.
The following actions are effective in preventing accidents while working near high voltages:
Wear shoes with rubber or leather soles.
Use a signalman to give warning if the machine approaches an electric cable.
If the work equipment should touch an electric cable, the operator should not leave the cab.
When performing operations near high voltage cables, do not allow anyone to approach the machine.
Check with the electrical maintenance department about the voltage of the cables before starting operations.
A3-10
11/02 A03017
When Dumping
Before starting the dumping operation, check that there is no person or objects behind the machine.
Stop the machine in the desired location. Check again for persons or objects behind the machine. Give the
determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position a
flagman.
When dumping on slopes, machine stability is poor and there is danger of tip over. Always perform such
operations using extreme care.
Never travel with the dump body raised.
Working On Loose Ground
Avoid operating the machine near cliffs, overhangs, and deep ditches. If these areas collapse, the machine
could fall or tip over and result in serious injury or death. Remember that ground surfaces in these areas may
be weakened after heavy rain or blasting.
Freshly laid soil and the soil near ditches is loose. It can collapse under the weight or vibration of the machine.
Avoid these areas whenever possible.
When Loading
Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
Do not leave the operator's seat during the loading operation.
Parking The Machine
Choose a horizontal road surface to park the machine. If the machine has to be parked on a slope, always put
blocks under all the wheels to prevent the machine from moving.
When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn
pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
Before leaving the machine, lower the dump body fully, activate the parking brake, stop the engine, and lock
everything. Always take the key with you.
TOWING
When Towing, Fix Wire To Hook
Improper towing methods may lead to serious personal injury and/or damage.
Use a towing device with ample strength for the weight of this machine.
Never tow a machine on a slope.
Do not use tow rope that has kinks or is twisted.
Do not stand astride the towing cable or wire rope.
When connecting a machine that is to be towed, do not allow anyone to go between the tow machine and the
machine that is being towed.
Set the coupling of the machine being towed in a straight line with the towing portion of the tow machine, and
secure it in position.
(For towing method, see the Operation and Maintenance Manual, Section 3, Operating Instructions - Towing.)
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WORKING NEAR BATTERIES

Battery Hazard Prevention
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of water, milk, beaten eggs or vegetable oil. Call a doctor or
poison prevention center immediately.
When working with batteries always wear safety glasses or goggles.
Batteries generate hydrogen gas. Hydrogen gas is very explosive, and is easily ignited with a small spark of
flame.
Before working with batteries, stop the engine and turn the key switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools,
across the terminals.
When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
Tighten the battery cap securely.
Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion.
Starting With Booster Cables
Always wear safety glasses or goggles when starting the machine with booster cables.
When starting from another machine, do not allow the two machines to touch.
Be sure to connect the positive (+) cable first when installing booster cables. Disconnect the ground or negative
(-) cable first during removal.
If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. Always use caution
when using tools near the battery.
Connect the batteries in parallel: positive to positive and negative to negative.
When connecting the ground cable to the frame of the machine to be started, connect it as far as possible from
the battery.
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11/02 A03017
PRECAUTIONS FOR MAINTENANCE

BEFORE PERFORMING MAINTENANCE
Warning Tag
If others start the engine or operate the controls while you are performing
maintenance, you could suffer serious injury or death.
Always attach the warning tag to the control lever in the operator's cab to
alert others that you are working on the machine. Attach additional warning
tags around the machine, if necessary.
These tags are available from your Komatsu distributor. (
Part No. 09963-03000)
Proper Tools
Use only tools suited to the task. Using damaged, low quality, faulty, or
makeshift tools could cause personal injury.
Stopping The Engine Before Service
Before performing inspections or maintenance, stop the machine on firm flat ground, lower the dump body,
stop the engine and apply the parking brake.
If the engine must be run during service, such as when cleaning the radiator, always move the shift control
lever to the NEUTRAL (N) position and apply the parking brake. Always perform this work with two people.
One person must sit in the operator's seat to stop the engine if necessary. Never move any controls not related
to the task at hand during these situations.
When servicing the machine, use care not to touch any moving parts. Never wear loose clothing.
Put blocks under the wheels.
When performing service with the dump body raised, always place the dump lever in the HOLD position, and
apply the lock (if equipped). Install the body-up safety pins or cable securely.
Securing The Dump Body

Any time personnel are required to perform maintenance on the vehicle with the dump body in the raised
position, the body-up retention cable MUST be
installed.
1. To hold the dump body in the up position, raise the
body to it's maximum height.
2. Remove cable (3) from its stored position on the
body, and install between rear body ear (1) and axle
housing ear (4).
3. Secure the cable clevis pins with cotter pins.
4. Return the cable to stored position (2) after maintenance is complete.
A03017 11/02
A3-13
DURING MAINTENANCE
Personnel
Only authorized personnel can service and repair the machine. Extra precaution should be used when
grinding, welding, and using a sledge-hammer.
Attachments
Place attachments that have been removed from the machine in a safe place and
manner to prevent them from falling.
Working Under The Machine
Always lower all movable work equipment to the ground or to their lowest position
before performing service or repairs under the machine.
Always block the tires of the machine securely.
Never work under the machine if the machine is poorly supported.
Keep The Machine Clean
Spilled oil or grease, scattered tools, etc. can cause you to slip or trip. Always
keep your machine clean and tidy.
If water gets into the electrical system, there is danger that the machine may
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 control cabinet around the doors or vents. Do not allow
any water to enter the cooling air inlet duct above the electrical control cabinet. If water enters the control
cabinet (through any opening or crevice) major damage to the electrical 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 retard grids. Excess water in the retard grids can cause a ground fault, which will
prevent propulsion.
Rules To Follow When Adding Fuel Or Oil
Spilled fuel and oil may cause slipping. Always clean up spills, immediately.
Always tighten the cap of the fuel and oil fillers securely.
Never use fuel for washing any parts.
Always add fuel and oil in a well-ventilated area.
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11/02 A03017
Radiator Water Level
If it is necessary to add coolant to the radiator, stop the engine, and allow the
engine and radiator to cool down before adding the coolant.
Slowly loosen the cap to relieve pressure during removal.
Use Of Lighting
When checking fuel, oil, coolant, or battery electrolyte, always use
lighting with anti-explosion specifications. If such lighting equipment is
not used, there is danger or explosion.
Precautions With The Battery
When repairing the electrical system or when performing electrical

welding, remove the negative (-) terminal of the battery to stop the flow
of current.
Handling High Pressure Hoses
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
Always repair any loose or broken hoses. If fuel or oil leaks, it may result in a fire.
Precautions With High Pressure Oil
Do not forget that work equipment circuits are always under pressure.
Do not add oil, drain oil, or perform maintenance or inspections before completely releasing the internal
pressure.
Small, high pressure pin-hole leaks are extremely dangerous. The jet of high-pressure oil can pierce the skin
and eyes. Always wear safety glasses and thick gloves. Use a piece of 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.
A03017 11/02
A3-15
Precautions When Performing Maintenance At High Temperature Or High Pressure
Immediately after stopping operation, engine coolant and operating oils are
at high temperature and under high pressure. In these conditions, if the cap
is removed, the oil or water drained, or the filters are replaced, it may result
in burns or other injury. Wait for the temperature to cool and pressure to
subside, before performing the inspection and/or maintenance in as
outlined in the service manual.
Rotating Fan And Belts
Stay away from all rotating parts such as the radiator fan and fan belts.
Serious bodily injury may result from direct or indirect contact with rotating
parts and flying objects.
Waste Materials
Never dump waste oil in a sewer system, rivers, etc.
Always put oil drained from your machine in appropriate containers. Never
drain oil directly onto the ground.
Obey appropriate laws and regulations when disposing of harmful objects

such as oil, fuel, coolant, solvent, filters, batteries, and others.
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11/02 A03017
TIRES
Handling Tires
If tires are not used under the specified conditions, they may overheat and burst, or be cut and burst by sharp
stones on rough road surfaces. This may lead to serious injury or damage.
To maintain tire safety, always adhere to the following conditions:
Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
Use the specified tires.
The tire inflation pressure and permissible speeds are general values. The actual values may differ depending on
the type of tire and the condition under which they are used. For details, please consult the tire manufacturer.
When tires become hot, a flammable gas is produced, and may ignite. It is particularly dangerous if the tires
become overheated while the tires are pressurized. If the gas generated inside the tire ignites, the internal pressure will suddenly rise, and the tire will explode, resulting in danger to personnel in the area. Explosions differ from
punctures or tire bursts because the destructive force is extremely large. Therefore, the following operations are
strictly prohibited when the tire is pressurized:
Welding the rim
Welding near the wheel or tire.
Smoking or creating open flames
If the proper procedure for performing maintenance or replacement of the wheel or tire is not used, the wheel or tire
may burst and cause serious injury or damage. When performing such maintenance, consult your authorized
regional Komatsu distributor, or the tire manufacturer.
Storing Tires After Removal
As a basic rule, store the tires in a warehouse in which unauthorized persons cannot enter. If the tires are
stored outside, always erect a fence around the tires and put up No Entry and other warning signs that even
young children can understand.
Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
If the tire should fall over, flee the area quickly. The tires for construction equipment are extremely heavy.
Trying to hold the tire must not be attempted and may lead to serious injury.
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ADDITIONAL JOB SITE RULES
Use this space to add any additional job site rules not covered in any of the previous discussions.
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11/02 A03017
WHEN REPAIRS ARE NECESSARY

1. Only qualified maintenance personnel who understand the systems being repaired should attempt repairs.
2. Many components on the Komatsu truck are large and heavy. Insure that lifting equipment - hoists, slings,
chains, lifting eyes - are of adequate capacity to handle the lift.
3. Do not under a suspended load. Do not work under raised body unless body safety cables, props, or pins are
in place to hold the body in up position.
4. Do not repair or service the truck while the engine is running, except when adjustments can only be made
under such conditions. Keep a safe distance from moving parts.
5. When servicing any air conditioning system with refrigerant, wear a face shield and cold resistant gloves for
protection against freezing. Be certain to follow all current regulations for handling and recycling refrigerants.
6. Follow package directions carefully when using cleaning solvents.
7. If an auxiliary battery assist is needed, first use one cable to connect the 24V positive (+) post of the disabled
truck batteries to the 24V positive (+) post of the auxiliary assist. Use second cable to connect the 24V negative (-) post of the auxiliary assist battery to a frame ground (-) on the disabled truck away from the battery.
8. Always disconnect the positive and negative battery cables of the vehicle before doing any welding on the
unit. Failure to do so may seriously damage the battery and electrical equipment. Disconnect battery charging
alternator lead wire and isolate electronic control components before making welding repairs. (It is not necessary to disconnect or remove any control circuit cards on electric drive dump trucks or any of the AID circuit
control cards.)
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. Never allow welding current to pass through ball bearings,
roller bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and possibly cause
damage to components.
9. If the truck is to be towed for any reason, use a rigid tow bar. Check truck cab for decal recommending special
towing precautions. (Also refer to the Operation and Maintenance Manual, Operating Instructions - Towing .)
10. Drain, clean and ventilate fuel tanks and/or hydraulic tanks before making any welding repairs.
Any operating fluid, such as hydraulic oil or brake fluid escaping under pressure, can have sufficient force
to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper
medical treatment by a physician familiar with this injury is not received immediately.
11. Relieve pressure in lines or hoses before making any disconnects.
12. After adjustments or repairs, replace all shields, screens and clamps.
13. Tire Care:
Do not stand in front of a rim and locking ring when inflating a tire mounted on the machine. Observers
should not be permitted in the area and should be kept away from the sides of such tires.
Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of tire and rim.
14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation should
move the truck under its own power in the repair facility or during road testing after repairs are complete.
A03017 11/02
A3-19
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK

Preliminary Procedures before Welding or Performing Maintenance
Prior to welding and/or repairing a 930E dump truck, maintenance personnel should attempt to notify a Komatsu
service representative. Only qualified personnel, specifically trained for servicing the AC Drive System, should perform this service.
If it is necessary to perform welding or repair to the truck without the field engineer present, the following procedures should be followed to ensure that the truck is safe for maintenance personnel to work on and to reduce the
chance for damage to equipment.
ANYTIME THE ENGINE IS RUNNING:
Do not open any of the cabinet doors or remove any covers.
Do not use any of the power cables for hand holds or foot steps.
Do not touch the retarder grid elements.
Before opening any cabinets or touching a grid element or a power cable, the engine must be shutdown
and the red drive system warning lights must not be illuminated.
Normal Engine Shutdown Procedure
1. Stop the truck out of the way of other traffic on a level surface (dry, if possible) and free of overhead power
lines or other obstructions (in case dump body should need to be raised).
a. Reduce engine speed to idle. Allow the engine to cool gradually by running at low idle for approx. 5 minutes.
b. Place the directional selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the parking brake applied indicator light in the overhead display
panel is illuminated.
2. Place rest switch in ON position to put AC drive system in rest mode of operation. Be sure the rest indicator light in the overhead panel is illuminated.
3. With engine cooled down, turn keyswitch counterclockwise to OFF position for normal shutdown of engine.
If the engine does not shutdown with keyswitch, use engine shutdown switch on operator cab center console,
and hold this switch down until engine stops.
4. With keyswitch OFF, and engine stopped, wait at least 90 seconds. Insure the steering circuit is completely
bled down by turning the steering wheel back and forth several times. No front wheel movement will occur
when hydraulic pressure is relieved. If the vehicle continues to steer after shutdown, notify maintenance personnel.
5. Verify that all the link voltage lights are off (one on back wall of operator cab, and two on deck control cabinets). Notify maintenance personnel if any light remains illuminated longer than five minutes after engine
shutdown.
6. Close and lock all windows, remove key from keyswitch, and lock the cab to prevent possible unauthorized
truck operation. Dismount the truck properly. Put wheel chocks in place.
A3-20
11/02 A03017
Engine Shutdown Procedure before Welding or

Performing Maintenance
Normal operation of the drive system at shutdown
should leave the system safe to maintain. However,
in the event of a system failure, performing the following procedure prior to any maintenance activities
will ensure that no hazardous voltages are present in
the AC drive system.
1. Before shutting down the engine, verify the status of all the drive system warning lights on the
overhead display panel. Use the lamp test
switch to verify that all lamps are functioning
properly.
If any of the red drive system warning lights
remain on, do not attempt to open any cabinets,
disconnect any cables, or reach inside the
retarder grid cabinet without a trained drive system technician present - even if engine is off.
Only qualified personnel, specifically
trained for servicing the AC drive system,
should perform this service.
2. If all red drive system warning lights are off, follow the Normal Engine Shutdown Procedure.
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, the retard grids, wheel motors,
alternator, and related power cables are safe to
work on.
4. Locate the GF cut-out switch in the access
panel on the left side of the main control cabinet. Place the switch in the alternator cutout
position. This will prevent the alternator from reenergizing and creating system voltage until the
switch is returned to its former position.
5. The blower motors, control cabinet and power
cables connecting these devices are still
unsafe. To establish that these devices are
safe, open the top control cabinet cover and
inspect the red lights on the blower control
panel.
If these lights are off, the blower system, blower
power cables and remainder of the control cabinet is safe to work on.
If these lights are on, refer to steps 11 - 12.
6. Before welding on the truck, disconnect all electrical harnesses from the Engine Control System (ECS) inside the electrical cabinet behind
the operator's cab. Also, disconnect the ground
strap from the ECS.
A03017 11/02
7. Do not weld on the rear of the control cabinet! The metal panels on the back of the cabinet are part of capacitors and cannot be heated.
8. Do not weld on the retard grid exhaust louvers - they are made of stainless steel. Some
power cable panels throughout the truck are
also made of aluminum or stainless steel. They
must be repaired with the same material or the
power cables may be damaged.
9. Power cables must be cleated in wood or other
non-ferrous materials. Do not repair cable
cleats by encircling the power cables with metal
clamps or hardware. Always inspect power
cable insulation prior to servicing the cables and
prior to 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
voltage could be induced into the electrical harness and cause damage to components.
Before doing any welding on the truck, always
disconnect the battery charging alternator lead
wire and isolate electronic control components.
In addition, always disconnect the positive and
negative battery cables of the vehicle. Failure
to do so may seriously damage the battery and
electrical equipment.
Never allow welding current to pass through
ball bearings, roller bearings, suspensions, or
hydraulic cylinders.
11. If the red lights on the exterior of the control
cabinet and/or the back wall of the operator's
cab continue to be illuminated after following
the above procedure, a fault has occurred.
Leave all cabinet doors in place; do not touch
the retard grid elements; do not disconnect any
power cables, or use them as hand or foot
holds.
Notify your Komatsu service representative,
immediately. Only qualified personnel, specifically trained for servicing the AC drive system,
should perform this service.
12. If the red lights on the blower control panel are
illuminated after following the above procedure,
A3-21
a fault has occurred. Reinstall the control cabinet panel. Do not perform maintenance on the blower control
panel, blower motor power cables.
Notify your Komatsu service representative, immediately. Only qualified personnel, specifically trained for
servicing the AC drive system, should perform this service.
13. Replace all covers and doors and place the GF cutout switch and battery disconnect switches in their original
positions. Reconnect all harnesses prior to starting the truck.
Leave the drive system in the rest mode until the truck is to be moved.
A3-22
11/02 A03017
TRUCK OPERATION
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 by
the operator before attempting to start the engine.
Local work practices may prevent an operator from

performing all tasks suggested here. To the extent
permitted, the operator should follow this or a similar
routine.
Safety Is Thinking Ahead

Prevention is the best safety program. Prevent a
potential accident by knowing the employer's safety
requirements, all necessary job site regulations, as
well as, use and care of the safety equipment on the
truck. Only qualified operators or technicians should
attempt to operate or maintain a Komatsu truck.
Safe practices start before the operator gets to
the equipment!
Wear the proper clothing. Loose fitting clothing,

unbuttoned sleeves and jackets, jewelry, etc.,
can catch on a protrusion and cause a potential
hazard.
Always use the personal safety equipment
provided for the operator such as hard hats,
safety shoes, safety glasses or goggles. There
are some conditions when protective hearing
devices should also be worn for operator safety.
When walking to and from the truck, maintain a
safe distance from all machines, even if the
operator is visible.
At The Truck - Ground Level Walk Around

Inspection
At the beginning of each shift, a careful walk around
inspection of the truck should be performed before
the operator attempts engine start-up. A walk around
inspection is a systematic ground level inspection of
the truck and its components to insure that the truck
is safe to operate before entering the operator's cab.
Start at the left front corner of the truck (see illustration, next page), and move in a counter-clockwise
direction. Move front-to-rear, across the rear, and
continuing forward up the opposite side of the truck
to the original starting point.
If these steps are performed in sequence, and are
repeated from the same point and in the same direction before every shift, many potential problems may
be avoided, or scheduled for maintenance. Unscheduled downtime and loss of production can be
reduced as a result.
A03017 11/02
HIGH VOLTAGE MAY BE PRESENT ON THIS

TRUCK! DO NOT OPEN ANY ELECTRICAL CABINET DOORS ON THIS TRUCK WHEN THE
ENGINE IS RUNNING! NEVER CLIMB ON ANY
POWER CABLES OR USE POWER CABLES FOR
HANDHOLDS OR FOOTHOLDS, UNLESS THE
ENGINE HAS BEEN SHUT DOWN AND SYSTEM
HAS BEEN VERIFIED AT REST!
1. Start at left front of truck. While performing the
walk around inspection, visually inspect all
lights and safety equipment for external damage from rocks or misuse. Make sure lenses
are clean and unbroken.
Empty the dust pans on the left side air cleaner
assemblies. Be sure battery box covers are in
place and secure.
2. Move behind the front of the left front tire,
inspect the hub and brake assemblies for leaks
and any abnormal conditions. Check front
wheel hub oil sight gauge for oil level.
Check that all suspension attaching hardware
is secure and inspect mounting key area for
evidence of wear. Check that the suspension
extension (exposed piston rod) is correct, and
that there are no leaks.
3. With engine stopped, check engine oil level.
Use the service light if necessary.
4. Inspect air conditioner belts for correct tension,
obvious wear, and tracking. Inspect fan guard
security and condition. When leaving this point,
be sure to turn off the service light, if used.
5. Inspect anchor end of steering cylinder for
proper greasing and for security.
6. Move outboard of the front wheel, and inspect
attaching nuts/studs to be sure all are tight and
in tact. Check tires for cuts, damage or bubbles
Check for evidence of incorrect tire inflation.
A3-23
START HERE
Walk Around Inspection

A3-24
11/02 A03017
7. Move in behind the front wheel, and inspect the

steering cylinder. Check the greasing and
attaching hardware. Check suspension attaching hardware and suspension extension. Be
sure the suspension protective boot is in good
condition. Inspect the hub and brakes for any
unusual conditions. Check entire area for leaks.
8. Inspect sight glass on hydraulic tank. With
engine stopped and body down, hydraulic fluid
must be visible in lower sight glass.
15. Perform the same inspection on the right rear

suspension as done on the left.
16. Move around the right dual tires; inspect
between the tires for rocks, and check condition
of the rock ejector. Inspect the tires for cuts or
damage, and for correct inflation.
17. Perform the same inspection for wheel nuts/
studs and wheel leaks that was done on the left
hand dual wheels.
9. Move around the hydraulic tank and in front of

the rear dual tires; inspect the hoist cylinder for
any damage and leaks. Inspect both upper and
lower hoist cylinder pins for security, and for
proper greasing.
18. Move in front of right dual tires, and inspect the

hoist cylinder in the same manner as the left
side. Check security and condition of body-up
limit switch. Remove any mud/dirt accumulation
from switch.
10. Before leaving this position, look under the

lower edge of the chassis to be sure the flexible
duct that carries the air from the main blower to
the final drive housing is in good condition with
no holes or breakage. Also look up at the main
hydraulic pumps to see that there is no leakage
or any other unusual condition with pumps or
pump drive shafts.
19. Move around the fuel tank. Inspect the fuel

quantity gauge, (this should agree with what will
show on the gauge in the cab). Inspect the
attaching hardware for the fuel tank at the upper
saddles, and then at the lower back of the tank
for the security and condition of the mounts.
Check hoist filters for leaks.
11. Move on around the dual tires, check to see that

all nuts/studs are in place and tight. Inspect
wheel for any oil that would indicate brake leakage or wheel motor leakage.
Check dual tires for cuts, damage or bubbles.
Verify that inflation appears to be correct. If the
truck has been run on a "flat", the tire must be
cooled before moving the truck inside.
Check for any rocks that might be lodged
between dual tires. Check rock ejector condition and straightness (so that it can not damage
a tire).
12. Inspect left rear suspension for damage and for
correct rod exposure. Check for leaks. Ensure
that the covers over the chrome piston rod are
in good condition and inspect for proper greasing.
13. Open rear hatch cover. Inspect for leaks around
the parking brakes. Inspect condition of cooling
air exhaust ductwork to be certain that it is intact
and that there are no obstructions.
14. While standing in front of the rear hatch, look up
to see that rear lights are in good condition,
along with the back-up horns. Look up at panhard rod to see that it is getting proper greasing.
Also look at both body hinge pins for greasing
and any abnormal condition. Check hoist limit
switch and clear any mud/debris from contacts.
A03017 11/02
20. Move in behind the right front wheel, and

inspect the steering cylinder. Check the greasing and attaching hardware. Check suspension
attaching hardware and suspension extension.
Be sure the suspension protective boot is in
good condition. Inspect the hub and brakes for
any unusual conditions. Check entire area for
leaks.
21. Move out and around the right front wheel;
inspect that all nuts/studs are in place and tight.
22. Move in behind the front of the right front wheel,
check hub and brakes for leaks and any
unusual condition. Inspect steering cylinder for
security and for proper greasing. Inspect the
engine compartment for any leaks and unusual
conditions. Inspect the fan guard and belts.
Check for any rags or debris behind radiator.
23. Inspect auto lube system. See Automatic Lubrication System in Section P, for specific details
concerning the auto lube system.
24. Move around to the right front of the truck, drop
the air cleaner pans to remove dirt, latch up,
and secure. Inspect battery box cover for damage and be sure it is in place and secure.
25. As you move in front of the radiator, inspect for
any debris that might be stuck in front of the
radiator and remove it. Check for any coolant
leaks. Inspect headlights and fog lights.
A3-25
26. Before climbing ladder to first level, be sure

ground level engine shutdown switch is ON.
Inspect fire control actuator to be sure safety
pin is in place and plastic tie that prevents accidental actuation is in place and in good condition. Be sure battery disconnect switches are
ON. Always use grab rails and ladder when
mounting or dismounting the truck. Clean ladder and hand rails of any foreign material, such
as ice, snow, oil or mud.
27. Use stairs and handrails while climbing from
first level to cab deck.
Always mount and dismount ladders facing the

truck. Never attempt to mount or dismount while
the truck is in motion.
ENGINE START-UP SAFETY PRACTICES

1. Ensure all personnel are clear of truck before
starting engine. Always sound the horn as a
warning before actuating any operational controls. If the truck is in an enclosure, ensure adequate ventilation before start-up. Exhaust
fumes are dangerous!
2. Be sure the parking brake switch is in the ON
position. Check and insure selector switch is in
NEUTRAL before starting.
Place rest switch in ON position (put drive system in "rest" mode of operation). Refer to discussion of the rest switch in Section N,
Operator Cab Controls.
3. If truck is equipped with auxiliary cold weather
heater system(s), do not attempt to start engine
while heaters are in operation. Damage to
coolant heaters will result!
28. When checking coolant level in the radiator, use

coolant level sight gauge. If it is necessary to
remove the radiator cap, shut down engine (if
running), and relieve coolant pressure by
slowly removing the radiator cap.
If the engine has been running, allow the coolant

to cool before removing the fill cap or draining
the radiator. Serious burns may result if skin
comes in contact with hot coolant.
29. Inspect covers over retarding grids to be sure
latches are in place and secure. Inspect main
air inlet to be sure it is clear. Ensure all cabinet
door latches are secure.
30. Move around the cab to the back. Open the
doors to the brake cabinet; inspect for leaks.
31. Clean cab windows and mirrors; clean out cab
floor as necessary. Ensure steering wheel, controls and pedals are free of any grease or mud.
32. Stow personal gear in cab so that it does not
interfere with any operation of the truck. Dirt or
trash buildup, specifically in the operator's cab,
should be cleared. Do not carry tools or supplies in the cab of truck or on the deck.
33. Adjust seat and steering wheel for use.
34. Read and understand the description of all
operator controls in Section N, Operator Cab
Controls. Be familiar with all control locations
and functions before operating the truck.
A3-26
4. The keyswitch is a three position (OFF, RUN,

START) switch. When the switch is rotated one
position clockwise, it is in the RUN position and
all electrical circuits (except START) are activated.
a. Turn keyswitch to RUN (not START) position.
b. With selector switch in NEUTRAL, rotate
keyswitch fully clockwise to START position,
and hold this position until engine starts (see
NOTE below). The START position is springloaded and will return to RUN when the key
is released.
11/02 A03017
c. After the engine has started, place rest

switch in the OFF position (de-activate the
"rest" mode of operation). Refer to discussion of rest switch, in Section N, Operator
Cab Controls.
NOTE: This truck is equipped with an engine prelube
system. With this feature, a noticeable time delay
may occur (while engine lube oil passages are being
filled and pressurized) before engine cranking will
begin.
Cold Weather Starting
Do not crank an electric starter for more than 30

seconds.
Allow two minutes for cooling before attempting

to start the engine again. Severe damage to the
starter motors can result from overheating.
AFTER ENGINE HAS STARTED

1. Become thoroughly familiar with steering and
emergency controls. After engine has started
and low pressure and warning systems are normal, test the truck steering in extreme right and
left directions. If the steering system is not
operating properly, shut the engine down,
immediately. Determine the steering system
problem and have repaired before resuming
operation.
2. Operate each of the truck's brake circuits at
least twice prior to operating and moving the
truck. These circuits include individual activation from the operator's cab of the service
brake, parking brake, and brake lock. With the
engine running and with the hydraulic circuit
fully charged, activate each circuit, individually.
If any application or release of any brake circuit
appears sluggish or improper, or if warning
alarms are activated on application or release,
shut the engine down and notify maintenance
personnel. Do not operate the truck until the
brake circuit in question is fully operational.
3. Check gauges, warning lights and instruments
before moving the truck to ensure proper system operation and proper instrument functioning. Give special attention to braking and
steering circuit hydraulic warning lights. If warning lights come on, shut down the engine immediately and determine the cause.
4. Insure headlights, worklights and taillights are in
proper working order. Good visibility may prevent an accident. Check operation of windshield
wiper.
5. When truck body is in dump position, do not
allow anyone beneath it unless body-up retaining pin or cable is in place.
6. Do not use the fire extinguisher for any purpose
other than putting out a fire! If extinguisher is
discharged, report the occurrence so the used
unit can be refilled or replaced.
7. Do not allow unauthorized personnel to ride in
the truck. Do not allow anyone to ride on the
ladder of the truck.
8. Do not leave the truck unattended while the
engine is running. Shut down the engine and
apply the park brake before getting out of the
cab.
A03017 11/02
A3-27
MACHINE OPERATION SAFETY

PRECAUTIONS
After the truck engine is started and all systems are
functioning properly, the operator must follow all local
safety rules to insure safe machine operation.
If any of the red warning lights come on or if any

gauge reads in the red area during truck operation, a malfunction is indicated. Stop the truck as
soon as safety permits, and shut down the
engine. Have the problem corrected before
resuming truck operation.
The truck is equipped with "slip/slide" control. If

this function should become inoperative, operating the truck with stalled or free spinning wheel
motors may cause serious damage to wheel
motors! If the truck does not begin to move
within 10 seconds after depressing throttle pedal
(selector switch in a drive position), release
throttle pedal and allow wheels to regain traction
before accelerating again.
1. Always look to the rear before backing the
truck. Watch for and obey ground spotter's
hand signals before making any reverse movements. Sound the warning horn (3 blasts).
Spotter should have a clear view of the total
area at the rear of the truck.
2. Operate the truck only while properly seated
with seat belt fastened. Keep hands and feet
inside the cab compartment while the truck is in
operation.
3. Check gauges and instruments frequently during operation for proper readings.
4. Observe all regulations pertaining to the job
site's traffic pattern. Be alert to any unusual traffic pattern. Obey the spotter's signals.
5. Match the truck speed to haul road conditions
and slow the truck in any congested area. Keep
a firm grip on the steering wheel at all times.
6. Do not allow the engine to run at idle for
extended periods of time.
7. Check parking brake periodically during shift.
Use parking brake only for parking. Do not use
park brake for loading / dumping. Do not
attempt to apply parking brake while truck is
moving!
A3-28
Do not use "brake lock" or "emergency brake" (if

equipped) for parking. With engine stopped,
hydraulic pressure will bleed down, allowing
brakes to release!
8. Check brake lock performance periodically for
safe loading and dump operation.
9. Proceed slowly on rough terrain to avoid deep
ruts or large obstacles. Avoid traveling close to
soft edges and the edge of fill area.
10. Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
operating the truck.
MACHINE OPERATION ON THE HAUL

ROAD
1. Always stay alert! If unfamiliar with the road,
drive with extreme caution. Cab doors should
remain closed at all times if truck is in motion or
unattended.
2. Obey all road signs. Operate the truck so it is
under control at all times. Govern truck speed
by the road conditions, weather and visibility.
Report haul road conditions, immediately.
Muddy or icy roads, pot holes or other obstructions can present hazards.
3. Initial propulsion with a loaded truck should
begin from a level surface whenever possible,
but when there are circumstances where starting on a hill or grade cannot be avoided. Refer
to Starting On A Grade With A Loaded Truck in
Secton A, General Safety and Operating
Instructions.
4. When backing the truck, give a back-up signal
(three blasts on the horn); when starting forward, two blasts on the horn. These signals
must be given each time the truck is moved forward or backward.
5. Use extreme caution when approaching a haul
road intersection. Maintain a safe distance from
oncoming vehicles.
6. Maintain a safe distance when following
another vehicle. Never approach another vehicle from the rear, in the same lane, closer than
50 ft. (15 m). When driving on a down grade,
this distance should not be less than 100 ft. (30
m).
11/02 A03017
7. Do not stop or park on a haul road unless

unavoidable. If you must stop, move truck to a
safe place, apply parking brake, and shut down
engine before leaving cab. Block wheels
securely and notify maintenance personnel for
assistance.
8. Before starting up or down a grade, maintain a
speed that will insure safe driving and provide
effective retarding under all conditions (Refer to
Dynamic Retarding, in Section N, Operator Cab
Controls. The grade/speed chart in the operator's cab should always be referenced to determine maximum safe truck speeds for
descending various grades with a loaded truck.
9. When operating truck in darkness, or when visibility is poor, do not move truck unless all headlights, clearance lights, and tail lights are on. Do
not back truck if back-up horn or lights are inoperative. Always dim headlights when meeting
oncoming vehicles.
10. If the "emergency steering" light and/or "low
brake pressure warning" light (if equipped) illuminate during operation, steer the truck immediately to a safe stopping area, away from
other traffic if possible. Refer to item 7 above.
11. Check tires for proper inflation periodically during shift. If truck has been run on a "flat", or
under-inflated tire, it must not be parked in a
building until the tire cools.
DYNAMIC RETARDING OPERATION

Dynamic Retarding is a braking torque (not a brake)
produced through electrical generation by the wheel
motors when the truck motion (momentum) is the
propelling force. For normal truck operation, dynamic
retarding should be used to slow and control the
speed of the truck.
Dynamic retarding is available in "FORWARD/
REVERSE" at all truck speeds above 0 mph/kph;
however, as the truck speed slows below 3 mph (4.8
kph), the available retarding force may not be effective. Use the service brakes to bring the truck to a
COMPLETE stop.
Dynamic retarding will not hold a stationary truck on
an incline; use the parking brake or wheel lock brake
for this purpose.
Dynamic retarding is available in NEUTRAL only
when truck speed is above 3 mph (4.8 kph).
When dynamic retarding is in operation, the engine
rpm will automatically go to an advance rpm retard
speed setting (usually 900 - 1000 rpm*).
A03017 11/02
NOTE: The exact engine speed in retarding may vary

due to the temperature of certain components; this is
controlled by the propulsion system controller.
Dynamic retarding will be applied automatically, if
the speed of the truck obtains the maximum truck
speed of 40 mph (64 kph). Any application of the
dynamic retarding system (automatic, retarder lever,
or foot pedal) will cause an indicator light to illuminate in the overhead display panel.
Dynamic Retarder Control Lever
The dynamic retarder control lever mounted on the
right side of the steering column can be used to modulate retarding effort. The lever will command the full
range of retarding and will remain at a fixed position
when released.
a. When the lever is rotated to full "up" (counterclockwise) position, it is in the "OFF/No
Retard" position.
b. When the lever is rotated to full "down"
(clockwise) position, it is in the full "ON/
Retard" position.
c. For long downhill hauls, the lever may be
positioned to provide a desired retarding
effort. It will remain where it is positioned.
NOTE: The retarder control lever must be rotated
back to the OFF position before the truck will resume
the propel mode of operation.
The lever and foot-operated retarder/service brake
pedal can be used simultaneously or independently.
The Propulsion System Controller (PSC) will determine which device is requesting the most retarding
effort and apply that amount.
Dynamic Retarder/Service Brake Pedal

The dynamic retarder/service brake pedal is a single,
foot-operated pedal which controls both retarding
and service brake functions. The first portion of pedal
travel commands retarding effort through a rotary
potentiometer. The second portion of pedal travel
modulates service brake pressure directly through a
hydraulic valve. Thus, the operator must first apply,
and maintain, full dynamic retarding in order to apply
the service brakes. Releasing the pedal returns the
brake and retarder to the OFF position.
When the pedal is partially depressed, dynamic
retarding is actuated. As the pedal is further
depressed to where dynamic retarding is fully
applied; the service brakes (while maintaining full
retarding) are then actuated through a hydraulic
A3-29
valve, which modulates pressure to the service

brakes. Completely depressing the pedal causes
full application of both dynamic retarding and the
service brakes. An indicator light in the overhead
panel will illuminate, and an increase in pedal resistance, will be felt when the service brakes are
applied.
For normal truck operation, dynamic retarding (lever
or foot-operated pedal) should be used to slow and
control the speed of the truck.
Service brakes should be applied only when dynamic
retarding requires additional braking force to slow the
truck speed quickly, or when bringing the truck to a
complete stop.
Starting On A Grade With A Loaded Truck

Initial propulsion with a loaded truck should begin
from a level surface whenever possible. There are
circumstances when starting on a hill or grade cannot
be avoided; use the following procedure:
1. Fully depress the foot-operated retarder/service brake pedal (Do Not use retarder lever) to
hold the truck on the grade. With service brakes
fully applied, move the selector switch to a drive
position (FORWARD/REVERSE) and increase
engine rpm with throttle pedal.
2. As engine rpm approaches maximum, and
operator senses propulsion effort working
against the brakes, release the brakes and let
truck movement start. Be sure to completely
release the foot-operated retarder/service brake
pedal. As truck speed increases above 3-5 mph
(5-8 kph) the Propulsion System Control (PSC)
will drop propulsion, if the retarder is still
applied.
Releasing and reapplying dynamic retarding
during a hill start operation will result in loss of
propulsion.
PASSING
1. Do not pass another truck on a hill or blind
curve!
2. Before passing, make sure the road ahead is
clear. If a disabled truck is blocking your lane,
slow down and pass with extreme caution.
LOADING
1. Pull into the loading area with caution. Remain
at a safe distance while truck ahead is being
loaded.
2. Do not drive over unprotected power cables.
3. When approaching or leaving a loading area,
watch out for other vehicles and for personnel
working in the area.
4. When pulling in under a loader or shovel, follow
"spotter" or "shovel operator" 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.
5. During loading, the operator must stay in the
truck cab with engine running. Place the selector switch in NEUTRAL and apply the brake
lock.
6. When loaded, pull away from shovel as quickly
as possible but with extreme caution.
DUMPING
Raising The Dump Body
1. Pull into dump area with extreme caution. Make
sure area is clear of persons and obstructions,
including overhead utility lines. Obey signals
directed by the spotter, if present.
Avoid unstable areas. Stay a safe distance
from edge of dump area. Position truck on a
solid, level surface before dumping.
As the body raises, the truck center of gravity will

move. Truck must be on level surface to prevent
tipping / rolling!
2. Carefully maneuver truck into dump position.
When backing truck into dump position, use
only the foot-operated brake pedal to stop and
hold truck; Do not rely on wheel brake lock to
stop truck; this control is not modulated and
applies rear service brakes only.
3. Use only the areas designated for passing.
A3-30
11/02 A03017
3. When truck is stopped and in dump position,

apply wheel brake lock and move the selector
switch to the NEUTRAL position..
The dumping of very large rocks (10% of payload,

or greater) or sticky material (loads that do not
flow freely from the body) may allow the material
to move too fast and cause the body to move rapidly and suddenly. This sudden movement may
jolt the truck violently and cause possible injury
to the operator, and/or damage to the hoist cylinders, frame, and/or body hinge pins. If it is necessary to dump this kind of material, refer to the
WARNING in the following procedure:
(When dumping on flat ground):

It is very likely when dumping on flat ground that the
dumped material will build up enough to prevent the
body from lowering. In this case, the truck will have to
be driven forward a short distance (just enough to
clear the material) before the body can be lowered.
1. Shift selector switch to FORWARD, release
brake lock, depress Override button and drive
just far enough forward for body to clear material. Stop, shift selector switch to NEUTRAL
apply brake lock.
2. Move hoist lever forward to DOWN position and
release. Releasing the lever places hoist control
valve in the FLOAT position allowing the body
to return to frame.
NOTE: If dumped material builds
up at the rear of the body and the
body cannot be lowered, then
perform Steps "a" and "b" below:
4. Pull the lever to

the rear to actuate hoist circuit.
(Releasing
the
lever anywhere
during "hoist up"
will hold the body
at that position.)
a. Move hoist lever back to the RAISE position

to fully raise the dump body. Then release
the hoist lever so it returns to the HOLD position.
5. Raise engine rpm

to accelerate hoist speed. Refer to the WARNING below.
If dumping very large rocks or sticky material as

described in WARNING above, slowly accelerate
engine rpm to raise body. When the material
starts to move, release hoist lever to HOLD position. If material does not continue moving and
clear body, repeat this procedure until material
has cleared body.
6. Reduce engine rpm as last stage of hoist cylinder begins to extend and let engine go to low
idle as last stage reaches half-extension.
7. Release hoist lever as last stage of hoist cylinder reaches full extension.
8. After material being dumped clears body, lower
body to frame.
A03017 11/02
Lowering The Dump Body
b. Shift selector switch to FORWARD, release

brake lock, depress override button and
drive forward to clear the material. Stop, shift
selector switch to NEUTRAL, apply brake
lock and lower body again.
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.
CAUTION! The truck is not to be moved with the

dump body raised except for emergency purposes only. Failure to lower body before moving
truck may cause damage to hoist cylinders,
frame and/or body hinge pins.
3. With body returned to frame, move selector
switch to FORWARD, release brake lock, and
leave dump area carefully.
A3-31
Lowering The Dump Body
TOWING
(When dumping over a berm or into a crusher):
Prior to towing a truck, many factors must be carefully considered. Serious personal injury and/or significant property damage may result if important
safety practices, procedures and preparation for
moving heavy equipment are not observed. Do not
tow the truck any faster than 5 mph (8 kph).
1. Move hoist lever forward to DOWN position and

release. Releasing the lever places hoist control valve in the FLOAT position allowing the
body to return to frame.
NOTE: If dumped material builds
up at the rear of the body and the
body cannot be lowered, perform
Steps "a" & "b" below:
Attachments for towing the 930E are available from

Komatsu Distributors as follows:
a. Move hoist lever back to

the HOIST position to
fully raise the dump body. Release the hoist
lever so it returns to the HOLD position.
NOTE: DO NOT drive forward if the tail of body will
not clear the crusher wall in the fully raised position.
b. Shift selector switch to FORWARD, release
brake lock, depress Override button and
drive forward to clear the material. Stop, shift
selector switch to NEUTRAL, apply brake
lock and lower body again.
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.
Front Bumper Modification Kit - MK3941: This kit

contains the parts necessary to modify the front
bumper for installation of towing bosses. One
MK3941 kit is required for each truck in the fleet.
Tow Adaptor Structure - MK3945: This structure
must be ordered (or designed) to mate with the
intended towing vehicle and is intended for towing an
unloaded vehicle only.
A disabled machine may be towed after the following
minimum precautions have been taken.
1. Shut down engine.
2. If truck is equipped, install hydraulic connections for steering and dumping between towing
and towed vehicles. Check towed vehicle for
braking system.
3. Inspect tow bar for adequacy (approximately
1.5 times the gross vehicle weight of truck being
towed).
4. Determine that towing vehicle has adequate
capacity to both move and stop the towed truck
under all conditions.
CAUTION! The truck is not to be moved with the

dump body raised except for emergency purposes only. Failure to lower body before moving
truck may cause damage to hoist cylinders,
frame and/or body hinge pins.
2. With body returned to frame, move selector
switch to FORWARD, release brake lock, and
leave dump area carefully.
A3-32
5. Block disabled truck to prevent movement while

attaching tow bar.
6. Release disabled truck brakes and remove
blocking.
7. Sudden movement may cause tow bar failure.
Smooth, gradual truck movement is preferred.
8. Minimize tow angle at all times - never exceed
30. The towed truck must be steered in the
direction of the tow bar.
11/02 A03017
SAFE PARKING PROCEDURES

The operator must continue the use of safety precautions when preparing for parking and engine shutdown.
3. With engine cooled down, turn keyswitch counterclockwise to OFF position for normal shutdown of engine.
In the event that the equipment is being worked in

consecutive shifts, any questionable truck performance the operator may have noticed must be
checked by maintenance personnel before the truck
is released to another operator.
If engine does not shutdown with keyswitch,

use engine shutdown switch on operator cab
center console, and hold this switch down until
engine stops.
1. The truck should be parked on level ground, if

at all possible. If parking must be done on a
grade, the truck should be positioned at right
angles to the grade.
2. The parking brake must be applied and/or
chocks placed fore/aft of wheels so that the
truck cannot roll. Each truck should be parked
at a reasonable distance from another.
3. Haul roads are not safe parking areas. In an
emergency, pick the safest spot most visible to
other machines in the area. If the truck
becomes disabled where traffic is heavy, mark
the truck with warning flags in daylight or flares
at night.
NORMAL ENGINE SHUTDOWN

PROCEDURE
The following procedure should be followed 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 or other obstructions (in case dump body
should need to be raised).
a. Reduce engine speed to idle.
b. Place the selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the
"parking brake applied" indicator light in the
overhead display panel is illuminated.
d. Allow engine to cool gradually by running at
low idle for 3 to 5 minutes, or if preferred,
activate the 5 minute shutdown delay timer
as described on the following page.
2. Place rest switch in ON position to put AC Drive
system in "rest" mode of operation. Be sure the
"rest" indicator light in the overhead panel is illuminated.
A03017 11/02
4. With keyswitch OFF, and engine stopped, wait

at least 90 seconds. Insure steering circuit is
completely bled down by turning steering wheel
back and forth several times. No front wheel
movement will occur when hydraulic pressure is
relieved. If the vehicle continues to steer after
shutdown, notify maintenance personnel.
5. Verify all link voltage lights are off (one on back
interior wall of operator cab, two on electrical
cabinet, on deck), and notify maintenance personnel if remains illuminated longer than five
minutes after the engine is shut down.
6. Close and lock all windows, remove key from
keyswitch and lock cab to prevent possible
unauthorized truck operation. Dismount truck
properly. Put wheel chocks in place.
DELAYED ENGINE SHUTDOWN

PROCEDURE
1. Stop the truck out of the way of other traffic on
a level surface and free of overhead power
lines or other obstructions (in case dump body
should need to be raised).
a. Reduce engine speed to low idle.
b. Place the directional selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the
"parking brake applied" indicator light in the
overhead display panel is illuminated.
2. Place rest switch in ON position to put AC Drive
System in "rest" mode of operation. Be sure the
"rest" indicator light in the overhead panel is illuminated.
3. Refer to Instrument Panel and Indicator Lights
in Section N for location of the engine shutdown
switch with 5 minute idle timer delay. This is a
3-position
rocker-type
switch
(OFF-ONMOMENTARY).
A3-33
4. Press the top of the

engine shutdown switch
to select the ON (center)
position. Press the top of
the switch again to activate the timer delay
(momentary
position).
Release the switch and
allow it to return to the
ON position.
When the engine shutdown
timer has been activated,
the timer delay indicator
light in the overhead status
panel will illuminate to indicate that the shutdown timing sequence has started.
The engine will continue to
idle for approximately 5 minutes to allow for
proper engine cool-down before stopping.
5. Turn the keyswitch counterclockwise to the
OFF position to cause the engine to shutdown
when the timing sequence is complete. When
the engine stops, this will activate the hydraulic
bleeddown timer and turn off the 24 VDC electric circuits controlled by the keyswitch.
NOTE: To cancel the 5 minute idle timer sequence,
press the timer delay shutdown switch to the OFF
(lower) position. If the keyswitch is in the OFF
position, the engine will stop. If the keyswitch is in the
ON position, the engine will continue to run.
A3-34
SUDDEN LOSS OF ENGINE POWER

Bring the truck to a safe stop as quickly as possible
by using the foot pedal to apply the service brakes.
Dynamic retarding will not be available! Do not

use the service brakes for continuous retarding
purposes.
If possible, steer the truck to the side of the road
while bringing it to a complete stop. Apply the parking
brake as soon as the truck has stopped moving. Turn
key switch OFF and notify maintenance personnel
immediately.
If the truck becomes disabled where traffic is heavy,
mark the truck with warning flags in daylight or flares
at night.
If the engine suddenly stops, there is enough hydraulic pressure stored in the brake and steering accumulators to allow the operation of the steering and brake
functions. However, this oil supply is limited so it is
important to stop the truck as quickly and safely as
possible after the loss of engine power. If the brake
supply pressure drops to a pre-determined level, the
"low brake pressure" warning light will illuminate and
a buzzer 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. Apply the parking brake as soon as the truck
comes to a complete stop.
11/02 A03017
WARNINGS AND CAUTIONS

The following pages give an explanation of the warning, caution, and service instruction plates and
decals attached to the truck. The plates and decals
listed here are typical of this Komatsu model, but
because of customer options, individual trucks may
have plates and decals that are different from those
shown here.
A plate attached to the right rear corner of the cab

states the Rollover Protective Structure (ROPS) and
Falling Object Protective Structure (FOPS) meets
various SAE performance requirements.
The plates and decals must be kept clean and legible. If any decal or plate becomes unable to be read
or damaged, it should be replaced with a new one.
A warning decal surrounds the key switch located to
the right of the steering column on the instrument
panel. The warning stresses the importance of reading the operator's manual before operation.
! WARNING ! Do not make modifications to this

structure, or attempt to repair damage without
written approval from Komatsu. Unauthorized
repairs will void certification.
A warning instruction is applied below the parking
brake and the rear wheel brake lock switches which
are located to the right of the steering column on the
instrument panel. Pushing the top of the rocker-style
switch turns the function ON, pushing the bottom,
turns it OFF.
A grade/speed retard chart is located on the left front

post of the operator's cab and 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, retarder grids,
tire sizes, etc.
The parking brake is spring applied and
hydraulically released. It is designed to
hold a stationary truck when the engine
is shutdown and keyswitch is turned
OFF. The truck must be completely
stopped before applying the parking brake, or damage may occur to parking brake.To apply the parking
brake, press the rocker switch toward the ON symbol. To release the parking brake, press the rocker
switch toward the OFF symbol. When the keyswitch
is ON and parking brake switch is applied, the parking brake indicator light (A3, overhead panel) will be
illuminated.
NOTE: Do not use the parking brake at shovel or
dump. With keyswitch ON and engine running,
sudden shock caused by loading or dumping could
cause the systems motion sensor to release the park
brake.
A04039
Warnings and Cautions
A4-1
The wheel brake lock switch is for holding the truck while parked at the shovel
during loading, or while dumping. It
applies the rear service brakes only. If
the brake treadle valve does not operate, apply this brake to stop the truck. Do Not use
this brake as a parking brake when leaving the truck.
With engine shut down, the hydraulic system will
eventually bleed down, releasing the service brakes.
Attached to the exterior of both battery compartments is a danger plate. This plate stresses the need
to keep from making any sparks near the battery.
When another battery or 24VDC power source is
used for auxiliary power, all switches must be OFF
prior to 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 good frame ground. Do not connect to the negative posts of the truck battery or
near the battery box. This hookup completes the
circuit but minimizes danger of sparks near the batteries.
These decals are placed above the battery disconnect switches on the right side of the front bumper to
indicate OFF and ON positions of the switches.
A warning plate is mounted on top of the radiator

surge tank cover near the radiator cap. The engine
cooling system is pressurized. Always turn the key
switch OFF and allow the engine to cool before
removing radiator cap. Unless the pressure is first
released, removing the radiator cap after the engine
has been running for a time will result in the hot coolant being expelled from the radiator. Serious scalding and burning may result.
Sulfuric acid is corrosive and toxic. Use proper safety

gear, goggles, rubber gloves and rubber apron when
handling and servicing batteries. Get proper medical
help immediately, if required.
Warning plates are mounted on the frame in front of,

and to the rear, of both front tires. All personnel are
warned that the clearances change when the truck is
steered and could cause serious injury.
This plate is placed on both battery boxes and near

the battery disconnect switches to indicate that the
battery system (24VDC) is a negative (-) ground system.
A4-2
A04039
Warning plates are attached to both the hydraulic

tank and fuel tank to alert technicians not to work on
the truck with the body in the raised position unless
body-up retention device (pins or cable) is in position.
This danger plate is attached to all four suspensions.
The plate contains instructions for releasing internal

pressure before disconnecting any hardware.
Serious injury can occur if these directions are not
followed.
These danger plates are mounted on the outside of
each frame rail to alert technicians to read the warning labels attached to the side of each of the accumulators (see below) prior to 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.
A plate on the side of the hydraulic tank furnishes

instructions for filling the hydraulic tank.
Keep the system open to the atmosphere only as
long as absolutely necessary to lessen chances of
system contamination. Service the tank with clean
Type C-4 hydraulic oil. All oil being put into the
hydraulic tank should be filtered through 3 micron filters.
These warning decals are mounted on the side of

each of the accumulators (both steering and brake)
to alert technicians to discharge all gas and hydraulic
pressure, and to read the maintenance/service manual prior to performing any service.
A04039
A4-3
A caution decal is attached below the hydraulic tank

oil level sight gauge. Check level with body down,
engine stopped, and key switch OFF. Add oil per filling instructions, if oil level is below top of sight glass.
A warning plate is attached to the hydraulic tank to

inform technicians that high pressure hydraulic oil is
present during operation. When it is necessary to
open the hydraulic system, be sure engine is stopped
and key switch is OFF to bleed down hydraulic pressure. There is always a chance of residual pressure
being present. Open fittings slowly to allow all pressure to bleed off before removing any connections.
A wheel motor oil level decal is attached to the gear

cover on both electric wheel motors. This decal
stresses the fact that the truck must be on a level
surface and parked for 20 minutes prior to checking
the oil level. This is necessary in order to get an
accurate reading.
A decal plate is located on the frame near the left

hoist cylinder which provides the operator or technician with the hook-up procedure for dumping a
loaded, disabled truck, by using a functional truck for
hydraulic power.
Refer to the Section L for additional instructions for
using this procedure.
Warning decals are applied to both brake accumulators located inside the brake system cabinet behind
the operator cab. These decals remind servicing
technicians to be sure to close the accumulator drain
valves after they have been opened to bleed brake
pressure. It further warns not to over-tighten the drain
valves to prevent damage to the valve seat(s).
Any operating fluid, such as hydraulic oil, escaping under pressure can have sufficient force to
enter a person's body by penetrating the skin.
Serious injury and possibly death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
A4-4
A04039
This caution decal is placed near the battery disconnect switches on the right side of the front bumper to
alert servicing technicians that before doing any
welding on the truck, always disconnect the battery
charging alternator lead wire and isolate electronic
control components before making welding repairs.
A caution decal is also attached to the door of the

rear hatch cover to alert personnel that hot exhaust
air is present and may cause injury.
This caution decal is also placed around the retarding grid cabinet.
In addition, always disconnect the positive and 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; grounding clamp must be
attached as near as possible to the weld area.
Never allow welding current to pass through ball
bearings, roller bearings, suspensions, or hydraulic
cylinders. Always avoid laying welding cables over or
near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and
possibly cause damage to components.
These warning plates are mounted on all of the AC

drive control housings and cabinets.
High voltage may be present, with or without, the
engine running!
Only authorized personnel should access these cabinets.
A high voltage danger plate is attached to the door of

the rear hatch cover. High voltage may be present!
Only authorized personnel should access this rear
housing.
A04039
A4-5
This caution decal is placed on the back of the control cabinet to alert service technicians that this area
contains capacitors and must not be disturbed in any
manner.
This decal is placed near three different indicator

lights:
In the operator cab, on the D.I.D. panel on the

rear wall.
On the front of the control box which is mounted
on the right side of the main control cabinet.
On the outside of the left control cabinet wall that
faces the right side of the operator cab. (See also
Information decal above.)
When any of these indicator lights are on, high
voltage is present throughout the propulsion and
retarding system. Extreme care should be exercised!
This information decal is placed on the outside of the

door panel on the control cabinet wall that faces the
right side of the operator cab.
A4-6
This decal is placed on the ground level engine shutdown switch which is mounted on the left side of the
front bumper structure. It specifies that this switch is
for emergency shutdown only.
A04039
This page illustrates a variety of decals which are

mounted on deck mounted cabinets, housings, and
structures which must be lifted in a specific manner,
and from specific points, in order to safely move or lift
any of these structures.
If any of these decals are damaged or defaced, so
that it is no longer legible, it should be replaced
immediately.
Maintenance personnel must follow these lifting
instructions.
A04039
A4-7
A product identification plate is located

on the main frame in front of the right
side front wheel and shows the truck
model number, maximum G.V.W. and
product identification number (truck
serial number).
The product identification number (truck
serial number) contains information
which will identify the original manufacturing bill of material for this unit.
The complete truck serial number will be
required for the proper ordering of many
service parts and/or warranty consideration.
The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrication and Service, in this manual for more complete lubrication instructions.
A4-8
A04039
STANDARD CHARTS AND TABLES

This manual provides dual dimensioning for most specifications. U.S. standard units are specified first, with
metric (SI) units in parentheses. References throughout the manual to standard torques or other standard
values will be to one of the following Charts or Tables.
For values not shown in any of the charts or tables,
standard conversion factors for most commonly used
measurements are provided in TABLE XIII, page 1-14.
INDEX OF TABLES
TABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1
TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2
TABLE III . . Standard Metric Assembly Torque . . A5-2
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . A5-3
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3
TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3
TABLE VIII . Torque Conversions (ft.lbs. - N.m) . . A5-4
TABLE IX . . Torque Conversions (ft.lbs. - kg.m) . . A5-4
TABLE X . . . Pressure Conversions (psi - kPa) . . A5-4
TABLE XI . . Pressure Conversions (psi - MPa) . . A5-5
TABLE XII . . . . . . . .Temperature Conversions . . A5-5
TABLE XIII . . . Common Conversion Multipliers . . A5-6
Grade 5
Capscrew
Thread
Size
kg.m
1/4-20
1/4-28
5/16-18
KOMATSU engineering department does NOT recommend the use of special friction-reducing lubricants
such as, Copper Coat, Never Seize, and other similar products on the threads of standard fasteners
where standard torque values are applied.
The use of special friction-reducing lubricants will significantly alter the clamping force being applied to fasteners during the tightening process.
If special friction-reducing lubricants are used with the
Standard Torque values listed below in Table I (and in
Komatsu shop manuals), excessive stress and possible breakage of the fasteners may result.
Where Torque Tables specify Lubricated Threads for
the Standard Torque values listed, 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, page 1-10) on the
threads and seats, unless specified otherwise.
NOTE: Always be sure threads of fasteners and
tapped holes are free of burrs and other imperfections before assembling.
Standard torque values are not to be used when
Turn-of-the-Nut tightening procedures are recommended.
TABLE I. -STANDARD TORQUE CHART

SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS) - TOLERANCES 10%
TORQUE GRADE 5
ft. lbs.
EFFECT OF SPECIAL LUBRICANTS

On Fasteners and Standard Torque Values
TORQUE GRADE 8
N.m
Capscrew
Thread
Size
Grade 8
TORQUE GRADE 5
TORQUE GRADE 8
N.m
ft. lbs.
kg.m
ft. lbs.
kg.m
N.m
ft. lbs.
kg.m
N.m
0.97
9.5
10
1.38
13.6
1.11
10.8
11
1.52
14.9
3/4-16
235
32.5
319
335
46.3
454
7/8-9
350
48.4
475
500
69.2
15
2.07
20.3
21
2.90
28
678
7/8-14
375
51.9
508
530
73.3
719
5/16-24
16
2.21
22
22
3.04
3/8-16
25
3.46
34
35
4.84
30
1.0-8
525
72.6
712
750
103.7
1017
47
1.0-12
560
77.4
759
790
109.3
3/8-24
30
4.15
41
40
1071
5.5
54
1.0-14
570
78.8
773
800
110.6
7/16-14
40
5.5
54
1085
58
8.0
79
1 1/8-7
650
89.9
881
1050
145
7/16-20
45
6.2
61
1424
62
8.57
84
1 1/8-12
700
96.8
949
1140
158
1546
1/2-13
65
88
90
12.4
122
1 1/4-7
910
125.9
1234
1480
205
2007
1/2-20
70
9.7
95
95
13.1
129
1 1/4-12
975
134.8
1322
1580
219
2142
9/16-12
90
12.4
122
125
17.3
169
1 3/8-6
1200
166
1627
1940
268
2630
9/16-18
95
13.1
129
135
18.7
183
1 3/8-12
1310
181
1776
2120
293
2874
5/8-11
125
17.3
169
175
24.2
237
1 1/2-6
1580
219
2142
2560
354
3471
5/8-18
135
18.7
183
190
26.2
258
1 1/2-12
1700
235
2305
2770
383
3756
3/4-10
220
30.4
298
310
42.8
420
1 ft. lbs. = 0.138 kg.m = 1.356 N.m
A05001 12/99
Standard Torque Chart and Tables
A5-1
Standard Assembly Torques For 12-Point, Grade 9,

Capscrews (SAE)
The following specifications apply to required assembly
torques for all 12-Point, Grade 9 (170,000 psi minimum
tensile), Capscrews.
Capscrew threads and seats SHALL be lubricated 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.
Standard Metric Assembly Torque For Class 10.9

Capscrews & Class 10 Nuts
The following specifications apply to required assembly
torques for all metric Class 10.9 finished hexagon head
capscrews and Class 10 nuts.
Capscrew threads and seats SHALL NOT be

lubricated when assembled. These specifications
are based on all capscrews, nuts, and hardened
washers being phosphate and oil coated.NOTE:
If zinc-plated hardware is used, each piece must
be lubricated with a Rust Preventive Grease or
Lithium-base grease to achieve the same clamping forces provided below.
Torques are calculated to give a clamping force of

approximately 75% of proof load.
The maximum torque tolerance shall be within

10% of the torque value shown.
TABLE III. - STANDARD METRIC ASSEMBLY TORQUE
CAPSCREW
SIZE*
TABLE II. - STANDARD ASSEMBLY TORQUE

for 12-Point, Grade 9 Capscrews
TORQUE
N.m
TORQUE
ft.lbs.
TORQUE
kg.m
1.22
M6 x1
12
M8 x 1.25
30
22
3.06
M10 x 1.5
55
40
5.61
CAPSCREW
SIZE*
TORQUE
ft. lbs.
TORQUE
N.m
TORQUE
kg.m
M12 x 1.75
95
70
9.69
0.250 - 20
12
16
1.7
M14 x 2
155
114
15.81
0.312 - 18
24
33
3.3
M16 x 2
240
177
24.48
0.375 - 16
42
57
5.8
M20 x 2.25
465
343
47.43
0.438 -14
70
95
9.7
M24 x 3
800
590
81.6
0.500 -13
105
142
14.5
M30 x 3.5
1600
1180
163.2
0.562 - 12
150
203
20.7
M36 x 4
2750
2028
280.5
0.625 - 11
205
278
28.3
* Shank Diameter (mm) - Threads per millimeter
0.750 - 10
360
488
49.7
0.875 - 9
575
780
79.4
This table represents standard values only. Do not use these values to replace torque values which are specified in assembly
instructions.
1.000 - 8
860
1166
119
1.000 - 12
915
1240
126
1.125 - 7
1230
1670
170
1.125 - 12
1330
1800
184
1.250 - 7
1715
2325
237
1.250 - 12
1840
2495
254
1.375 - 6
2270
3080
313
1.375 - 12
2475
3355
342
1.500 - 6
2980
4040
411
1.500 - 12
3225
4375
445
* Shank Diameter (in.) - Threads per inch

This table represents standard values only. Do not use these values to replace torque values which are specified in assembly
instructions.
Suggested* Sources for Rust Preventive Grease:

AMERICAN ANTI-RUST GREASE #3-X from Standard 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.

RUSTOLENE B GREASE from Sinclair Oil Company.
RUST PREVENTIVE GREASE - CODE 312 from

the Southwest Grease and Oil Company.
* NOTE: This list represents the current Engineering approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet
the same specifications of this list.
A5-2
12/99 A05001
TABLE IV.
TORQUE CHART FOR JIC 37 SWIVEL NUTS
WITH OR WITHOUT O-RING SEALS
TABLE VI.
TORQUE CHART FOR
O-RING BOSS FITTINGS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
0.125
0.312 24
4 1
0.125
0.312 24
4 2
0.188
0.375 24
8 3
0.188
0.375 24
5 2
0.250
0.438 20
12 3
0.250
0.438 20
8 3
0.312
0.500 20
15 3
0.312
0.500 20
10 3
0.375
0.562 18
18 5
0.375
0.562 18
13 3
0.500
0.750 16
30 5
0.500
0.750 16
24 5
10
0.625
0.875 14
40 5
10
0.625
0.875 14
32 5
12
0.750
1.062 12
55 5
12
0.750
1.062 12
48 5
14
0.875
1.188 12
65 5
14
0.875
1.188 12
54 5
16
1.000
1.312 12
80 5
16
1.000
1.312 12
72 5
20
1.250
1.625 12
100 10
20
1.250
1.625 12
80 5
24
1.500
1.875 12
120 10
24
1.500
1.875 12
80 5
32
2.000
2.500 12
230 20
32
2.000
2.500 12
96 10
TABLE V.
TORQUE CHART FOR
PIPE THREAD FITTINGS
TABLE VII.
TORQUE CHART FOR
O-RING FACE SEAL FITTINGS
SIZE
CODE
PIPE
THREAD
SIZE
WITH
SEALANT
FT. LBS.
WITHOUT
SEALANT
FT. LBS.
0.125 27
15 3
20 5
0.250 18
20 5
25 5
0.375 18
25 5
35 5
0.500 14
35 5
45 5
12
0.750 14
45 5
55 5
16
1.000 11.50
55 5
65 5
20
1.250 11.50
70 5
80 5
24
1.500 11.50
80 5
95 10
32
2.000 11.50
95 10
120 10
A05001 12/99
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
0.250
0.438 20
11 1
0.375
0.562 18
18 2
0.500
0.750 16
35 4
10
0.625
0.875 14
51 5
12
0.750
1.062 12
71 7
16
1.000
1.312 12
98 6
20
1.250
1.625 12
132 7
24
1.500
1.875 12
165 15
A5-3
TABLE VIII. TORQUE CONVERSIONS

Foot Pounds ft. lbs. To Newton-meters (N.m)
FT. LBS.
(N.m)
1.36
2.71
4.07
5.42
6.78
8.14
9.49
10.85
12.20
10
13.56
14.91
16.27
17.63
18.98
20.34
21.69
23.05
24.40
25.76
20
27.12
28.47
29.83
31.18
32.54
33.90
35.25
36.61
37.96
39.32
30
40.67
42.03
43.39
44.74
46.10
47.45
48.81
50.17
51.52
52.87
40
54.23
55.59
56.94
58.30
59.66
60.01
62.37
63.72
65.08
66.44
50
67.79
69.15
70.50
71.86
73.21
74.57
75.93
77.28
78.64
80.00
60
81.35
82.70
84.06
85.42
86.77
88.13
89.48
90.84
92.20
93.55
70
94.91
96.26
97.62
98.97
100.33
101.69
103.04
104.40
105.75
107.11
80
108.47
109.82
111.18
112.53
113.89
115.24
116.60
117.96
119.31
120.67
90
122.03
123.38
124.74
126.09
127.45
128.80
130.16
131.51
132.87
134.23
See NOTE on page A5-5 regarding Table usage
TABLE IX. TORQUE CONVERSIONS

Foot Pounds ft. lbs. To kilogram-meters (kg.m)
FT. LBS.
(kg.m)
0.138
0.277
0.415
0.553
0.692
0.830
0.968
1.106
1.245
10
1.38
1.52
1.66
1.80
1.94
2.07
2.21
2.35
2.49
2.63
20
2.77
2.90
3.04
3.18
3.32
3.46
3.60
3.73
3.87
4.01
30
4.15
4.29
4.43
4.56
4.70
4.84
4.98
5.12
5.26
5.39
40
5.53
5.67
5.81
5.95
6.09
6.22
6.36
6.50
6.64
6.78
50
6.92
7.05
7.19
7.33
7.47
7.61
7.74
7.88
8.02
8.16
60
8.30
8.44
8.57
8.71
8.85
8.99
9.13
9.27
9.40
9.54
70
9.68
9.82
9.96
10.10
10.23
10.37
10.51
10.65
10.79
10.93
80
11.06
11.20
11.34
11.48
11.62
11.76
11.89
12.03
12.17
12.30
90
12.45
12.59
12.72
12.86
13.00
13.14
13.28
13.42
13.55
13.69
TABLE X. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
PSI
(kPa)
6.895
13.79
20.68
27.58
34.47
41.37
48.26
55.16
62.05
10
68.95
75.84
82.74
89.63
96.53
103.42
110.32
117.21
124.1
131.0
20
137.9
144.8
151.7
158.6
165.5
172.4
179.3
186.2
193.1
200.0
30
206.8
213.7
220.6
227.5
234.4
241.3
248.2
255.1
262.0
268.9
40
275.8
282.7
289.6
296.5
303.4
310.3
317.2
324.1
331.0
337.9
50
344.7
351.6
358.5
365.4
372.3
379.2
386.1
393.0
399.9
406.8
60
413.7
420.6
427.5
434.4
441.3
448.2
455.1
462.0
468.9
475.8
70
482.6
489.5
496.4
503.3
510.2
517.1
524.0
530.9
537.8
544.7
80
551.6
558.5
565.4
572.3
579.2
586.1
593.0
599.9
606.8
613.7
90
620.5
627.4
634.3
641.2
648.1
655.0
661.9
668.8
675.7
682.6
A5-4
12/99 A05001
TABLE XI. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
PSI
10
20
30
40
50
60
70
80
90
(MPa)
0.069
0.14
0.21
0.28
0.34
0.41
0.48
0.55
0.62
100
0.69
0.76
0.83
0.90
0.97
1.03
1.10
1.17
1.24
1.31
200
1.38
1.45
1.52
1.59
1.65
1.72
1.79
1.86
1.93
2.00
300
2.07
2.14
2.21
2.28
2.34
2.41
2.48
2.55
2.62
2.69
400
2.76
2.83
2.90
2.96
3.03
3.10
3.17
3.24
3.31
3.38
500
3.45
3.52
3.59
3.65
3.72
3.79
3.86
3.93
4.00
4.07
600
4.14
4.21
4.27
4.34
4.41
4.48
4.55
4.62
4.69
4.76
700
4.83
4.90
4.96
5.03
5.10
5.17
5.24
5.31
5.38
5.45
800
5.52
5.58
5.65
5.72
5.79
5.86
5.93
6.00
6.07
6.14
900
6.21
6.27
6.34
6.41
6.48
6.55
6.62
6.69
6.76
6.83
See NOTE below regarding Table usage
NOTE: Tables such as Table VIII, IX, X, and XI may

be used as in the following example:
3. Multiply by 10:
970 psi = 6688 kPa.
Example: Convert 975 psi to kilopascals (kPa).
4. Go to PSI row 0, column 5; read 34.475

psi = 34.47 kPa. Add to step 3.
1. Select Table X.
2. Go to PSI row 90, column 7; read 668.8
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.
TABLE XII. 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.
A05001 12/99
A5-5
TABLE XIII
COMMON CONVERSION MULTIPLIERS

ENGLISH To METRIC

METRIC To ENGLISH
TO
Multiply
By
inch in.
millimeter (mm)
25.40
millimeter (mm)
inch in.
0.0394
inch in.
centimeter (cm)
2.54
centimeter (cm)
inch in.
0.3937
foot ft.
meter (m)
0.3048
meter (m)
foot ft.
3.2808
yard yd.
meter (m)
0.914
meter (m)
yard yd.
1.0936
1.61
kilometer (km)
mile mi.
0.6210
To Convert From
mile mi.
kilometer (km)
2
To Convert From
sq. in. in.
sq. centimeters
(cm2)
6.45
sq. centimeters (cm
sq. ft. ft.2
sq. centimeters (cm2)
929
cu. in. in.3
cu. centimeters (cm3)
cu. in. in.3
Multiply
By
TO
in.2
0.1550
sq. centimeters (cm2)
sq. ft. ft.2
0.001
16.39
cu. centimeters (cm3)
cu. in. in.3
0.061
liters (l)
0.016
liters (l)
cu. in. in.3
61.02
cu. ft. ft.3
cu. meters (m3)
0.028
cu. meters (m3)
cu. ft. ft.3
35.314
cu. ft. ft.3
liters (l)
28.3
liters (l)
cu. ft. ft.3
0.0353
ounce oz.
kilogram (kg)
0.028
grams (g)
ounce oz.
0.0353
fluid ounce fl. oz.
milliliter (ml)
29.573
milliliter (ml)
fluid ounce fl. oz.
0.0338
pound (mass)
kilogram (kg)
0.454
kilogram (kg)
pound (mass)
2.2046
pound (force) lbs.
0.2248
pound (force) lbs.
2)
Newton (N)
4.448
Newton (N)
Newton.meters (N.m)
0.113
Newton.meters (N.m)
ft. lbs. (force)
Newton.meters (N.m)
1.356
ft. lbs. (force)
kilogram.meters (kg.m)
0.138
Newton.meters (N.m)
9.807
in. lbs. (force)
kilogram.meters
(kg.m)
0.102
Newton.meters (N.m)
ft. lbs. (force)
0.7376
ft. lbs. (force)
7.2329
Newton.meters (N.m)
9.807
psi (pressure)
0.1450
Kilopascals (kPa)
psi (pressure)
kilopascals (kPa)
6.895
psi (pressure)
megapascals (MPa)
0.007
psi (pressure)
kilograms/cm2 (kg/cm2)
0.0704
ton (short)
kilogram (kg)
907.2
ton (short)
metric ton
0.0907
quart qt.
liters (l)
0.946
gallon gal.
liters (l)
3.785
HP (horsepower)
Watts
745.7
HP (horsepower)
kilowatts (kw)
0.745
A5-6
sq. in.
megapascals (MPa)
psi (pressure)
145.038
psi (pressure)
14.2231
kilograms/cm (kg/cm )
kilopascals (kPa)
98.068
kilogram (kg)
ton (short)
0.0011
metric ton
ton (short)
1.1023
liters (l)
quart qt.
1.0567
kilograms/cm (kg/cm )
liters (l)
gallon gal.
0.2642
Watts
HP (horsepower)
0.00134
kilowatts (kw)
HP (horsepower)
1.3410
12/99 A05001
SECTION A7
STORAGE AND IDLE MACHINE PREPARATION
INDEX
STORAGE AND IDLE MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3

Short Term Idle Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
PREPARATION FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-4
REMOVAL FROM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-5
RECONDITIONING AN IDLE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-7
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10
After The Engine Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-11
ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Preparing Engine For Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Temporary Storage (30 Days Or Less) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Extended Storage (more Than 30 Days) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
RESTORING AN ENGINE AFTER EXTENDED STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
ELECTRIC DRIVE TRUCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Storage Instructions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Placing Equipment Into Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Storing A Truck That Is Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Storing A Truck That Is Not Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Storing A Major Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
Placing Equipment Into Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
When A Truck Is Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
When A Truck Is Not Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
For The First Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18
A07003
Storage Procedures
A7-1
NOTES
A7-2
Storage Procedure
A07003
STORAGE AND IDLE MACHINE PREPARATION

There may be periods when it is necessary for a
machine to be idle for an extended period of time.
Properly prepared, a stored machine may promptly
and safely be put back into operational service.
Improper preparation, or complete lack of preparation, can make the job of getting the vehicle back to
operating status difficult.
The following information outlines the essential
proper steps for preparing a unit for extended storage, and the necessary steps to bring it back to operational status - these are the ideals. Additional
information is given to help restore those machines
which were not put into storage, merely shut down
and left idle for a long period of time.
2. On a weekly schedule, perform a visual check

of the vehicle, start and run the engine until it is
up to operating temperature. Move the vehicle
around the yard for a few minutes to insure that
all internal gears and bearings are freshly lubricated.
3. Operate all hydraulic functions through complete range to insure that cylinder rams and all
seals are fully lubricated.
4. Check and operate all systems.
5. After shutdown, drain air tank (if so equipped) to
expel any accumulated moisture.
Much of this material is of a general nature since the

environment, where the machine has been standing
idle, will play a big part in its overall condition. Hot,
humid climate will affect vehicle components much
differently than the dry desert atmosphere or a cold
arctic environment. These climatic aspects must be
considered, and appropriate actions taken when
restoring a long term idle vehicle.
These instructions are not intended to be all inclusive, but are furnished to provide the minimum guide
lines. The final aim should always be to provide the
operator with a safe, fully productive vehicle, that he
can rely on.
6. Once a month, perform the 10 hour service

items shown in the Operation and Maintenance
Manuals. Keep batteries properly serviced.
Short Term Idle Periods

There will be periods when a vehicle may be idle
from 30-60 days, but must be ready for use at all
times.
The most effective handling of this type situation is to
follow the procedure given below to prevent any
deterioration from beginning.
1. Keep the vehicle fully serviced.
A07003
Storage Procedures
A7-3
PREPARATION FOR STORAGE

For long term idle periods, proper preparation will
pay large dividends in time and money when future
operation of the vehicle is scheduled.
1. Engine should be prepared for storage according to instructions found in the engine manufacturer's manual.
2. The vehicle should be in top operating condition
with all discrepancies corrected. Paint should
be in good condition, no rust or corrosion, all
exposed, machined or unpainted surfaces
should be coated with a good rust preventative
grease.
7. New hydraulic filters should be installed and the

hydraulic tank fully serviced with Type C-4 oil as
specified in Section P, Lubrication and Service.
Any operating fluid, such as hydraulic oil, escaping under pressure can have sufficient force to
enter a person's body by pentrating the skin.
Serious injury and possible death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
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 rams clean
and, coat (including seals on ends of barrel)
with good preservative grease.
4. If long term storage is anticipated, the vehicle
should be blocked up with the tires clear of the
ground or floor to remove vehicle weight from
the tires. Lower air pressure in the tires to 15-25
psi (103-172 kPa). Completely cover the tires
with tarpolins to minimize rubber oxidation and
deterioration.
8. Disconnect batteries, If possible, batteries
should be removed and stored in a battery shop
or a cool dry location on wooden blocks. Do not
store batteries on a concrete floor. Clean battery compartment, remove all corrosion and
paint compartment with acid proof paint.
9. Wheel axle housings should be fully serviced
with prescribed lubricants. Seal all vents.
5. Clean the radiator; refer to Engine Service Manual and the Vehicle Service Manual for the
proper cleaning instructions.
10. Exhaust openings and air cleaners should be

covered tightly with moisture barrier paper and
sealing tape.
6. The cooling system should be completely

drained, chemically flushed, and refilled with a
conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
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.
11. All lubrication points (grease fittings) should be

serviced with the prescribed lubricants.
12. Relieve tension from all drive belts. The engine
manufacturer recommends insertion of heavy
kraft paper between belts and pulleys to prevent
sticking.
13. All vandalism covers and locks should be in
place and secured.
NOTE: NEVER store a vehicle with a dry cooling

system.
A7-4
Storage Procedure
A07003
14. If so equipped, cab windows should be closed,

locked and sealed and the cab door locked to
prevent vandalism and weather effects.
15. The vehicle fuel tank should be completely
drained of fuel, fogged with preservative lubricant, ("NOX-RUST" MOTOR STOR., SAE10)
and closed tightly. All fuel filters should be
replaced.
16. If at all possible, to aid those who will eventually
place the unit back in operation, all available
service publications (vehicle and engine) and a
current parts catalog should be packaged in a
moisture proof package and placed in the vehicle cab.
5. Thoroughly inspect all drive belts and hydraulic

oil lines for evidence of damage, wear or deterioration. Replace any suspected lines. Don't
take chances on ruptures or blow-outs.
6. New hydraulic filters should be installed and the
hydraulic tank (reservoir) checked and serviced
with Type C-4 oil as specified in Section P,
Lubrication and Service.
7. Drain on fuel tank should be opened to remove
any build up of moisture or sediment that may
have accumulated while in storage. Close drain
then fill the fuel tank with approved diesel fuel.
17. Be certain water drain holes in truck body are

open.
REMOVAL FROM STORAGE

If the STORAGE preparations were conscientiously
followed in placing the vehicle into storage, getting it
back to operational status is a matter of reversing
those steps.
NOTE: Before starting the job or restoring a vehicle
to operation, obtain copies of the Operation and
Maintenance Manual, Service Manual, Engine
Manuals and/or the Parts Book and follow all special
instructions regarding servicing the vehicle and its
components.
Never blend gasoline, gasohol and/or alcohol

with diesel fuel. This practice creates an extreme
FIRE HAZARD and under certain conditions may
cause an EXPLOSION.
8. Make certain that all hydraulic controls, steering
linkage and throttle linkage points are lubricated
and operate freely before engine start up.
9. All electrical connections must be clean and
tight. Check security of all ground straps and
cables.
In addition to removing the storage materials, the following actions should be taken.
1. Inspect the entire vehicle carefully for rust and
corrosion, correct as necessary.
2. Service the engine according to the engine
manufacturer's Operation and Maintenance
Manual.
3. Clean the radiator; refer to the engine manufacturer's Operation and Maintenance Manual.
4. The cooling system should be completely
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.
A07003
10. Install fully charged batteries in unit. Clean connectors and connect battery cables. Compartment must be free of corrosion. Secure
batteries with hold downs.
11. Check all electrical cables for weathering,
cracks and/or damage. Replace any defective
cables.
Storage Procedures
A7-5
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 serviceability and
inflate to 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 specified tension.
16. Make certain that all hydraulic controls, steering
linkage and throttle linkage points are free
before engine start up.
17. Use the Operation and Maintenance Manual for

guidance on engine start and vehicle checkout.
Make a thorough check of all hose and line connections for leakage when the engine is running.
18. Before moving the vehicle, cycle all hydraulic
controls and steering to verify proper operation.
Verify proper operation of service brakes, emergency braking system and parking brake.
Check all system instruments to insure that all
systems are operational.
19. When all systems are operational and all discrepancies are corrected, road test the vehicle
in a smooth, level, unobstructed area (with qualified, experienced operator only) to check steering response, service brake efficiency, and
hydraulic functions. Only when it is assured that
the vehicle is in safe operational condition
should it be turned over to an operator for production.
20. Fire protection equipment on a machine which
has been in storage should be recharged before
the machine is returned to service.
A7-6
Storage Procedure
A07003
RECONDITIONING AN IDLE VEHICLE

3. Inspect tires thoroughly for tread and side wall
condition, weathering, cuts and cracks.
Never attempt operation of a vehicle which has

been standing idle for a long period until all systems which affect steering, brakes, engine, transmission and running gear have been completely
reconditioned. An unsafe vehicle can cause serious injuries and/or major property damage Dont take chances!
At times a vehicle is subjected to long idle periods
without being properly serviced for storage - merely
shut down and left to the elements for an extended
period. Reconditioning of this vehicle can and does
present a major expenditure of time and money when
it is to be put into operating condition.
1. Remove all trash and thoroughly clean the
vehicle before starting any inspection or maintenance.
a. Any tire suspected of being unserviceable

should be dismounted and thoroughly
inspected inside and out before being
inflated.
Do not mix rim parts of different rim manufacturers. Rim parts may resemble those of a different
manufacturer, but the required tolerances may be
wrong. Use of mismatched rim parts is hazardous.
b. If tires are dismounted, all wheel components must be cleaned, inspected, all rust
and corrosion removed and parts repainted
as applicable before remounting the tires.
Follow the safety rules when mounting and
inflating tires.
c. Mount and inflate tires as shown in Operation and Maintenance Manual or service
manual.
4. Inspect vehicle service brakes carefully.
Before disabling the brake circuit, block all

wheels to prevent possible movement of the
vehicle.
a. All brake lines, connections must be clean,
serviced and free of rust and corrosion.
2. Remove vehicle batteries and move to battery
shop for service and charging or replacement
as necessary.
b. When system reconditioning, the service

brake hydraulic circuits should be checked
out according to instructions in Section J,
Brake Circuit Check-Out Procedure.
Do not disassemble an inflated tire. Remove

valve core slowly, and allow pressure to bleed
off, before attempting to remove lockring. Also,
eye protection should be worn during tire deflation to protect against any foreign object being
projected into the eyes.
A07003
Storage Procedures
A7-7
5. The vehicle engine should be inspected and

serviced according to the engine manufacturer's Operation And Maintenance Manuals.
6. If fuel was left in the tanks, it must be removed.

Do not attempt to use old diesel fuel.
a. With tanks empty, remove inspection plates
and thoroughly check interior of tanks; clean
to remove sediment and contamination. If
fuel was contaminated, lines should be disconnected and blown clear.
a. Insure that exhaust is clear and clean, no foreign materials. If water entry is suspected,
disconnect air tubes at the turbochargers to
check for water damage before attempting
startup.
b. Check all fuel lines for deterioration or damage. Replace lines as necessary.
b. Replace fuel filters, fill filter cans with fresh

fuel for engine priming.
c. Replace inspection covers;install new gaskets.

d. Service tanks with specified diesel fuel.
e. Replace fuel filters.
Have a new safety filter (secondary) filter element

on hand before removing old one. Do not keep
intake system open to atmosphere any longer
than absolutely necessary.
c. Remove and replace both the primary and
safety filter (secondary) elements in the air
cleaners. Check all intake lines between air
cleaners and engine. All clamps must be
tight. Indicating plunger in filter condition
indicators must be free.
d. The tubes in precleaner section of air
cleaner assembly should be inspected, all
tubes should be clear and clean. Use a light
to inspect the tubes. The light should be visible. If clogging is evident, precleaner must
be cleaned. Clean precleaner according to
instructions in Section C, Air Cleaners.
e. Drain and flush engine cooling system. Fill
with coolant and inhibitors after checking all
lines, hoses and connections. Refer to Section P, Lubrication and Service, for antifreeze recommendations. Radiator cores
must be clear of dirt and trash.
Any operating fluid, such as hydraulic oil or

brake fluid escaping under pressure, can have
sufficient force to enter a person's body by penetrating the skin. Serious injury and possible
death may result if proper medical treatment by a
physican familiar with this injury is not received
immediately.
7. The hydraulic tank should be drained. If oil is
not contaminated and is stored in clean containers, it may be reused if filtered through 3-micron
filter elements when being pumped back into
the tank. Do not attempt to use contaminated
hydraulic oil, especially if water entry into the
system is suspected.
NOTE: If filling is required, use clean hydraulic oil
only. Refer to the Lubrication chart in Section P,
Lubrication and Service, for proper oil specifications.
To prevent injuries, always release spring tension before replacing the fan belt.
f. Check and tighten engine fan drive belts,
install new belt set if necessary.
g. Check and tighten engine mounts.
A7-8
Storage Procedure
a. Replace hydraulic filter elements and clean

suction strainer elements. While suction
strainers are removed, inspect and clean
interior of tank thoroughly to remove all sediment and foreign material.
b. Inspect all hydraulic lines for deterioration or
damage. Replace suspected lines - don't risk
hose ruptures or blow outs.
c. Check hydraulic components (pumps, valves
and cylinders) for damage and corrosion.
Secure all mountings and connections. Control valves must be free moving with no binding.
A07003
d. Check exposed portions of all hydraulic cylinder rams for rust, pitting and corrosion. If
plating is deteriorated, the cylinder should be
removed and overhauled or replaced; pitted
or scored plating will cause leakage at the
cylinder seals.
8. Check front wheel hub, final drive and wheel
axle lubricant. If contamination is suspected, oil
should be drained completely and the component serviced with clean prescribed lubricant. If
major contamination is present, disassembly
and overhaul will be in order.
9. Check parking brake. Since it is spring applied,
the brake pads may be stuck tightly to the disc;
it may be necessary to remove and overhaul
the parking brake assembly.
10. Lubricate all grease fittings with prescribed
lubricants which are not part of the automatic
lubrication system. Pay particular attention to
the steering linkage connections. All pivot
points must be free of any binding.
12. Check security of steering cylinder ball joints

link and hydraulic connections.
13. Examine Hydrair suspensions for signs of damage.
a. Discharge nitrogen from suspensions as outlined in the service manual. Check conditon
of suspension oil and cylinder wipers. If wipers are cracked or hardened, the suspension
must be rebuilt. Recharge suspension with
new oil if old oil is deteriorated.
b. Check exposed chrome portions of cylinder
for rust, pitting and corrosion. If plating is
deteriorated the suspension should be
removed and overhauled or replaced; pitted
or scored plating will rapidly cause leakage
at the seals.
c. Recharge suspensions as outlined in the
service manual.
If not previously done, install fully-charged batteries
and insure that hook-up is correct.
11. Check battery charging alternator for corrosion

or deterioration. Alternator rotor must be free,
with no binding or roughness. Inspect, install
and properly tension the alternator drive belts.
A07003
Storage Procedures
A7-9
ENGINE OPERATION
1. Insure all personnel are clear of equipment
before starting engine. Always sound the horn
as a warning before actuating any operational
controls.
Insure that all tools and loose equipment have
been removed prior to engine start-up. Sound
horn prior to engine start. Make sure emergency
shut down is reset. Cables must be free moving
in their housings.
When all reconditioning operations have been completed, a static check of engine operation along with
operation of systems as well as verification of braking
and steering must be done before the vehicle is
moved.
Before starting engine, clear the immediate area

of personnel and obstructions.
Never start the engine in a building unless the
doors and windows are open and ventilation is
adequate.
2. Turn key switch ON. Warning lights for low
brake and steering pressure should illuminate
and the horn should sound. If it does not, check
all components in the circuit and correct the discrepancy before continuing.
3. Turn key switch to start position to crank
engine, release switch when engine fires.
Watch engine oil pressure gauge; if pressure
does not show in 10 - 15 seconds, shut down
and locate problem.
4. While engine is warming up, make a careful
inspection of engine coolant, oil and fuel lines
for leaks. Check hydraulic pump for leakage as
well as all hydraulic lines.
5. When engine is up to operating temperature,
check operation of throttle circuit; acceleration
should be smooth. Keep a close watch on the
gauges for any abnormal activity. Proper temperatures and pressures are shown in the Operation and Maintenance Manual.
A7-10
Storage Procedure
A07003
After The Engine Has Started

5. When satisfied that all discrepancies have been
corrected, the vehicle is ready for a road test.
This test should be done only by a capable and
experienced operator and should be accomplished in a large open area where plenty of
maneuvering room is available. Some of the
road test items which should be covered will
include:
Any machine which is unsafe and/or not in top operating condition should not be assigned to an operator
for production use.
1. Become thoroughly familiar with steering and
emergency controls. Test the steering in
extreme right and left directions. If the steering
system is not operating properly, shut engine
down immediately. Determine the steering system problem and have repairs made before
resuming operation.
2. Operate each of the brake circuits at least twice

prior to operating and moving the machine.
These circuits include individual activation of
the service brake and parking brake from the
operator's cab.
6. When all tests and checks have been made and

the vehicle is ready for work, it should be visually rechecked and fully serviced according to
Section P, Lubrication and Service.
a. Activate each circuit individually with the

engine running and with hydraulic circuit fully
charged.
b. If any application or release of any brake circuit does not appear proper or if sluggishness is apparent on application or release,
shut the engine down and notify maintenance personnel. Do not operate machine
until brake circuit in question is fully operational.
3. Check gauges, warning lights and instruments
before moving the machine to insure proper
system operation and proper gauge functioning.
Give special attention to braking and steering
circuit warning lights. If warning lights come on,
shut down the engine immediately and determine the cause.
4. Cycle hoist controls and steering several times
to remove trapped air. Complete steering cycles
in both directions to verify steering response,
smoothness and reliability. Check seals and
lines for leaks.
A07003
Repeated test of braking efficiency at

progressively higher speeds. Start at slow
speeds. Don't take chances with higher speeds
until the machine is determined to be completely
safe.
A few of the conditions (others may be found) which

might be encountered after a machine has been
exposed to the elements for a long period would
include:
Increased corrosion and fungus growth on

electrical components in humid/tropical areas.
Accelerated rust formation in humid climates.
Increased sand and dust infiltration in windy, dry

dusty areas. (These conditions can approach
sand blasting effects.)
Deterioration of rubber products in extreme cold

areas. Cables, hoses, O- rings, seals and tires
may become weather checked and brittle.
Animal or bird's nests in unsealed openings.
Storage Procedures
A7-11
ENGINE STORAGE
6. Clean the entire exterior of the engine (except

the electrical system) with fuel oil and dry it with
compressed air.
Preparing Engine For Storage

When an engine is to be stored or removed from
operation for a period of time, special precautions
should be taken to protect the interior and exterior of
the engine and other parts from rust accumulation
and corrosion. The parts requiring attention and the
recommended preparations are given below.
It will be necessary to remove all rust or corrosion
completely from any exposed part before applying a
rust preventative compound.
To prevent possible personal injury, wear adequate eye protection and do not exceed 40 psi
(276 kPa) compressed air pressure.
Therefore, it is recommended that the engine be processed for storage as soon as possible after removal
from operation.
7. Seal all of the engine openings. The material

used for this purpose must be waterproof,
vaporproof and possess sufficient physical
strength to resist puncture and damage from
the expansion of entrapped air.
The engine should be stored in a building which is

dry and can be heated during the winter months.
Moisture absorbing chemicals are available commercially for use when excessive damage prevail in the
storage area.
An engine prepared in this manner can be returned

to service in a short period of time by removing the
seals at the engine openings, checking the engine
coolant, fuel oil, lubricating oil, transmission oil and
priming the raw water pump (if used).
Temporary Storage (30 Days Or Less)
Extended Storage (more Than 30 Days)
To protect an engine for a temporary period of time,

proceed as follows:
To prepare an engine for extended storage, (more

than 30 days), follow this procedure:
1. Drain the engine crankcase.

2. Fill the crankcase to proper level with the recommended viscosity and grade of oil.
3. Fill the fuel tank with the recommended grade
of fuel oil. Operate the engine for two minutes at
1,200 rpm and no load. Shut down engine, do
not drain the fuel system or the crankcase after
this run.
4. Check the air cleaner and service, if necessary.
5. If freezing weather is expected during the storage period, add an ethylene glycol base antifreeze solution in accordance with the
manufacturer's recommendations.
1. Drain the cooling system and flush with clean,

soft water. Refill with clean, soft water and add
a rust inhibitor to the cooling system.
2. Remove, check and recondition the injectors, if
necessary, to make sure they will be ready to
operate when the engine is restored to service.
3. Reinstall the injectors, time them and adjust the
exhaust valve clearance.
4. Circulate the coolant by operating the engine
until normal operating temperature is reached
160 - 185 F ( 71 - 85 C).
5. Stop the engine.
6. Drain the engine crankcase, then reinstall and
tighten the drain plug. Install new lubricating oil
filter elements and gaskets.
7. Fill the crankcase to the proper level with a 30weight preservative lubricating oil MIL-L21260C, Grade 2.
A7-12
Storage Procedure
A07003
8. Drain the fuel tank. Refill with enough clean No.

1 diesel fuel or pure kerosene to permit the
engine to operate for about ten (10) minutes. If
it isn't convenient to drain the fuel tank use a
separate portable supply of the recommended
fuel.
If engines in vehicle are stored where condensation of water in the fuel tank may be a problem,
add pure, waterless isopropyl alcohol (isopropanol) to the fuel at a ratio of one pint to 125 gallons(473 L) of fuel, or 0.010% by volume. Where
biological contamination of fuel may be a problem, add a biocide such as Biobor JF, or equivalent to the fuel. When using a biocide, follow the
manufacturer's
concentration
recommendations, and observe all cautions and warnings.
9. Drain and disassemble the fuel filter and
strainer. Discard the used elements and gaskets. Fill the cavity between the element and
shell with No. 1 diesel fuel or pure kerosene,
and reinstall on the engine. If spin-on fuel filters
and strainers are used, discard the used cartridges, fill the new ones with No. 1 diesel fuel
or pure kerosene, and reinstall on the engine.
10. Operate the engine for five (5) minutes to circulate 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 and turbine outlet connections should be sealed off
with moisture resistant tape.
13. Apply a rust preventive compound to all
exposed non-painted surfaces.
14. Drain the engine cooling system.
Drain the preservative oil from the engine crankcase.
Reinstall and tighten the drain plug.
A07003
15. Remove and clean the batteries and battery

cables with baking soda-water solution and
rinse them with fresh water. Do not allow the
soda solution to enter the battery. Add distilled
water to the electrolyte, if necessary, and fully
charge the battery. Store the battery in a cool
(never below 32 F or 0 C) dry place. Keep
the battery fully charged and check the level
and the specific gravity of the electrolyte regularly. Never set batteries on concrete floor.
Place on wooded blocks.
16. Insert heavy paper strips between the pulleys
and belts to prevent sticking.
17. Seal all engine openings, including the exhaust
outlet, with moisture resistant tape. Use cardboard, plywood or metal covers where practical.
18. Clean and dry the exterior painted surfaces of
the engine and spray with a suitable liquid automotive body wax, a synthetic resin varnish or a
rust preventive compound.
19. Protect the engine with a good weather-resistant tarpaulin and store it under cover, preferably in a dry building with temperatures above
freezing.
Outdoor storage of engines is not recommended.
However, in some cases outdoor storage may be
unavoidable. If units must be kept out-off-doors, follow the preparation and storage instructions already
given. Protect units with quality, weather-resistant
tarpaulins (or other suitable covers) arranged to provide air circulation.
Do not use plastic sheeting for outdoor storage.

Plastic may be used for indoor storage. However,
when used outdoors, moisture can condense on
the inside of the plastic and cause ferrous metal
surfaces to rust and/or pit aluminum surfaces. If
a unit is stored outside for any extended period
of time, severe corrosion damage can result.
The stored engine should be inspected periodically. If
there are any indication of rust or corrosion, corrective steps must be taken to prevent damage to the
engine parts. Perform a complete inspection at the
end of one year and apply additional treatment, as
required.
Storage Procedures
A7-13
RESTORING AN ENGINE AFTER

EXTENDED STORAGE
1. Remove the covers and tape from all of the
openings of the engine, fuel tank and electrical
equipment. Do not overlook the exhaust outlet
or the intake system.
2. Wash the exterior of the engine with fuel oil to
remove the rust preventive.
3. Remove the rust preventive from the flywheel.
4. Remove the paper strips from between the pulleys and the belts.
5. 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 to proper level,
using a pressure prelubricator, with the recommended grade of lubricating oil.
6. Fill the fuel tank with the engine manufacturer's
specified fuel.
A7-14
7. Close all of the drain cocks and fill the engine

cooling system with clean soft 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
coolant specifications in Lubrication and Service, Section P.
8. Install and connect the fully charged batteries.
9. 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.
Storage Procedure
A07003
ELECTRIC DRIVE TRUCKS
Placing Equipment Into Storage
Storage Instructions and Procedures

This instruction provides the recommended procedures for protecting equipment from damage during
both short-term and long-term storage periods and
for maintaining adequate protection while in storage.
Also included are instructions for placing this equipment into service after having been stored.
For the purposes of this instruction, a short-term storage period is considered to be less than three
months; a long-term storage period is considered to
be three months or longer.
General Electric recommends a maximum storage
period of three years, with these storage procedures
being repeated after each year. After a storage
period of three years or more, the motorized wheels
should be removed and sent to an overhaul facility
for teardown and inspection of seals and bearings.
These should be replaced if necessary.
Periodic (every three months) inspections should be
made to determine the lasting qualities of long-term
storage protection measures. Such inspections will
indicate the need for renewing protective measures
when necessary to prevent equipment deterioration.
Proper storage of this equipment is vital to equipment
life. Bearings, gears, and insulation may deteriorate
unless adequate protective measures are taken to
protect against the elements. For example, bearings
and gears in the motorized wheel gear case are susceptible to the formation of rust; insulation in rotating
electrical equipment can accumulate moisture; and
bearings may become pitted.
Never apply any spray, coating, or other protective materials to areas not specifically recommended.
It is also important to note that these instructions
cannot possibly anticipate every type of storage condition and, therefore, cannot prevent all equipment
deterioration problems caused by inadequate storage. However, these instructions should be considered as a minimum procedure to achieve the best
possible equipment life and the lowest operating cost
when the equipment is returned to service.
NOTE: Local conditions and/or experience may
require additional procedures and/or additional storage precautions.
A07003
Perform the following instructions when preparing

General Electric equipment for storage. There are
three main equipment categories to consider:
1. When storing a truck that is operational.
2. When storing a truck that is not operational.
3. When storing major components (Motorized
Wheel, alternator, etc.).
These three major categories are the basis for determining required protective measures.
NOTE: In addition to these instructions, refer to truck
storage instructions.
Storing A Truck That Is Operational

When a fully operational truck is being placed into
storage for less than three months, the best protective measure which can be taken is to drive the truck
once a week for at least 30 minutes. Prior to driving
the truck, the rotating equipment should be Meggered and:
1. If greater than 2 megohms, run normally.
2. If less than 2 megohms, isolate condition and
correct before running.
Driving the truck circulates oil in the gear case to
keep gears and bearings lubricated and free from
rust. It also prevents deterioration of the brushes,
commutators and slip rings.
When a fully operational truck is being placed into
storage for three months or longer, and the truck
cannot be operated weekly throughout the storage
period as indicated above, perform the following:
1. Drain the oil from the gear case and install rust
preventive 4161 (product of Van Straaten
Chemical Co.) or equivalent. Fill per General
Electric Motorized Wheel Service Manual.
2. Megger the wheels as indicated in the instructions above. Operate the truck for at least 30
minutes to insure that the rust preventive compound has been thoroughly circulated throughout the gear case. Stop the truck and drain the
rust preventive compound.
NOTE: Do not run a loaded truck with rust preventive
compound in the wheel motor gear cases.
Storage Procedures
A7-15
Storing A Truck That Is Not Operational
Do not operate trucks without oil in the wheel

motor gear cases.
3. Perform a megohmmeter test. Refer to the
truck's Vehicle Test instructions for the correct
procedure. Record the Megger readings for
future reference. They will be helpful in determining if deterioration is being experienced
when additional Megger tests are made as part
of the periodic inspection.
4. Lift all brushes in the motorized wheels, blowers
and the alternator. They must be removed from
the brushholder. Disconnecting brush pigtails is
not required.
5. Cover any open ductwork with screening material to prevent rodents from entering. Then tape
over the screen to prevent the entry of water
and dirt (allow breathing).
6. Examine all exposed machined surfaces for
rust or other dirt accumulation. Remove all dirt
as necessary. Remove rust by using a fine
abrasive paper. Old flushing compound can be
removed with mineral spirits (GE-D5B8). Methanol should be used to remove all residue.
When clean, coat with Tarp B rust preventive.
Refer to General Electric Motorized Wheel Service Manual for specifications.
7. Loosen exciter drive belts (where applicable).
When a truck which is not fully operational is being

stored for a period of any length, perform the following:
1. Drain the oil from the gear case and install rust
preventive compound 4161 (or equivalent). Fill
per General Electric Motorized Wheel Service
Manual.
2. Jack each side of the truck (one side at a time)
enough to rotate the tires.
3. Connect a D-C welder as described in the Vehicle Test Instructions (Wheel Motor inst. 400A,
arm & field in stress 900- 1000 rpm arm).
4. Rotate each Motorized Wheel (one at a time)
for at least 30 minutes to insure that the rust
preventive compound has been thoroughly circulated throughout the gear case. Disconnect
the welder. Remove the jacks. Drain the gear
case.
5. If the truck is partially dismantled, pay careful
attention to ductwork, blower shrouds, etc.,
which may be exposed to weather conditions as
a consequence. These areas will require the
same sealing measures as in Step 5 above
which deals with protecting ductwork. Cover
exposed blower housings to prevent entry of
water and dirt.
6. Perform Steps 3 through 11 in Storing a Truck
that is Operational, in this section.
8. Open all switches in the control compartment.

9. Install a 500 watt heat source inside all control
groups which house electronic control equipment. These heat sources are to be energized
below 32 F (0 C) and de-energized above 41
F (5 C).
10. Install a 500 watt heat source inside the commutator chamber of both motorized wheels 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.
Storing A Major Component

When storing a motorized wheel, alternator, blower
or control group for a period of any length, always
store it inside a warm, climate-controlled environment. Do not attempt to store individual components
where they would be exposed to inclement weather,
climatic changes, high humidity and/or temperature
extremes.
11. Seal compartment doors with a weatherproof

tape to prevent entry of rain, snow and dirt
(allow breathing).
A7-16
Storage Procedure
A07003
Periodic Inspections
It is important that periodic inspections (every three
months) of stored equipment be performed to insure
the continued serviceability of all protective measures initially taken when the storage period began.
Items which should be checked at each inspection
interval are listed as follows:
1. Remove the weatherproof tape from the compartment doors and preform a Megger test as
described in the Vehicle Test Instructions.
Record the test results and compare them with
the recorded megger readings taken when storage first began, and those taken throughout the
storage period. Remove all test equipment and
close up the compartment. Reseal the compartment doors with new weatherproof tape. If
megger readings indicate a deterioration of
insulation quality, to below 2.0 megohms then
consideration should be given to providing
more protection.
2. Check all other weatherproofing tape. Replace
any that has become loose or is missing completely.
3. Check all heat sources. Replace or repair any
units which have become inoperative.
4. Check all machine surfaces which were coated
with flushing compound when storage began. If
compound appears to be deteriorating, it must
be cleaned off and renewed.
Placing Equipment Into Service After Storage
When taking equipment out of storage, perform the
following procedures:
5. Clean all motorized wheel grease fittings in the

axle box. Insure that all grease lines are completely full of grease. Then add the recommended amount of grease to all fittings.
6. Install brushes in motorized wheels, blowers
and alternator. Make sure that brushes move
freely in their carbonways and that they have
enough length to serve until the truck's next
inspection period. Install new brushes if necessary. Insure that all brush pigtail screws are
tight.
7. Perform a megohmmeter test. Refer to the
truck's Vehicle Test Instructions for the correct
procedure. If megger readings are less than 2.0
megohms, the problem could be an accumulation of moisture in motor or alternator. If this is
the case, the faulty component will have to be
isolated and dried out using procedures recommended in the G.E.Service Manual.
8. Perform a thorough inspection of the motorized
wheels, alternator, blowers and control compartments. Look for:
a. Rust or dirt accumulation on machine surfaces
b. Damaged insulation
c. An accumulation of moisture or debris
d. Loose wiring and cables
e. Any rust on electrical connectors in the control compartment
When A Truck Is Operational

If a truck has been operated weekly throughout the
storage period, perform a complete visual inspection
of the motorized wheels, blowers, alternator and control compartments. Repair any defects found, then
place the truck directly into service.
f. Any loose cards in the card panels

g. Any accumulation of moisture or debris in
ductwork.
9. Clean and make repairs as necessary.
10. Check retarding grids and insulators for loose
connections and dirt accumulation. Clean and
When A Truck Is Not Operational

If the truck was not operated weekly throughout the
storage period, perform the following procedures:
1. Remove all weatherproofing tape from control
compartment doors and ductworks.
2. Remove all screening material from ductwork.
3. Remove all heat sources from Motorized
Wheels, control compartments and the alternator.
A07003
4. Fill with recommended oil. Refer to the Motorized Wheel Service Manual for the type and
amount oil to be used. This oil should be
drained and new oil should be added after 500
hours of operation.
11. Where applicable, check exciter drive belts for

cracks, and deterioration. If acceptable, set belt
tension to specification.
12. Before starting engine, turn on control power.
Check that contactors and relays pick up and
drop out normally.
13. Perform a start-up procedure on the complete
system to insure maximum performance during
Storage Procedures
A7-17
service. Refer to the truck's Vehicle Test

Instructions for the complete test procedure.
For The First Hour
After all storage protection has been removed, the
truck has been cleaned and inspected and repairs
made as necessary, the motorized wheel gear case
has been filled with new oil, the dirt seals have been
completely purged with new grease and the system
completely checked, the truck can be placed into service. It is recommended, however, that the truck be
driven unloaded at a low speed (10 mph) for the first
hour of operation.
A7-18
Storage Procedure
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
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
GRILLE, HOOD AND LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
RIGHT DECK AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
LEFT DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
CENTER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
B02015
Structural Components
B2-1
NOTES
B2-2
B02015
STRUCTURAL COMPONENTS
The 930E deck components are removable in sections as shown in Figure 2-1. The following removal
and installation instructions detail the steps to be
taken before the decks and hood can be removed.
Additional steps may be required before the deck or
other major structure is removed, depending on
optional equipment installed on the truck at the factory or after delivery.
Prior to removal or repair procedures, it may be necessary to remove the body to provide clearance for
lifting equipment to be used. If body removal is not
required, the body should be raised and the safety
cables installed at the rear of the truck.
Read and observe the following instructions
before attempting any repairs!
Do not attempt to work in deck area until body

safety cables have been installed.
Do not step on or use any power cable as a

handhold when the engine is running.
Do not open any electrical cabinet covers or

touch the retarding grid elements until all
shutdown procedures have been followed.
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.
After the truck is parked in position for the repairs,

the truck must be shut down properly to ensure the
safety of those working in the areas of the deck, electrical cabinet and retarding grids. The following procedures will ensure the electrical system is properly
discharged before repairs are started.
FIGURE 2-1. DECK COMPONENTS

1. LH Deck Structure
2. Electrical Cabinet
3. Cab
4. Diagonal Ladder
5. Center Deck Str.

6. RH Deck Structure
7. Retarding Grids
8. Blower Intake
Preparation
1. Reduce the engine speed to idle. Place the
selector switch in NEUTRAL and apply the
parking brake. Be certain the parking brake
applied indicator lamp in the overhead panel is
illuminated.
2. Place the drive system in the rest mode by turning the rest switch on the instrument panel ON.
Be certain the rest warning lamp is illuminated.
3. Shut down the engine using the keyswitch. If,
for some reason the engine does not shut
down, use the shutdown switch on the center
console.
4. Verify the link voltage lights are off. If they
remain on longer than 5 minutes after shutdown, notify the electrical department.
5. Verify the steering accumulators have bled
down by attempting to steer.
6. Bleed down the brake accumulators using the
manual bleed valves on the brake manifold.
7. Open the battery disconnect switches.
B02015
B2-3
The anti-slip material on the decks should be

inspected and maintained for the safety of all personnel.
If weld repairs are necessary, disconnect all

electrical harnesses and remove the ground
strap from the engine control system (governor)
located in the auxillary control cabinet behind the
cab.
All hoses and mating fittings should be capped as

they are removed to prevent possible system
contamination.
It is important to tag and visually verify all cables,

harnesses, hoses etc. have been removed
before the structure is lifted off the truck.
For cab removal instructions, refer to Section N,

Truck Cab, in this manual.
FIGURE 2-2. HOOD AND GRILLE REMOVAL

1. Hood & Grille
Assembly
2. Capscrews and
Lockwashers
GRILLE, HOOD AND LADDER

Installation
Removal
1. Remove hardware attaching diagonal ladder (4,
Figure 2-1) to front bumper.
1. Move hood and grille assembly (1, Figure 2-2)

from work area to truck and lift into place.
2. Attach lifting device to the ladder and lift structure off truck.
2. Align mounting holes with brackets attached to

radiator assembly. Install side mounting capscrews (2).
3. Disconnect wiring harnesses and remove cable

clamps as necessary to allow hood removal.
4. Attach lifting device to the hood and grille
assembly (1, Figure 2-2).
5. Remove all side mounting capscrews and lockwashers (2).
6. Verify all harnesses, cables, hoses etc. are
removed.
3. Lift diagonal ladder into position over mounting

pads on front bumper. Align mounting holes and
install hardware. Tighten capscrews to standard
torque.
4. Connect harnesses, hoses etc. that were
removed previously. Install all clamps removed.
7. Lift hood and grille assembly from truck and

move to work area.
B2-4
B02015
FIGURE 2-3. TYPICAL DECK STRUCTURE MOUNTING

(NOTE: Bottom, RH deck shown. LH deck mounting is similar to RH deck.)
1. Deck Structure
2. Deck Mounting Location
3. Payload Indicator Lights
4. Clearance Light
DECKS
The right and left deck mounting pad locations are
nearly identical. The decks are mounted directly to the
frame support structures using hardened flatwashers.
Be certain to use hardened flatwashers during reassembly.
RIGHT DECK AND COMPONENTS

Removal
1. Shut down engine following all the procedures
listed on page 2-1 in this section of the manual.
2. Remove access covers from retarding grid
assembly. Tag and disconnect all electrical leads
in preparation for removal. Attach lifting device to
grid lifting eyes.
3. Remove grid assembly mounting hardware at
four locations (6) shown in Figure 2-3.
B02015
5. Headlights
6. Retard Grid Mounting Location
7. Electrical Connector
4. Lift grid assembly clear of deck structure and

move to a work area.
NOTE: If grid assembly or cooling blower repairs are
required refer to applicable G.E. publication for
service and maintenance procedures.
5. Disconnect electrical harness at connector (7,
Figure 2-3). Inspect underside of deck and if
necessary, remove any hoses or cables that
remain. (Light harness and clamps do not
require removal.)
6. Install lifting device at eyes at each corner of the
deck and take up slack. Do not attach lifting
device to the hand rail structure.
7. Remove deck mounting hardware at deck support and front upright (2).
8. Verify all wiring harnesses, cables or hoses have
been removed. Carefully raise deck and remove
from deck supports.
B2-5
Installation
Repeat above procedures in reverse order for installation of the deck and components. Tighten all
attaching hardware to standard torque specifications
as listed in Section A, Standard Torque Chart and
Tables.
4. Install lifting device to lift eyes at each corner of

the deck and take up slack. Do not attach lifting device to the hand rail structure.
Clean all mount

installation.
before
5. Remove deck mounting hardware at frame support and front upright.
Clean mounting area before installing ground

cables.
Be certain all electrical connections and harness

clamps are reinstalled and secure.
6. Verify all wiring harnesses, cables or hoses

have been removed. Carefully raise deck and
remove from deck supports.
mating
surfaces
All propulsion system power cables must be

properly secured in their wood or other non-ferrous cable cleats. If clamps are cracked and broken, oil soaked or otherwise damaged, replace
them with new parts. Inspect cable insulation and
replace cable if insulation is damaged.
Installation
Repeat above procedures in reverse order for installation of the deck and components. Tighten all
attaching hardware to standard torque specifications
as listed in Section A, Standard Torque Chart and
Tables.
Clean all mount

installation.
Clean mounting area before installing ground

cables.
Be certain all electrical connections and harness

clamps are reinstalled and secure.
If the air conditioning system has been

discharged, refer to Section N, Operator
Comfort, for the correct procedure for system
service.
LEFT DECK
Removal
NOTE: The left deck mounting arrangement is nearly
identical to the right deck. Refer to Section N, Truck
Cab, for cab removal and installation instructions.
1. Shut down engine following all the procedures
listed on page 2-1 of this Section of the manual.
2. Be certain the brake system accumulators have
been bled to release pressure.
3. Tag and disconnect all hydraulic lines and electrical cables which will interfere with deck
removal. Cap all lines to prevent entrance of
foreign material.
mating
surfaces
before
1. Start engine and allow systems to charge.

Observe for any air or oil leaks. Make sure all
shields, covers and clamps are in place.
2. Service the hydraulic reservoir if required.
Check for proper operation of the steering and
brake systems, including dynamic retarding.
CENTER DECK
Center deck removal only requires removal of any
attached hoses cables etc. before removing the
mounting hardware and lifting the deck structure off.
If equipped with air conditioning and air conditioning system components are to be removed,
refer to Section N, Operator Comfort, for special
instructions on discharging the air conditioning
system prior to disconnecting any air conditioning lines.
B2-6
Be certain to follow proper shutdown procedures

as described on page 2-1.
B02015
SECTION B3
DUMP BODY
INDEX
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
BODY UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
BODY-UP RETENTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Rock Ejectors (Type I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Rock Ejectors (Type II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
B03017 08/03
Dump Body
B3-1
NOTES
B3-2
Dump Body
08/03 B03017
DUMP BODY
2. Remove mud flaps and rock ejectors from both
sides of the body. Remove electrical cables,
lubrication hoses etc. attached to the body.
Removal
3. Attach chains around upper end of hoist cylinders to support them after the mounting pins
are removed.
Inspect all lifting devices. Slings, chains, and/or

cables used for lifting components must be
inspected daily for serviceable condition. Refer
to the manufacturer's manual for correct capacities and safety procedures when lifting components. Replace any questionable items.
Slings, chains, and/or cables used for lifting
components must be rated to supply a safety factor of approximately 2X the weight being lifted.
When in doubt as to the weight of components or
any assembly procedure, contact the Komatsu
area representative for further information.
Lifting eyes and hooks should be fabricated from
the proper materials and rated to lift the load
being placed on them.
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, be sure there is
adequate clearance between the body and overhead structures or electric power lines.
Be sure that the lifting device is rated for at least
a 45 ton capacity.
1. Park truck on a hard, level surface and block all
the wheels. Connect cables and lifting device to
the dump body and take up the slack as shown
in Figure 3-1.
4. Remove pin retainer capscrew (4, Figure 3-2)

from each of the upper hoist cylinder mounting
eyes. With adequate means of supporting the
hoist cylinders in place, remove each of the
mounting pins (2, Figure 3-2).
FIGURE 3-2. HOIST CYLINDER MOUNT (UPPER)

1. Dump Body
2. Hoist Cylinder Pin
3. Hoist Cylinder
4. Pin Retainer
5. Remove capscrews (1, Figure 3-3) and lock

nuts (2) from each pivot pin.
6. Attach a body pivot pin support fixture to
bracket on underside of dump body to aid in
supporting the pin as it is removed.
Remove body pivot pins (3) far enough to allow
shims (6) to drop out. Complete removal of pins
is not necessary unless new pins are to be
installed.
7. Lift dump body clear off the chassis and move
to storage or work area. Block the body to prevent damage to the body guide etc.
8. Inspect bushings (5, 8, & 9), body ear (4), and
frame pivot (7) for excessive wear or damage.
FIGURE 3-1. DUMP BODY REMOVAL

1. Lifting Cables
B03017 08/03
2. Guide Rope
Dump Body
B3-3
1. Park truck on a hard, level surface and block all

the wheels.
Installation
Inspect all lifting devices. Slings, chains, and/or

cables used for lifting components must be
inspected daily for serviceable condition. Refer
to the manufacturer's manual for correct capacities and safety procedures when lifting components. Replace any questionable items.
Attach cables and lifting device to the dump body

and take up the slack as shown in Figure 3-1. Lower
body over the truck frame and align body pivots to
frame pivot holes.
Slings, chains, and/or cables used for lifting

components must be rated to supply a safety factor of approximately 2X the weight being lifted.
When in doubt as to the weight of components or
any assembly procedure, contact the Komatsu
area representative for further information.
Lifting eyes and hooks should be fabricated from
the proper materials and rated to lift the load
being placed on them.
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, be sure there is
adequate clearance between the body and overhead structures or electric power lines.
Be sure that the lifting device is rated for at least
a 45 ton capacity.
2. Install shims (6, Figure 3-3) in both body pivots,

as required, to fill the outside gaps and center
the body on the frame pivot. Do not install
shims at the inside. A minimum of 1 shim is
required at the outside end of both frame pivots.
3. Align the hole in pivot pin (3) with capscrew
hole in pin retainer (part of body pivot ear, 4)
and push the pivot pin through the shims (6),
frame pivot (7), and into the pivot bushings (5,
9) in each side of the body pivot.
4. Install capscrew (1) through each pin and
tighten the nuts (2) to 300 ft.lbs. (407 N.m)
torque. Use washers, as necessary on the nut
side only, to ensure the capscrew does not run
out of threads when tightening.
5. Align hoist cylinder upper mounting eye bushings with the hole through the body, align retaining capscrew (4, Figure 3-2) hole and install the
pin.
6. Install the pin retaining capscrews and nuts and
tighten to 300 ft.lbs. (407 N.m).
7. Install mud flaps, rock ejectors, electrical cables
and lubrication hoses.
FIGURE 3-3. DUMP BODY PIVOT PIN

1. Capscrew - M36
2. Lock Nut - M36
3. Body Pivot Pin
4. Body Ear
5. Body Pivot Bushing
B3-4
6. Shim
7. Frame Pivot
8. Pivot Bushing
9. Body Pivot Bushing
Dump Body
08/03 B03017
BODY PADS
It is not necessary to remove the dump body to
replace body pads. Pads should be inspected
during scheduled maintenance inspections and
replaced if worn excessively.
1. Raise the unloaded dump body to a height sufficient to allow access to all pads.
5. Install the mounting hardware and torque to 65

ft.lbs. (88.1 N-m).
6. Remove blocks from frame and lower body
onto the frame.
Adjustment
1. Vehicle must be parked on a flat, level surface
for inspection.
2. All pads, except the rear pad on each side,
should contact the frame with approximately
equal compression of the rubber.
3. A gap of approximately 0.075 in. (1.9 mm) is
required at each rear pad. This can be accomplished by using one less shim at each rear
pad.
Place blocks between the body and frame.

Secure blocks in place.
2. Remove hardware attaching pads to the dump
body. Refer to Figure 3-4.
3. Remove body pad and shims. Note number of
shims installed at each pad location. (The rear
pad on each side should have one less shim
than the other pads.)
4. Install new pads with the same number of
shims as removed in step 3.
4. If pad contact appears to be unequal, repeat

the above procedure.
! IMPORTANT !
Proper body pad to frame contact is required to
assure maximum pad life.
FIGURE 3-4. BODY PAD INSTALLATION

1. Dump Body
2. Pad Mounting Hardware
B03017 08/03
3. Frame
4. Body Pad
Dump Body
5. Shim
6. Mounting Pad
B3-5
BODY GUIDE
BODY-UP RETENTION CABLE
1. Body guide wear points should be inspected

each time a body pad inspection is performed.
(Refer to Figure 3-5) The body guide should be
centered between the wear plates (3), with a
maximum gap of 0.19 in. (4.8 mm) at each side
when new.
2. If gap becomes excessive, replacement parts
should be installed. (Refer to the Parts Catalog).
Any time personnel are required to perform maintenance on the vehicle with the dump body in the
raised position, the body-up retention cable
MUST be installed.
1. To hold the dump body in the up position, raise
the body to it's maximum height. Refer to Figure
3-6.
FIGURE 3-5. BODY GUIDE

1. Dump Body
2. Body Guide
3. Body Guide Wear

Plates
FIGURE 3-6. BODY-UP CABLE INSTALLATION

1. Rear Body Ear
Structure
2. Cable Storage
HOIST LIMIT SWITCH

Refer to Section "D", Electrical System (24VDC) for
adjustment procedure of the hoist limit switch.
3. Cable Assembly
4. Axle Housing Ear
Structure
2. Remove the cable (3) from its stored position on

the body and install between the Rear Body Ear
(1) and the Axle Housing Ear (4).
3. Secure the cable clevis pins with cotter pins.
BODY UP SWITCH
Refer to Section "D", Electrical System (24VDC) for
adjustment procedure of the body up switch.
B3-6
Dump Body
4. After maintenance work is completed, reverse

the above procedure to remove cable assembly
and place it in the storage position.
08/03 B03017
ROCK EJECTORS
Rock Ejectors are placed between the rear dual
wheels to keep rocks or other material from lodging
between the tires. Failure to maintain the Rock Ejectors could allow debris to build up between the dual
wheels and cause damage to the tires.
Rock Ejectors (Type I)
2. With the truck parked on a level surface, the

arm structure should be approximately 4.33 in.
(110 mm) from the wheel spacer ring (3). Refer
to Figure 3-7.
NOTE: With Rock Ejector Arm (1, Figure 3-8)
hanging vertical as shown in Figure 3-7, there must
be NO GAP at Stop Block (3, Figure 3-8).
Inspection
1. The ejectors must be positioned on the center
line between the rear tires within 0.25 in. (6.0
mm).
FIGURE 3-7. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm
2. Wear Plate
B03017 08/03
3. Rear Wheel Spacer

Ring
Dump Body
3. If the arm (1) becomes bent, it must be

removed and straightened.
4. Inspect the mounting brackets (4, Figure 3-8),
pins (2) and stops (3) at each shift change for
wear and/or damage, and repair as necessary.
FIGURE 3-8. ROCK EJECTOR MOUNTING

BRACKET (Detail View)
1. Rock Ejector Arm
3. Stop Block
2. Pin
4. Mounting Bracket
B3-7
Rock Ejectors (Type II)

Inspection
1. The rock ejectors must be positioned on the
center line between the rear tires within 0.25 in.
(6.0 mm).
2. With the truck parked on a level surface, the
arm structure should be approximately 17.9 in.
(454.5 mm) from wheel housing (2). Refer to
Figure 3-10.
NOTE: With rock ejector arm (1, Figure 3-9) hanging
vertical as shown in Figure 3-10, there must be NO
GAP at stop block (3, Figure 3-9).
3. If arm (1) becomes bent, it must be removed
and straightened.
4. Inspect mounting brackets (4, Figure 3-9), pins
(2) and stops (3) at each shift change for wear
and/or damage, and repair as necessary.
FIGURE 3-10. ROCK EJECTOR INSTALLATION

1. Rock Ejector Arm
2. Wheel Housing
FIGURE 3-9. ROCK EJECTOR MOUNTING

BRACKET
1. Rock Ejector
2. Pin
B3-8
3. Stop Block
4. Mounting Bracket
Dump Body
08/03 B03017
SECTION B4
FUEL TANK
INDEX
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
FUEL GAUGE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
LOW FUEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
WIGGINS QUICK FILL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
FUEL RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
TANK BREATHER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
LEFT SIDE FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-7
B04015 07/03
Fuel Tank
B4-1
NOTES
B4-2
Fuel Tank
07/03 B04015
FUEL TANK
FIGURE 4-1. FUEL TANK INSTALLATION

1. Fuel Tank
2. Capscrews & Lockwashers
3. Mounting Cap
4. Lifting Brackets
5. Breather
6. Filler Cap
7. Fuel Return Hose
8. Fuel Supply Hose
B04015 07/03
9. Fuel Gauge Sender

10. Drain Cock
11. Fuel Supply Connector
13. Low Fuel Switch
14. Wire Harness
15. Tank Mount Bracket
16. Capscrew, Flatwasher, Lockwasher
Fuel Tank
17. Flatwasher
18. Rubber Dampener
19. Ground Wire
20. Wire Harness
23. Refueling Cap
24. Fuel Receiver
B4-3
Repair
Removal
1. Raise the truck body and install the body-up
cable.
If a tank has been damaged and requires structural

repair, perform such repairs before final cleaning.
2. Drain the fuel from the tank into clean containers.

3. Disconnect the fuel tank wire harness and
remove the clamps attached to the tank.
Remove ground wire (19, Figure 4-1).
4. If equipped, close the in-line shut-off valves.
Remove fuel supply hose (8) and return (hose
7). Cap the hoses and tank fittings to prevent
contamination.
5. Remove the hydraulic filter assembly on the
frame side of the tank. Support the filter assembly by placing a chain over the frame rail. (It is
not necessary to remove the hydraulic hoses.)
The weight of the empty fuel tank is approximately 3725 lbs (1690 kg). Be certain to use lifting
devices with adequate capacity.
6. Attach a lifting device to tank lift eyes (4).
7. Remove lower mount capscrews (16). Remove
upper mount capscrews (2) and mounting caps
(3).
8. Lift tank assembly from brackets and move to
work area.
9. Remove fuel gauge sending unit (9), breather
(5) on top of the tank, and other fittings as
required to perform interior cleaning.
Installation
1. Thoroughly clean the frame mounting brackets
and the mounting capscrew hole threads. Retap the threads if damaged.
The weight of the empty fuel tank is approximately 3725 lbs (1690 kg). Be certain to use lifting
devices with adequate capacity.
If a tank is to be weld repaired, special precautions are necessary to prevent fire or explosion.
Consult local authorities for safety regulations
before proceeding.
Cleaning
The fuel tank is provided with a drain and a cleaning
port in the side that allows steam or solvent to be utilized in cleaning tanks that have accumulated foreign
material.
It is not necessary to remove the tank from the truck
for cleaning of sediment, however rust and scale on
the walls and baffles may require complete tank
removal. This allows cleaning solutions to be in contact with all interior surfaces by rotating the tank in
various positions, etc.
Prior to a cleaning procedure of this type, all vents,
fuel gauge, and hose connections should be
removed and temporarily sealed. After all scale, rust,
and foreign material has been removed, the temporary plugs can be removed.
A small amount of light oil should be sprayed into the
tank to prevent rust if the tank is to remain out of service. All openings should be sealed for rust prevention.
2. Lift the fuel tank into position over the frame

trunnion mounts and lower into position. Install
mount caps (3, Figure 4-1), capscrews (2) and
lockwashers. Do not tighten at this time.
3. Install the four capscrews, lockwashers, and
flatwashers (16), flat washers (17), and rubber
dampeners (18) in the lower mounts and tighten
the lower mounting bolts to 310 31 ft. lbs.
(420 42 N.m) torque.
4. Tighten the trunnion mount capscrews (2) to
525 53 ft. lbs. (711 72 N.m) torque.
5. Connect the hoses removed during the removal
procedure. Install the wire harness and clamps.
Open the in-line shut-off valves, if equipped.
B4-4
Fuel Tank
07/03 B04015
FUEL GAUGE SENDER
LOW FUEL SWITCH
A fuel gauge sending unit (9, Figure 4-1) mounted on

the side of the tank provides an electrical signal to
operate the fuel gauge on the instrument panel.
Low fuel switch (13, Figure 4-1) controls the low fuel
level indicator on the overhead warning indicator light
panel in the operator cab. The switch is calibrated to
turn on the low fuel indicator when the usable fuel
remaining in the tank is approximately 25 gallons (95
liters).
Removal
1. Drain the fuel below the level of the gauge
sender.
2. Disconnect the wire from the terminal.
3. Loosen the small screws holding the fuel gauge
sender unit and carefully remove.
Installation
1. Clean mating surfaces, and install a new gasket.
2. Reinstall the sender unit in the tank. Use care
and ensure that the float is oriented properly
and works freely in the vertical plane during
installation.
3. Reinstall the four socket head capscrews and
tighten to standard torque. Reconnect the wire
to the terminal.
4. Refill the tank and check for leaks.
B04015 07/03
Fuel Tank
B4-5
WIGGINS QUICK FILL FUEL SYSTEM

FUEL RECEIVER
The fuel receiver (24, Figure 4-1) is mounted on the
fuel tank (1). Receiver assembly (6, Figure 4-3) is
mounted on the left hand frame rail.
properly on the stem. If not, adjust the cage,

accordingly.
Keep the cap on the receivers to prevent dirt build up

in valve area and nozzle grooves. If fuel spills from
tank breather valve, or if the tank does not completely fill, check the breather valve to see that the
float balls are in place and the outlet screen is clean.
If the valve is operating properly, the problem will
most likely be with the fuel supply system.
TANK BREATHER VALVE

NOTE: The relief pressure of the breather valve is
10.2 - 12.9 psi (70 - 89 kPa).
Removal
Unscrew breather valve (5, Figure 4-1) from fuel tank
(1).
Installation
Screw breather valve (5, Figure 4-1) into fuel tank
(1).
Disassembly
1. Remove clamp (3, Figure 4-2).
2. Remove cover (2) and screen (1).
3. Remove ball cage (10), solid ball (11), and float
balls (12).
FIGURE 4-2. BREATHER VALVE
4. Unscrew end fitting (7) from body (4).

5. Remove stem (8) and valve spring (5).
Assembly
1. Clean and inspect all parts. If damaged components are evident, replace the entire assembly.
2. Place valve spring (5) into position in body (4).
1. Screen
2. Cover
3. Clamp
4. Body
5. Valve Spring
6. O-Ring
7. End Fitting
8. Stem
9. O-Ring
10. Ball Cage
11. Solid Ball
12. Float Ball
3. Insert stem (8) into end fitting (7).

4. Screw end fitting (7) into body (4). Ensure the
components are properly aligned and seated.
5. Place screen (1) and cover (2) into position on
the breather. Install clamp (3).
6. Insert the balls into ball cage (10) with solid ball
(11) on top.
7. Insert the ball cage onto the stem. A minimum
of two cage coils must be seated in the groove
on the stem. Ensure the solid ball is able to seat
B4-6
Fuel Tank
07/03 B04015
LEFT SIDE FILL

This location permits fueling the truck from the left side.
FIGURE 4-3. LEFT SIDE FILL

1. Hydraulic Tank
2. Filler Hose
3. Frame Rails
4. Fuel Tank
5. Filler Cap
6. Receiver Assembly
7. Refueling Box
8. Capscrew
9. Tapped Bar
NOTE: This illustration represents a typical installation. Installation may vary depending on truck model.
B04015 07/03
Fuel Tank
B4-7
NOTES
B4-8
Fuel Tank
07/03 B04015
SECTION C
ENGINE
INDEX
POWER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3
Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-4
Removal - Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-7
Installation - Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-9
Hookup - Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-9
C02021
Power Module
C2-1
NOTES
C2-2
Power Module
C02021
POWER MODULE
The radiator, engine and alternator assemblies are
mounted on a roller equipped subframe which is contained within the truck's main frame and is referred to
as a power module. This arrangement permits
removal and installation of these components with a
minimum amount of disconnect and by utilizing the
unique roll in/roll out feature.
Although the instructions in this section are primarily
based upon the Rollout method for major component removal, the radiator and fan may be removed
as separate items. Instructions for radiator and fan
removal are contained later in this section. Optional
equipment may be installed on the truck, requiring
additional removal and installation steps not listed.
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
mine site. Prior to removal or repair procedures, it
may be necessary to remove the body to provide
clearance for lifting equipment to be used. If body
removal is not required, the body should be raised
and the safety cables installed at the rear of the
truck.
Read and observe the following instructions before
attempting any repairs!

Preparation
illuminated.
console.
5. Place the GF cutout switch in the CUTOUT
position. (See Figure 3-1 in Section E, Propulsion System, for switch location.)





C02021
Power Module
Tag or mark all hydraulic lines, fuel lines and

electrical connections to assure correct
hookup at time of power module installation.
Plug all ports and cover all hose fittings or
connections when disconnected to prevent
dirt or foreign material from entering.
It is not necessary to remove the radiator
prior to the removal of the power module.
However, the coolant must be drained and
the piping connected to the brake cooling
heat exchanger removed. If radiator removal
is desired or if only radiator repair is
necessary, refer to Section C, Cooling
System.
C2-3
FIGURE 2-1. HYDRAULIC PUMP DRIVE SHAFT

4. Pump Drive Shaft
1. Hydraulic Pump
2. Shaft Guard
5. Alternator
3. Blower Duct
Preparation for Removal
The complete power module, including the hood

and grille weighs approximately 37,386 lbs.
(16,958 kg). Make sure lifting device to be used
has adequate capacity.
1. If radiator removal is required, refer to Section
B, Structural Components, for hood and grille
removal instructions. (Power module may be
removed with hood installed if desired.)
FIGURE 2-2. MAIN ALTERNATOR BLOWER DUCT

6. Wheel Motor Duct
1. Electrical Cabinet
7. Main Alternator
2. Intake Duct
8. Alternator Inlet
3. Alternator Inlet Duct
Transition Structure
4. Blower Assembly
5. Wheel Motor DuctTransition Structure
2. Remove driveshaft guard cover (2, Figure 2-1).

Disconnect hydraulic pump drive shaft (4) at the
drive shaft U-joint companion flange mounted
on the alternator (5).
4. Remove engine air intake duct support rods (9,

Figure 2-3). Remove any hoses or electrical
cables attached to center deck structure.
3. Remove main alternator blower ducts to provide

clearance to raise the engine off the subframe
mounts. (Refer to Figure 2-2):
5. Attach overhead hoist to center deck structure.

Remove deck mounting hardware, lift deck from
truck and move to storage area.
a. Disconnect cables and hoses as required.
6. Disconnect the air cleaner restriction indicator

nylon tubes at ports on inlet ducts.
b. Remove alternator inlet transition structure

(8) and gasket.
c. Remove wheel motor cooling air duct transition structure (5).
d. Cover all openings to prevent entrance of
foreign material.
C2-4
7. Loosen clamps (5) on hump hoses (4) between

the four engine air inlet ducts and air cleaner
outlet ducts.
8. Disconnect inlet ducts at each of the four turbochargers. Remove inlet ducts from truck. Cover
openings at turbochargers.
Power Module
C02021
FIGURE 2-3. ENGINE AIR INLET PIPING

1. Air Cleaner Assemblies
2. Left Rear Intake Duct
3. Left Front Intake Duct
4. Hump Hose
5. T-Bolt Clamp
6. T-Bolt Clamp
C02021
Power Module
7. Reducer Elbow
8. T-Bolt Clamp
9. Duct Support Rod
10. Right Front Intake Duct
11. Right Rear Intake Duct
C2-5
11. Close cab heater shutoff water valves, disconnect water lines and drain water from the heater
core. Secure water lines away from engine
compartment to prevent interference with power
module removal.
12. Drain engine coolant into clean containers for
re-use after engine installation. Coolant capacity is approximately 195 gal (738 l).
13. Disconnect and remove piping (6, Figure 2-5)
from engine water pump and radiator routed to
the brake system cooling heat exchanger (7).
14. Remove upper radiator support rod (11) at each
side of radiator.
15. Remove capscrews and washers at vertical and
diagonal ladder mounting pads. Lift ladders
from truck and move to storage area.
FIGURE 2-4. ENGINE EXHAUST PIPING

1. Capscrew
2. Lockwasher
3. Nut
4. Front Exhaust Pipe

5. Rear Exhaust Pipe
6. Clamp Bands
16. Refer to Section N, Operator Comfort, for procedures required to properly remove the refrigerant. After the system has been discharged,
disconnect refrigerant hoses routed to cab at
the compressor and receiver/drier (10).
NOTE: System contains HFC-134A refrigerant.
9. Remove exhaust duct clamps (6, Figure 2-4).

Remove capscrews (1), lockwashers (2) and
nuts (3) retaining exhaust pipes to turbocharger
outlet flange. Remove exhaust ducts (4 & 5).
Cover opening on engine exhaust outlets.
10. Remove alternator power cable protective
cover. Disconnect all (already marked) electrical
cables, oil and fuel lines that would interfere
with power module removal (see Figure 2-5).
Cover or plug all lines and their connections to
prevent entrance of dirt or foreign material. To
simplify this procedure, most connections utilize
quick disconnects.
C2-6
Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere.
An approved recovery/recycle station must be
used to remove the refrigerant from the air conditioning system.
Power Module
C02021
FIGURE 2-5. POWER MODULE REMOVAL & INSTALLATION

1. 1. Alternator
2. 2. Rear Power Module Lift Eye
3. Rear Frame/Sub-frame Mount
4. Engine/Alternator Cradle Structure
5. Power Module Sub-frame

6. Heat Exchanger Piping
7. Heat Exchanger
Removal - Power Module

Recheck to be certain all hoses, electrical cables,
ground straps etc. have been removed.
1. Remove capscrews, nuts and washers (8, Figure 2-5) securing front subframe support to
main frame.
Install safety chain around the engine subframe

cross member and main frame to prevent the
power module from rolling when the subframe
rollers are installed.
C02021
8. Front Frame/Sub-frame Mount

9. Front Power Module Lift Eye
10. Receiver/Drier
11. Upper Radiator Support Rod
2. Remove capscrews and caps securing subframe mounting bushings to the subframe support bracket (3) at rear of subframe.
3. Check engine and alternator to make sure all
cables, wires, hoses, tubing and linkages have
been disconnected.
Lift power module only at the lifting points on

subframe and engine/alternator cradle structure.
(Refer to Figure 2-5 and 2-7.)
Power Module
C2-7
FIGURE 2-7. POWER MODULE LIFTING POINTS

1. Module Lifting Tool
2. Alternator
3. Lifting Points
FIGURE 2-6. SUBFRAME ROLLERS

1. Roller Assembly
2. Subframe
3. Capscrews
4. Locate a jack under the rear of the power module. Raise the rear portion of engine subframe
and install subframe rollers (Refer to Figure 26). Lower the rear portion of the subframe carefully until the rollers rest on the main frame
guide rail.
NOTE: Subframe rollers are supplied in the truck tool
group and can be installed in the storage position
after use, as shown in Figure 2-6.
5. Position hoist to front subframe lifting points (9,
Figure 2-5). Raise the engine subframe until the
engine is on a level plane. Remove the safety
chain.
4. Engine
5. Power Module Subframe
6. Roll the power module forward sufficiently so

that adequate clearance is provided in front of
electrical cabinet for the lifting device to be
attached to the engine/alternator cradle structure (2, Figure 2-5) and front subframe lifting
points (9). Place stands or block under front of
subframe and lower hoist until front of subframe
is supported. Install safety chain to prevent subframe from rolling.
7. Attach lifting device (1, Figure 2-7) to hoist and
attach to engine/alternator cradle structure and
front subframe lifting points as shown in Figure
2-7. Remove safety chain.
8. Raise the power module slightly to determine if
module is on an even plane. Move the power
module straight out of truck to a clean work area
for disassembly.
For further disassembly of the engine, alternator, and
radiator, refer to the appropriate section of this manual.

C2-8
Power Module
C02021
Installation - Power Module

1. Inspect the main frame guide rails. Remove
any debris which would interfere with power
module installation.
2. Clean the main frame rear support brackets.
Apply a light film of soap solution to each rubber
bushing (3, Figure 2-5) located at the rear of the
subframe.
3. Check the subframe rollers making sure they
roll freely and are in the roll-out position. (Figure 2-6).
4. Attach a lifting device to engine/alternator cradle structure and front subframe lifting points
(Figure 2-7).
6. Lower the power module to the subframe guide

rails, relax the hoist slightly and roll the power
module into truck frame as far as possible
before the lifting chains contact the electrical
cabinet.
7. Place stands or blocking under front of subframe to support assembly while repositioning
hoist.
8. Install a safety chain around the truck frame
and the subframe. The safety chain will prevent
the power unit from rolling forward.
9. Place a small block behind each rear subframe
roller to prevent rolling.
10. Lower hoist to allow subframe to rest on stands
and rollers. Remove lifting device.
11. Attach hoist to front lifting eyes on subframe.

12. Remove the small blocks behind the subframe

rollers, remove safety chain, and slowly roll the
power module into position over the main frame
mounts. Lower hoist until front subframe
mounts are aligned and seated on the front,
main frame mounts. Reinstall safety chain.
5. Raise the power module and align the subframe

rollers within the main frame guide rails.
13. Place a jack under rear of subframe to support

the power module. Raise power module just
enough to permit removing the subframe rollers.
14. Lower the rear portion of the subframe until the
subframe rubber bushings are seated in the
mounting brackets (3, Figure 2-5) located on
the main frame of the truck.
15. After subframe is seated in frame mounts, the
safety chain may be removed from the front
subframe member.
16. Install rubber bushings, capscrews, washers
and nuts in the front mounts (8, Figure 2-5).
Tighten capscrews to 525 ft. lbs. (712 N.m)
torque.
17. Install the rear subframe mounting caps and
secure caps in place with lubricated capscrews.
torque. (Refer to Figure 2-5).
FIGURE 2-8. POWER MODULE INSTALLATION

Hookup - Power Module
1. Install all ground straps between frame and
subframe. Reconnect wire harnesses at power
module subframe connectors.
2. Install vertical and diagonal ladders on mounting pads at front bumper.
C02021
Power Module
C2-9
3. Attach hoist to the front center deck and lift into

position. Install capscrews, flatwashers, lockwashers and nuts at each mounting bracket.
Tighten capscrews to standard torque.
4. Install engine air intake duct supports. Reinstall
intake ducts between turbochargers and aircleaner outlet ducts (see Figure 2-3). Clamp
securely to insure a positive seal is made. (Refer
to Figures 2-3 & 2-9 for correct installation and
alignment examples.) Install exhaust ducts (4 &
5, Figure 2-4) on turbocharger outlet flanges and
pipes at frame crossmember.
5. Connect the cab heater inlet and outlet hoses
and open both valves.
6. Install piping (6, Figure 2-5) between heat
exchanger (7) and engine water pump and radiator.
7. Inspect alternator/wheel motor cooling duct gaskets and replace if damaged. Install Alternator
inlet transition structure (8, Figure 2-2) and

wheel motor duct transition structure (5).
8. Connect the hydraulic pump drive shaft companion flange (4, Figure 2-1) to the alternator (5).
Tighten capscrews to standard torque. Install
driveshaft guard (2).
9. Connect all remaining electrical, oil, and fuel
lines.
10. Connect the air filter restriction indicator hoses.
11. Close battery disconnect switches.
12. Connect hoses routed from cab to receiver/drier
and air conditioning compressor.
13. Refill radiator and service engine with appropriate fluids. Refer to Section P, Lubrication and
Service, for capacity and fluid specifications.
14. Recharge air conditioner system per instructions
in Section N, Operator Comfort.
FIGURE 2-9. AIR INLET PIPING CONNECTIONS
C2-10
Power Module
C02021
SECTION C3
COOLING SYSTEM
INDEX
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
Removal - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
RADIATOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8
Additional Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8
Installation - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9
RADIATOR FILLING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10
COOLANT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10
C03023 03/01
Cooling System
C3-1
NOTES
C3-2
Cooling System
03/01 C03023
COOLING SYSTEM
RADIATOR
Removal - Radiator
1. Drain coolant from radiator and engine. Be prepared to catch approximately 200 gallons (757
liters) of coolant. If the coolant is to be reused, it
must be stored in clean containers.
2. If radiator is being removed without the removal
of the complete power module, remove grille
and hood according to removal instructions in
Section B, Structural Components.
An approved recovery/recycle station must be
3. Refer to instructions in Section N, Operator
Comfort, and discharge the refrigerant from the
system with a recovery/recycle station. The system is charged with HFC-134A refrigerant.
a. Remove refrigerant hose clamps and
remove the receiver/drier (7, Figure 3-1)
mounted on rear, left side of the radiator
shroud. Disconnect wiring from low pressure
switch.
b. Remove clamp and disconnect inlet and outlet hoses (4 & 5, Figure 3-2) at the condenser. Remove mounting capscrews (3)
and remove condenser.
c. Cap all hoses to prevent contamination.
Remove any remaining clamps attaching
hoses and wiring to radiator shroud and
reposition to allow removal of the radiator
and shroud assembly.
FIGURE 3-1. RADIATOR INSTALLATION

1. Fuel Cooler
2. Radiator
3. Upper Hoses
4. Upper Support Rod
5
C03023 03/01
7. Heat Exchanger
8. Receiver Drier
9. Mount Capscrews
FIGURE 3-2. AIR CONDITIONER CONDENSER

1. Grille Structure
2. Condenser
3. Mounting Capscrews
Cooling System
4. Inlet Hose
5. Outlet Hose
C3-3
FIGURE 3-4. FAN GUARD

1. Fan Guard (LH)
2. Fan Shroud
3. Fan Guard (RH)

4. Engine Subframe
FIGURE 3-3. RADIATOR PIPING

(Bottom View)
1. Drain Cock
2. Outlet Elbow (Front)
3. Radiator Mounting
Capscrews
4. Outlet Elbow (Rear)

5. Heat Exchanger
6. Engine Subframe
4. Disconnect lines at fuel cooler (1, Figure 3-1).

Remove clamps securing fuel lines to radiator.
5. Unclamp and separate all upper tank lines (3)
between the radiator and engine.
6. Remove outlet elbows (2 & 4, Figure 3-3) at
bottom tanks. Cap all coolant lines to prevent
contamination.
7. Remove and cap hoses from radiator top tank
and surge tank.
NOTE: The radiator and shroud assembly weigh

approximately 5,730 lbs. (2,600 Kg.).
10. Remove the upper radiator side support rods (4,
Figure 3-1). Remove lower support rods (5).
11. Remove nuts, lockwashers, flat washers and
capscrews (2, Figure 3-5) from power module
subframe (3) at the lower radiator mounts.
12. Verify all hoses and wiring harnesses have
been removed. Lift radiator slightly with the
hoist, move assembly forward until clear of
engine fan. Move radiator to work area for service.
8. Remove capscrews and lockwashers to free fan

guard (1 & 3, Figure 3-4) from radiator shroud
(2). The two halves of the fan guard may be disassembled and removed or the complete guard
may be moved to the rear to clear the fan
shroud during radiator removal.
9. Attach hoist to lift radiator and take up slack.
C3-4
Cooling System
03/01 C03023
RADIATOR REPAIR
Internal Inspection
If desired, an internal inspection can be performed on
the radiator before complete disassembly. The
inspection entails removing tubes in the radiator core
and cutting them open. This type of inspection can
indicate overall radiator condition, as well as coolant
and additive breakdown.
To perform this inspection, remove about four random tubes from the air inlet side of the radiator.
Remove tubes from both the top and bottom cores,
and near each end of the radiator. Refer to Disassembly and Assembly in this section for proper
instructions for tube removal and installation. Analyze any contaminant residue inside the tube to
determine the cause. Flush the system before returning to service. Contact your nearest L&M Radiator
facility for further instruction or visit the L&M website
for further information at www.mesabi.com.
FIGURE 3-5. RADIATOR MOUNT

1. Radiator
2. Mounting Hardware
3. Subframe
4. Battery Box
5. Outlet Elbow
External Cleaning
Many radiator shops use a hot alkaline soap, caustic
soda, or chemical additives in their boil-out tanks
which can attack solders. These tanks are generally
not recommended. Before such tanks are used for
cleaning, ensure that the cleaning solutions are
not harmful to solder, otherwise damage to the
radiator will result. Be sure to completely rinse the
cleaned tube/core in clean water after removing 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 1200 psi.
Unlike conventional cores, you can and should get
right up next to the core with the spray nozzle. 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. Make
sure to spray straight into the core, not at an angle.
Continue washing until the exit water is free of dirt.
Repeat from the opposite side.
C03023 03/01
Cooling System
C3-5
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 tool should be positioned just below the
rectangular section of the tube. The bottom jaw
should rest on the seal. Squeeze the 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, first, and use the
breaker tool (XA2307) to loosen the tube to be
removed. When using the 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 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 during removal.
Refer to Figure 3-8. Removing the tube at an
excessive angle may cause damage to the
tube.
C3-6
Cooling System
03/01 C03023
4. Remove all the tubes at the top, before removing the bottom tubes.
5. After all of the tubes are removed, pliers can be
used to remove the seals from the tanks. Discard all seals. New seals must be used for
assembly.
Assembly
NOTE: For easier installation, soak the seals in hot
water before installing.
1. Install the new tube seals onto the bottom tank
and the bottom side of the center tank. Do not
install seals for the top core at this time. Seals
for the top of the tubes do not have locking
grooves, bottom tube seals do. Ensure the correct seals are installed in the proper position.
Cleaning and Inspection
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
force will drive the seals in too far. The seals
should be slightly convex when installed properly. Improperly installed seals are concave with
a smaller diameter hole. Refer to Figure 3-9.
1. Clean tube holes using a drill with a 3/4 in. (19

mm) wire brush.
2. Clean the holes of any foreign debris and wipe
clean.
3. Clean the inside of the tanks and tubes. In most
cases just flushing the inside with a high pressure hot water washer, with soap, will do the
job. If not, contact an L&M manufacturing facility
or visit the L&M website for further instruction at
www.mesabi.com.
Properly installed;
slightly convex
Improperly installed;
concave
4. Check for signs of internal blockage in 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
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.
5. Buff the tube ends with a polishing wheel and a
copper polishing compound. If any debris can
not be removed by buffing, emery cloth, steel
wool, or a wire wheel (wire size 0.006 - 0.008 in.
(0.15 - 0.20 mm) is acceptable for use. Use
extreme care not to mar the tube ends.
C03023 03/01
FIGURE 3-9. PROPER SEAL INSTALLATION
2. Use a 1/2 in. (13 mm) diameter brush to lubricate the seals with lube/release agent
(XA2308).
Cooling System
C3-7
3. Use a spray bottle to lubricate the tube ends

with the lube/release agent.
When installing tubes, start at one end and work

towards the center. After you reach the center,
move to the opposite end, and again, work
towards the center. If any of the tubes are difficult
to install, do not proceed to force the tube.
Remove the tube and determine the problem.
Possible causes may be:
inadequate seal/tube lubrication
Ensure that all tube beads are seated in their

respective bottom seals.
Align and straighten all tubes during the installation of each row to allow maximum air flow
through the radiator.
6. Install tube stay ends and install the felt air baffles behind the front and back rows while completing tube installation.
improperly installed seal

damaged seal or tube end
tube angle excessive during installation
and/or tube not centered in seal
Inspect seals for damage before trying to reinstall tube. Replace as necessary.
4. Working from the front of the radiator (opposite
of fan side) install the bottom row of tubes starting with the fan side row.
When installing the tubes, center the top of the
tube in the top seal while angling the tube only
as much as necessary. Twist the tube while
applying upward force. Push the tube into the
seal until enough clearance is available to
install the bottom end of the tube into the bottom seal.
5. Center the bottom end of the tube in the bottom
seal. Push the tube downward until the formed
bead on the tube is seated inside of the lock
ring groove in the seal. If necessary, you may
use the installation tool (VJ6567) to pull the
tube downward into the seal. The tool has a
hooking device on the end of one of the handles
for aiding in installation.
Pressure Testing
Radiators should be pressure tested at 15 psi for 30
minutes. Various methods of pressure testing include
the following:
Pressurize the radiator and submerge into a test
tank. Watch for leaks.
Lay the front side of the radiator on the floor. Cap
off ports, and fill the radiator with hot water.
Pressurize the radiator and check for leaks.
Cap off radiator ports. Install an air pressure
gauge and pressurize to 15 psi. Remove the air
source and monitor the pressure gauge.
Pressurize the radiator with air, and spray sealed
joints with soapy water.
Additional Service Information

Additional service information can be found on the
L&M Radiator website located at www.mesabi.com.
FIGURE 3-10. USING INSTALLATION TOOL TO

INSTALL TUBE
C3-8
Cooling System
03/01 C03023
Installation - Radiator
1. Attach a hoist to the radiator assembly and lift
into position on the subframe.
11. Route hoses to fuel cooler, clamp in place and

attach to fuel cooler fittings.
2. Insert the capscrews, washers, and nuts (2,

Figure 3-5) at the lower radiator mounting
brackets but do not tighten at this time.
12. Reinstall air conditioning system components:

a. Install condenser, condenser hoses, and
clamps.
3. Inspect rubber bushings for lower support rods

(5, Figure 3-1) and replace if worn or damaged.
Install flatwashers, rubber bushings and nuts on
the lower end of radiator support rods and insert
rods into the subframe mounting brackets.
Insert remaining bushings, flatwashers and
locknuts but do not tighten. Install rods at radiator brackets and tighten to standard torque.
4. Install upper support rods (4) and mounting
hardware at radiator brackets and front upright
brackets. Do not tighten at this time.
5. Adjust the lower stabilizer support rods to position the radiator perpendicular to the subframe
within 0.12 in. (3.0 mm) measured at top of
radiator. When position is established, tighten
locknuts to 525 ft. lbs (712 N.m) torque to lock
adjustment.
6. Tighten upper support rod mounts and recheck
perpendicularity of radiator.
b. Install receiver/drier and clamp

Attach wires to low pressure switch.
hoses.
c. Clamp all hoses and wiring to studs using

clamps removed during disassembly. Refer
to Section N, Operator Comfort, for complete
instructions to evacuate and recharge the air
conditioning system refrigerant supply.
13. Install grille and hood according to instructions
in Section B, Structural Components.
14. Make sure all coolant drains are closed, pipe
plugs installed, and all hoses installed. Service
cooling system with the proper mixture of antifreeze as recommended in Section P, Lubrication and Service Check for static leakage and
correct any leaks. Start engine and run until
cooling system reaches operating temperature,
recheck the cooling system for leakage during
engine operation.
7. Tighten nuts on capscrews (2, Figure 3-5) at

lower radiator mounting brackets to standard
torque.
8. Install the fan guard using capscrews and
washers removed during disassembly.
9. Install upper radiator hoses and lines between
radiator and engine, seat hoses fully and tighten
clamps securely.
10. Install lower radiator hoses and lines between
radiator and engine, seat hoses fully and tighten
clamps. If outlet elbows (2 & 4, Figure 3-3) have
been removed during radiator removal, install
new gaskets during installation.
C03023 03/01
Cooling System
C3-9
RADIATOR FILLING PROCEDURE
COOLANT SYSTEM
TROUBLESHOOTING
If abnormal coolant temperatures are experienced,
perform the following visual inspections and tests:
The cooling system is pressurized due to thermal

expansion of coolant. DO NOT remove the radiator cap while the engine and coolant are hot.
Severe burns may result.
1. Check coolant level and thoroughly inspect

system for leaks.
a. Check for proper coolant/antifreeze mixture.
b. Follow engine manufacturer's recommendations regarding use of cooling system additives.
1. With engine and coolant at ambient temperature, remove radiator cap.
2. Inspect radiator fins for restrictions. Be certain

the air flow through the radiator is not restricted
by debris or bent radiator fins.
Note: If coolant is added using the Wiggins quick fill

system, the radiator cap must be removed prior to
adding coolant.
3. Visually inspect fan blades for damage. Check

radiator cap sealing surfaces.
2. Fill radiator with proper coolant mixture (as

specified by the engine manufacturer) until
coolant is visible in the sight gauge.
3. Install radiator cap.
4. If equipped with a fan clutch, refer to Section N,

Operator Comfort for complete instructions for
test and repairs if required.
5. Refer to engine manufacturer's Service Manual
for information regarding test and replacement
of the coolant system thermostats.
4. Run engine for 5 minutes, check coolant level.

5. If coolant is not visible in the sight gauge,
repeat steps 1 through 4. Any excess coolant
will be discharged through the vent hose after
the engine reaches normal operating temperature.
Engine coolant must always be visible in the sight
gauge before truck operation.
C3-10
Cooling System
03/01 C03023
SECTION C4
POWERTRAIN
INDEX
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
Removal - Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
ENGINE/ALTERNATOR MATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Power Train
C4-1
NOTES
C4-2
Power Train
C04027
POWER TRAIN
ALTERNATOR
Removal - Alternator
The following instructions cover the removal of the
main alternator from the engine after the power
module has been removed from the truck. (Refer to
Figure 4-2.)
When lifting the alternator, attach a hoist to the

lift eyes only. The alternator weighs approximately 8,200 lbs. (3,720 kg). Use a lifting device
that can handle the load safely.
1. Attach a hoist with two lifting chains to the two
alternator lifting eyes (8, Figure 4-2).
2. Block under the rear of the engine
a. Loosen cradle adjustments setscrews (3,
Figure 4-1).
b. Loosen engine/cradle capscrews (5, Figure
4-2).
FIGURE 4-1. CRADLE STRUCTURE

1. Cradle Structure
2. Jam Nut
3. Adjustment Setscrew
4. Subframe
5. Gap
FIGURE 4-2. ENGINE AND ALTERNATOR

1. Alternator
4. Flywheel Housing
7. Sub Frame
5. Capscrews
8. Alternator Lift Eyes
3. Cradle
6. Engine
C04027
Power Train
C4-3
3. Remove the access cover at the front, right side

of the engine flywheel housing. Reach through
the access openings and remove twelve [12]
capscrews (6, Figure 4-3) joining the engine
drive ring (7) to alternator rotor (8). (Rotate
crankshaft to align each capscrew with access
hole.)
Be certain all capscrews have been removed!

4. Remove sixteen capscrews (3) securing 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. Be sure all
the capscrew threads are completely disengaged
from alternator housing (1).
5. Take up slack in the hoist and remove capscrews and lockwashers (2, Figure 4-2) securing the alternator to the cradle structures.
6. Keep the alternator as level as possible and
move away from engine.
7. Note shim location and quantity. Retain shims
for possible use during reinstallation.
8. For further disassembly instructions for the
alternator, refer to the General Electric Service
Manual.
C4-4
FIGURE 4-3. ALTERNATOR TO ENGINE

MOUNTING
5. Capscrew
1. Alternator
6. Capscrew (12 ea.)
2. Flywheel Housing
7. Engine Drive Ring
Adapter
8. Alternator Rotor
3. Capscrew (16 ea.)
4. Engine Flywheel
Housing
Power Train
C04027
ENGINE/ALTERNATOR MATING
Measuring Procedure
1. Thoroughly clean the alternator housing mounting surface, rotor drive adapter mounting surface and flywheel housing adapter mounting
surfaces.
The following instructions must be followed to

ensure proper alignment and engine crankshaft
endplay. Failure to follow these instructions can
result in serious damage to the engine and/or
alternator.
2. With magnetic base mounted on the front of the

engine and the dial indicator on the front of the
crankshaft, measure total crankshaft end-play:
Verify end play is within 0.13 - 0.38 mm
(0.005 - 0.015 in.)
Record Total Crankshaft End_______________
3. Refer to Figure 4-4. Move the engine crankshaft
to the rear of its end travel.
General Instructions
Never pry on the engine crankshaft damper!
Loosen or remove fan belts prior to measuring

crankshaft end-play to insure that the crankshaft
moves easily and completely.
When taking measurements, always take four

equally spaced readings and average them.
Always measure from mating surface to mating

surface.
References to crankshaft rotation; clockwise

(CW), or counterclockwise (CCW), is the
direction of rotation when looking at the front
(damper end) of engine.
Crankshaft end-play: 0.13 - 0.38 mm (0.005 0.015 in.)
a. Carefully measure Dimension C at four

locations, 90 apart:
1st measurement:___________________
2nd measurement:__________________
3rd measurement:___________________
4th measurement:___________________
Dimension C: Average______________
b. Add 1/2 (one-half) of Total End-play (Step 2).
c. Record (a + b) as;
Measurement C:___________________
SERVICE DATA - Eccentricity & Runout Limits

Description
T.I.R
Max. Flywheel Housing Bore Eccentricity 0.66 mm

Max. Face Runout Flywheel Housing
0.25 mm
Max. Eccentricity of Flywheel

(Coupling Assy.)
0.18 mm
Max. Axial Runout of Flywheel Face

(Coupling Assy.)
0.25 mm
FIGURE 4-4. SHIM LOCATION

1. Alternator Housing
2. Alternator Rotor
3. Flywheel Housing
Adapter
4. Engine Flywheel
Housing
C04027
Power Train
A - Dimension A
B - Drive Shims
C - Dimension C
D - Housing Shims
C4-5
4. Refer to Figure 4-5. Alternator End-play:

a. Using a flat steel bar (3, Figure 4-5) bolted
rigidly to the alternator rotor (2), install a 5/8"
- 11 capscrew (4) at each end into alternator
housing (1). Leave capscrews finger-tight.
b. Move alternator rotor (2) axially towards the
rear (slip-ring end) by alternately tightening
the capscrews (4) one-half-turn-at-a-time.
Do NOT exceed 12.0 ft. lbs. (16.3 N.m)
torque on each capscrew. This establishes
the maximum permissIble rear travel for the
alternator rotor.
c. Alternately loosen capscrews (4) one-turnat-a-time, until all torque is released. Carefully remove the bar (3).
Note: The object is to leave the rotor in its most
rearward position.
Refer to Figure 4-4.
d. Carefully measure Dimension A (Do not
move the alternator rotor) at four locations,
90 apart, and average the measurements.
1st measurement:___________________
2nd measurement:___________________
3rd measurement:___________________
4th measurement:___________________
Dimension A:_______________Average
e. Add 0.010" to Dimension A.
f. Record (d + e) as;
Measurement A:___________________
FIGURE 4-5. ALTERNATOR END-PLAY

2. Alternator Rotor
3. Steel Bar
4. Capscrew
5. Determining Shims:
Compare Measurement C (Step 3.c.) with
Measurement A (Step 4.f.).
a. If C is greater than A, subtract: (C - A) = B
B = ______________Shim pack thickness
to be installed at location B, Figure 4-4.
b. If A is greater than C, subtract: (A - C) = D

D = ________________Shim pack thickness
to be installed at location D, Figure 4-4.
Rotor-to-Drive Ring
Location B
Shim Part Number
Shim Thickness
TM3467
0.004 inch
TM3469
0.007 inch
C4-6
Alternator-to-Flywheel Housing Adapter

Location D
Power Train
Shim Part Number
Shim Thickness
TM3466
0.004 inch
TM3468
0.007 inch
C04027
Joining The Alternator and Engine
When lifting the alternator, attach hoist to lift

eyes only. The alternator weighs approximately
8,200 lbs. (3,720 kg). Use a lifting device that can
handle the load safely.
1. Use the two top lift brackets provided on the
alternator for lifting. The top front lifting bracket
should be equipped with some method of
adjusting the alternator to keep it horizontal.
2. Carefully move alternator into place and
engage the engine drive ring (6, Figure 4-6) into
the alternator rotor drive (7) using shims B, if
required (refer to step 5.a. Determining Shims,
in Measuring Procedure).
3. Install flywheel housing adapter capscrews (2)
into alternator housing (1). Tighten to 175 ft.
lbs. (237 N.m) torque.
4. Install capscrews (5) through engine drive ring
(6) into the alternator rotor adapter (7). Rotate
crankshaft to access and align holes. Tighten
capscrews (5) to 175 ft. lbs. (237 N.m) torque.
5. Install alternator-to-cradle structure mounting
capscrews and washers (2, Figure 4-2) and
tighten to 525 ft. lbs. (712 N.m) torque.
6. Tighten engine-to-cradle structure mounting
capscrews (5, Figure 4-2) to 345 ft. lbs. (465
N.m) torque.
FIGURE 4-6. ALTERNATOR TO ENGINE

MOUNTING
2. Point Capscrew
3. Flywheel Housing
Adapter
4. Engine Flywheel
Housing
The total engine crankshaft end-play (step 7)

must equal the original measurement or 0.020 in.
(0.51 mm) (alternator end-play), whichever is
smaller.
If the end-play after the alternator and engine are
assembled is less than 0.020 in. (0.51 mm), and
less than the starting engine crankshaft end-play,
Reshimming is required.
Never pry on the engine crankshaft damper!

7. With magnetic base mounted on the front of the
engine and the dial indicator on the front of the
crankshaft, measure total crankshaft end-play:
9. Rotate the crankshaft one full revolution and listen for any unusual noise caused by moving
components contacting stationary parts.
Record Total Crankshaft End-play:__________

8. Compare the step 7 value to the measurement
taken before alternator was installed on engine.
C04027
5. Capscrew
7. Alternator Rotor
B - Drive Shims
D - Housing Shims
10. Install engine side cover, if removed. Install

lockwire on all alternator mounting capscrews.
11. Install access cover on flywheel housing.
Power Train
C4-7
ENGINE
Service
Removal
Refer to instructions in previous sections for removal
instructions for the power module, alternator, and
radiator assembly.
Complete instructions covering the disassembly,

assembly and maintenance of the engine and its
components can be found in the engine manufacturer's service manual.
Installation
1. Disconnect any remaining wiring or hoses

between the engine and subframe.
1. Align engine to subframe and install front

mounting capscrews and lockwashers (5, Figure 4-7). Align and install rear engine mounting
capscrews and lockwashers (2) through cradle
structure, but do not tighten at this time. Tighten
front mount capscrews to 345 ft. lbs. (465
N.m) torque.
2. Remove capscrews and lockwashers (5, Figure

4-7) securing front engine mount to subframe.
2. Install alternator on engine following. Refer to

Engine/Alternator Mating.
3. Attach spreader bar with lifting straps at front lift

hooks and rear lift hooks (6) on engine. Remove
capscrews and lockwashers (2) at rear engine
mount securing engine to cradle structure (1).
Always use a spreader bar to ensure lift straps
are vertical at each lift hook.
3. Tighten rear engine mounting capscrews (2) to

345 ft. lbs. (465 N.m) torque after alternator is
installed.
The engine weighs approximately 20,514 lbs.

(9,305 kg) wet. Be sure lifting devices are capable
of handling the load safely.
4. Lift engine from subframe and move to clean

work area for further disassembly.
4. Adjust setscrew (3, Figure 4-2) to equalize gap

(5) between cradle structure (1) and subframe
(4) at left and right side. Lock setscrew with jam
nut (2).
FIGURE 4-7. ENGINE MOUNTING
C4-8
1. Cradle Structure
3. Engine Subframe
5. Capscrews and Lockwashers
2. Capscrews and Lockwashers
4. Engine
6. Engine Lift Hooks
Power Train
C04027
SECTION C5
AIR CLEANERS
INDEX
AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3

AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
General Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
FILTER ELEMENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-4
Main Filter Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
Precleaner Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-6
Cleaning Precleaner Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-6
AIR INTAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7
C05013 05/98
Air Filtration System
C5-1
NOTES
C5-2
05/98 C05013
AIR CLEANERS
AIR CLEANERS
Operation
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 filter
cartridges.
The engine demand for air creates a vacuum in the
air cleaners and causes outside air to be drawn in
through air inlets on the air cleaners. Dirty air entering here is drawn through a series of tubes that are
designed to produce a cyclonic action. As the air
passes through the outer portion of the tubes, a circular motion is set up causing dust and dirt particles
to be thrown from the air stream into dust collectors
(1, Figure 5-1). At the same time, the air stream turns
and is directed up through the center of the tubes into
the filter chamber. Here the air passes through the
main filter element and safety filter element and out
the clean air outlet to the engine's air intake system.
The function of the safety filter is to increase overall
reliability and engine protection.
The truck engine must be shut down before servicing the air cleaner assemblies or opening the
engine air intake system.
Never start the engine with the filter elements
removed. Engine operation with elements
removed can cause serious engine damage.
General Service Information
Inspect and empty dust collector cups at regular

intervals; daily inspection is recommended.
Never allow the dust level to build up to the tube
(precleaner) chamber.
During operation or after the engine has been

shut down, observe the air cleaner vacuum
gauges mounted on the overhead display panel
in the operator's cab. Filter service is required
when a gauge shows maximum restriction.
Check all engine air inlet tubes, hoses and

clamps. All connections must be air tight to
prevent dirt entry.
Air cleaner housing fasteners and mountings

must be tight.
After filter service has been accomplished, reset

air cleaner service vacuum gauges by pressing
the reset button on the face of the gauge.
FIGURE 5-1. ENGINE AIR CLEANERS

1. Dust Collectors
2. Precleaner Section
C05013 05/98
3. Air Intake Cover

4. Element Cover
C5-3
FIGURE 5-2. AIR CLEANER ASSEMBLY

1. Dust Cap
2. Dust Cap Gasket
3. Tube
4. Unfiltered Air Inlet
5. Wing Nut
6. Wing Nut Gasket

7. Safety Element
Indicator
8. End Cover
FILTER ELEMENT REPLACEMENT

1. Follow normal procedures and shut down the
engine. Clean dirt and dust off area around air
cleaner element cover (4, Figure 5-1).
10. Safety Filter Element

11. Main Filter Element
12. Main Element Gasket
13. Clean Air Outlet

14. Pre-Cleaner Gasket
15. Safety Filter Element
Gasket
4. Check safety (secondary) filter element indicator nut (7). If solid red area is showing, safety filter replacement is required. If center is green,
safety element does not require service.
2. Loosen large wing nut (5, Figure 5-2) on air

cleaner cover to free main element assembly
(10). Pull main element clear of assembly.
3. Inspect filter element carefully for possible damage, holes, breaks, etc., which might affect
reuse of element. If element appears serviceable other than being dirty, proceed with the
cleaning procedure. If defects are found in filter
element, wing nut assembly (5) must be
removed from element assembly and installed
on the new filter element.
C5-4
Have a new safety (secondary) filter element on

hand before removing old one. Do not keep
intake system open to the atmosphere any longer
than absolutely necessary.
5. If indicator indicates safety filter replacement is
required, remove indicator and remove safety
filter element. Discard element; DO NOT
attempt to clean the safety element.
05/98 C05013
Main Filter Element Cleaning

6. Reset the indicator nut from red to green by
gently blowing air into threaded hole from gasket side of nut.
7. Install new safety element and tighten safety
indicator wing nut to 10 ft. lbs. (13 N.m) torque.
NOTE: Remember that 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.
8. Install clean or new, main filter element into air

cleaner and secure with wing nut. Tighten wing
nut hand tight, do not use a wrench or pliers. If
filter element is being reused, make sure sealing gasket is not damaged. The gasket must
seal completely.
After inspection, determine the condition of the element and choose either the washing or compressed
air method for cleaning the filter element. If the element is clogged with carbon, soot, oil and/or dust, the
complete washing procedure will produce the best
results.
9. Close and latch the dust collectors on the bottom of the air cleaner assembly.
1. Wash elements with water and detergent as follows:

a. Soak the element in a solution of detergent
and water for at least 15 minutes. Rotate element back and forth in the solution to loosen
dirt deposits. DO NOT soak elements for
more than 24 hours.
b. Rinse element with a stream of fresh water in
the opposite direction of normal air flow until
rinse water runs clear. Maximum permissible
water pressure is 40 psi (276 kPa). A complete, thorough rinse is essential.
c. Dry the element thoroughly. If drying is done
with heated air, the maximum temperature
must not exceed 140F (60C) and must be
circulated continually. Do not use a light bulb
for drying elements.
d. After cleaning the element, inspect thoroughly for slightest ruptures and damaged
gaskets. A good method to detect 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 part.
FIGURE 5-3. INSPECTING FILTER ELEMENT
C05013 05/98
C5-5
FIGURE 5-4. CLEANING FILTER ELEMENT

WITH COMPRESSED AIR
2. Clean dust loaded elements with dry filtered
compressed air:
a. Maximum nozzle pressure must not exceed
30 psi (207 kPa). Nozzle distance from filter
element surface must be at least one inch
(25 mm) to prevent damage to the filter
material.
b. As shown in Figure 5-4, direct stream of air
from nozzle against inside of filter element.
This is the clean air side of the element and
air flow should be opposite of normal air flow.
FIGURE 5-5. REMOVING DUST FROM

PRECLEANER TUBES
Cleaning Precleaner Tubes
c. Move air flow up and down vertically with

pleats in filter material while slowly rotating
filter element.
d. When cleaning is complete, inspect filter element as shown in Figure 5-3 and if holes or
ruptures are noted, discard the element.
Precleaner Section
The tubes in the precleaner section of the air cleaner
assembly should be cleaned at least once annually
and at each engine overhaul. More frequent cleaning
may be necessary depending upon operating conditions and local environment should tubes become
clogged with oil, sludge or dirt.
To inspect tubes in precleaner section, remove main
filter element. Do not remove the safety element.
Loosen clamps and remove dust collector cup. Use a
light to inspect the tubes, all tubes should be clear
and the light should be visible.
Clean the tubes as follows if clogging is evident.
Both the main and safety elements must be

installed in the air cleaner while Steps 1 and 2 are
being accomplished to prevent any possibility of
dirt being forced into the engine intake area.
1. Dust can be removed with a stiff fiber brush.
DO NOT use a wire brush. Dust may also be
removed effectively using compressed air.
2. Heavy plugging of tubes may require soaking
and washing of complete precleaner section.
The following instructions cover these procedures.
NOTE: The precleaner section may be separated
from the air cleaner assembly without dismounting
the complete air cleaner from the truck.
3. Remove the air intake cover (3, Figure 5-1).
Remove capscrews and locknuts holding precleaner section to the cleaner assembly and
remove precleaner. The safety element must
remain in place to protect the engine intake.
4. Loosen clamps and remove dust collector cup
(1) from precleaner section. Wash dust cup with
water and liquid soap solution.
C5-6
05/98 C05013
AIR INTAKE TROUBLESHOOTING

5. Submerge precleaner section (see Figure 5-6.)
in a solution of Donaldson D-1400 and warm
water (mix solution according to package directions). Tube section must be down. Soak for 30
minutes, remove from solution and rinse thoroughly with fresh water and blow dry.
6. Severe plugging may require the use of an Oakite 202 and water solution. The solution should
be mixed 50% Oakite 202 and 50% fresh water.
Soak precleaner section for 30 minutes, rinse
clean with fresh water and blow dry completely.
7. Check precleaner gaskets carefully for any evidence of air leaks and replace if necessary
8. Install precleaner section, with serviceable gaskets, on air cleaner assembly and install all
mounting hardware removed.
To insure maximum engine protection, be sure that

all connections between air cleaners and engine
intake are tight and positively sealed. If air leaks are
suspected, check the following:
1. All intake lines, tubes and hump hoses for
breaks, cracks, holes, etc., which could allow
an intake air leak.
2. Check all air cleaner gaskets for positive sealing.
3. Check air cleaner elements, main and safety,
for ruptures, holes or cracks.
4. Check air cleaner assembly for structural damage, cracks, breaks or other defects which
could allow air leakage. Check all mounting
hardware for tightness.
9. With a serviceable gasket, install dust collector

cup assembly on precleaner section and secure
with mounting clamps.
FIGURE 5-6. WASHING AND SOAKING

PRECLEANER SECTION
C05013 05/98
C5-7
NOTES
C5-8
05/98 C05013
SECTION C7
FAN CLUTCH
INDEX
FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL & INSTALLATION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FAN CLUTCH - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLY - FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C07001
Fan Clutch
C7-1
NOTES
C7-2
Fan Clutch
C07001
FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
TOOL A - FRONT SLEEVE BEARING INSTALLER
TOOL B - REAR SLEEVE BEARING INSTALLER
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 (LARGE)
C07001
Fan Clutch
C7-5
FAN CLUTCH - DISASSEMBLY
FIGURE 7-1. FAN CLUTCH EXPLODED VIEW

1. Orifice Fitting
2. Dowel Pin (Rear)
3. Pitot Tube
4. Wear Sleeve
5. Retainer/Seal Assembly
6. Shaft Assembly
7. Nameplate Kit
8. Washer
9. Bolt
10. Oil Seal
11. Bearing Retainer (rear)
12. Bearing Spacer (External Snapring)
13. O-Ring Seal
14. Main Bearing (rear)
15. Internal Snapring
C7-6
16. External Snapring (spacer)

17. Sealring (Hook type)
18. Bolt
19. Washer
20. Pulley
21. Pulley Adapter
22. Sealring (large)
23. Piston
24. Sealring (small)
25. Spring Washer
26. Shim
27. External Snapring
29. Clutch Hub
30. Facing Plate
Fan Clutch
31. Steel Clutch Plate

33. Main Bearing (front)
34. O-Ring Seal
35. Bearing Retainer (front)
36. Oil Seal
37. Washer
38. Bolt
39. Wear Sleeve
41. Sleeve Bearing (rear, short)
42. Fan Mounting Hub Assembly
43. Dowel Pin (Front)
44. Sleeve Bearing (front, long)
45. End Cap
C07001
3. Pitot Tube
4.Wear Sleeve
6. Shaft Assembly
8. Washer
9. Bolt
10. Oil Seal
11. Bearing Retainer
13. O-Ring Seal
14. Main Bearing
C07001
FIGURE 7-1. FAN CLUTCH CUTAWAY (Typical)

29. Clutch Hub
17. Sealring (Hook type) 30. Facing Plate
31. Steel Clutch Plate
20. Pulley
22. Sealring (large)
33. Main Bearing
23. Piston
34. O-Ring Seal
24. Sealring (small)
25. Spring Washer
36. Oil Seal
26. Shim
37. Washer
Fan Clutch
38. Bolt
39. Wear Sleeve
41. Sleeve Bearing
(rear, short)
42. Fan Mounting Hub
Assembly
44. Sleeve Bearing
(front, long)
45. End Cap
C7-7
FIGURE 7-4.
FIGURE 7-2.
1. Support the fan clutch on a bench with fan
mounting hub (42) facing upward. Support the
assembly beneath the pulley. Remove bolts
(38) and washers (37).
FIGURE 7-5.
FIGURE 7-3.
2. Install lifting eyes, and attach a hoist and chains
to front bearing retainer (35). Use a small
screwdriver to separate the front bearing
retainer from pulley adapter (21), and set it
aside on a bench.
C7-8
3. Remove O-Ring seal (34).
Fan Clutch
4. Position the bearing retainer and hub assembly

on the bench with clutch hub (29) up. Remove
external snap ring (28).
C07001
FIGURE 7-8.
FIGURE 7-6.
7. Remove front oil seal (36).
5. Remove clutch hub (29).
FIGURE 7-9.
FIGURE 7-7.
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
8. Remove internal snap ring (32).
C7-9
FIGURE 7-10.
FIGURE 7-12.
9. Turn bearing retainer (35) over on the press
bed. Press front bearing (33) out of the bearing
retainer using tooling (D).
11. Remove front retainer/seal assembly (40).

Wedge a large chisel or other appropriate tool
behind the retainer to force it off fan mounting
hub (42).
FIGURE 7-13.
FIGURE 7-11.
10. Support beneath the fan mounting hub with end
cap (45) down, but approximately 2 in. (50 mm)
above the press bed. Using a solid steel bar or
equivalent, press the end cap from the fan
mounting hub.
C7-10
Use a chisel to make three indentations in wear

sleeve (39) in order to loosen the sleeve. The indentations should be approximately 120 apart from one
another. Remove the wear sleeve.
Use caution when using the chisel. Do not cut
through the sleeve. Damage to the shaft can
cause future leaks.
Fan Clutch
C07001
FIGURE 7-14.
12. Inspect sleeve bearing (44) and sleeve bearing
(41). Compare the color of each bearing to the
chart below. The lighter the appearance of the
bearing, the more worn it is. If either bearing
needs replacing, proceed to the next step. If the
bearings are in good condition, skip the next
step.
FIGURE 7-16.
14. Remove the stack of facing plates (30) and steel
clutch plates (31) from inside the pulley.
FIGURE 7-17.
FIGURE 7-15.
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
15. Remove external snap ring (27), shim (26), and

spring washer (25).
Fan Clutch
C7-11
FIGURE 7-20.
FIGURE 7-18.
16. Attach wire lifting hooks to piston (23). Use the
lifting hooks to pull the piston from pulley
adapter (21).
18. Support beneath the pulley to prevent it from

dropping to the bench. Remove bolts (9) with
lockwashers (8).
FIGURE 7-19.
FIGURE 7-21.
17. Remove seal rings (22 & 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 Oring 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 phillipshead 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 remove the
pitot tubes from the hole in the shaft.
FIGURE 7-24.
22. Remove external snap ring (16).
FIGURE 7-23.
21. Remove both seal rings (17).
C07001
FIGURE 7-25.
23. Remove internal snap ring (15).
Fan Clutch
C7-13
FIGURE 7-28.
26. Use tooling (E) to press rear bearing (14) out of

rear bearing retainer (11).
FIGURE 7-26.
24. Support the bearing retainer as close as possible to the bearing bore. Use care not to damage
the retainer/seal assembly. Press the shaft out
of bearing (14) using tooling (E).
FIGURE 7-29.
FIGURE 7-27.
25. Remove oil seal (10) from bearing retainer (11).
C7-14
27. Use a chisel to make three indentations in wear

sleeve (4). The indentations should be approximately 120 apart from one another. Remove
the wear sleeve. Use caution when using the
chisel. Damage to the shaft can cause future
leaks.
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 snaprings - Must not be damaged or worn. Must be flat and have square edges at outer diameter.
External snaprings - Must not be damaged or worn. Must be flat and have square edges at inner diameter.
Sealrings - Replace during rebuild.
Oil seals - Replace during rebuild.
Bolts & 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 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 0.121 in. minimum thickness (new) and must be flat within
0.005 in.
9. Inspect facing plates (30). New minimum thickness for facing plates is 0.109 in. Grooves are
0.006 in. deep. The plates must be flat within
0.005 in. Check teeth for excessive wear. When
new, the space between the teeth is approximately 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 - FAN CLUTCH

NOTE: The fan clutch is reassembled using Loctite
(or equivalent) sealants. Follow manufacturer's
recommendations regarding minimum cure time to
prevent oil from washing the sealant from the sealing
surfaces.
1. Place end cap (45) in a freezer or on dry ice to
prepare for installation in the following steps.
FIGURE 7-39.
2. If removed, install dowel pin (43) into fan

mounting hub assembly (42). Refer to Figure
####. Press the pin into the hub leaving 0.090
in. (2.3 mm) exposed.
If the shaft did not originally come with
pinned bearings, install the dowel per
instructions in Figures # and ########.
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.
Again 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
0.040 in. (1.0 mm) below the shoulder.
Check carefully to insure 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 after
assembly.
Front
wear
sleeve
(39)
is
NOT
interchangeable with rear (notched) wear
sleeve (4). The ID of the front wear sleeve is
color coded red.
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.
FIGURE 7-45.
6. Coat the I.D. of front wear sleeve (39), and the

wear sleeve diameter of the shaft with Loctite
Primer N and #242 (or equivalent). Using tooling (D), press the wear sleeve onto the shaft,
flush with the shoulder.
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
surfaces of front bearing (33) and front bearing
retainer (35). Place the bearing into position on
the retainer with the notch for the bearing pin
facing downward.
Press the front bearing into the bearing retainer
using tooling (E) or equivalent. Press ONLY on
the outer race of the bearing until it seats at the
bottom of the bore.
C07001
10. Turn the retainer over on the press bed. Coat

the O.D. of front oil seal (36) and mating surface
on the bearing retainer with Loctite Primer N
and #242 (or equivalent). Use tooling (E) to
press the oil seal into the front bearing retainer,
flush with the front face. Ensure the lip of the
seal is dry. Wipe any excess Loctite from the
seal area and remove any rubber strings from
the seal.
Fan Clutch
C7-23
FIGURE 7-50.
11. Coat the bearing I.D.and the fan mounting hub
bearing journal with Loctite Primer N and #609
(or equivalent). Place the front bearing retainer
sub-assembly into position on the fan mounting
hub. (Ensure the notch in the bearing is aligned
with the bearing dowel pin.) Do not allow the
seal lip to come in contact with the Loctite.
Press the bearing onto the hub using tooling (D)
until it contacts the wear sleeve.
FIGURE 7-51.
12. Install clutch hub (29) on the fan mounting hub
assembly (42) with the open end down. (No
special timing is necessary.)
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 the rear retainer/seal

assembly (5) onto shaft (6). The inner race of
the retainer should be recessed 0.040 in. (1.0
mm) below the shoulder.
Check carefully to insure 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 after
assembly.
FIGURE 7-54.
14. If removed, install rear dowel pin (2) in shaft

assembly (6). Press the pin until 0.080 in. (2.0
mm) 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 OD 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. Press the bearing into the bearing
retainer using tooling (F) or equivalent. 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 ID 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 I.D. of the 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 lube
hole in the shoulder. Press the wear sleeve onto
the fan mounting hub, flush with the shoulder
using tooling (D).
C7-26
FIGURE 7-58.
18. Install internal snap ring (15).
Fan Clutch
C07001
FIGURE 7-59.
19. Some fan clutches were assembled with an external snapring that is used as a spacer between the bearing
and the oil seal. Newer models were assembled using a notched spacer. If an external snapring was used,
place the snapring (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 following step.
FIGURE 7-60.
FIGURE 7-61.
20. Coat the O.D. of rear oil seal (10) with Loctite
Primer N and #242 (or equivalent). Use tooling
(E) or the equivalent to install the oil seal in the
rear bearing retainer, flush with the rear face.
Do not lubricate the seal. The seal is made of
teflon and must be installed dry.
C07001
21. If a bearing spacer is used instead of a snapring

as explained in Step 19, place the spacer into
position in the groove on shaft assembly (6).
Note the location of the spacer in Figure (7-61).
Fan Clutch
C7-27
FIGURE 7-62.
FIGURE 7-63.
22. Place the shaft sub-assembly on the press bed.

Coat the bearing I.D., and bearing journal on
the shaft with Loctite Primer N and #609 (or
equivalent).
23. Install external snap ring (16). Ensure the

snapring is fully seated in the groove. It may be
necessary to tap on the snapring with a screwdriver to fully seat the snapring.
Carefully, lower the rear bearing retainer subassembly 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 snapring (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 interference is found, remove the bearing retainer and
eliminate the point of interference.
FIGURE 7-64.
24. Be sure 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
C7-28
Fan Clutch
C07001
tube to approximately 0.75 in. (20 mm) from the

end.
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 counter-clockwise 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 conveniently 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. Install small seal ring (24) in the inside groove,
and large seal ring (22) in the outside groove of
piston (23). Lubricate the seal ring grooves with
an oil-soluble lubricant such as engine assembly grease before installation. Refer to the 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 apart from one another.
FIGURE 7-67.
27. Lubricate the external surfaces of seal rings (22

& 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
28. Carefully, place the piston in the pulley.

Do Not push the piston in place!
Without pressing down on the piston, rotate it
slowly clockwise-counterclockwise until it falls
into place. (Forcing the piston will usually cause
the seal rings to be cut.)
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 easy 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.
Then, rotate the bearing retainer (and piston)
until the bolt holes align in the bearing retainer
and pulley. Carefully, remove the bearing
retainer sub-assembly.
FIGURE 7-70.
31. Place the front bearing retainer sub-assembly
on the bench with the clutch hub up.
Install one steel clutch plate (31) in place in the
bearing retainer. Now dip a facing plate (30) in
new engine oil, allow the excess to drain off,
and place the 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 apart. Install a guidebolt 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 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) and snug. Insert the bolts 90 apart.
FIGURE 7-72.
C07001
Fan Clutch
C7-31
FIGURE 7-76.
FIGURE 7-74.
36. Install bolts (9) with lockwashers (8), and torque

each one to 36-43 ft. lbs. (49-58 Nm).
34. Lubricate O-Ring seal (13) with petroleum jelly

or an oil-soluble grease and install in the pulley
groove.
FIGURE 7-77.
FIGURE 7-75.
35. Lubricate the hook type sealrings (17) on the
shaft assembly. Carefully lower the shaft subassembly 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
37. If removed, install orifice fitting (1) in the "oil in"

port of the bracket.
Fan Clutch
C07001
FIGURE 7-78.
38. Turn the assembly over on the bench. Install the remaining bolts (38) and lockwashers (37), and torque all to
36-43 ft. lbs. (49-58 Nm).
C07001
Fan Clutch
C7-33
TEST PROCEDURE
1. The fan clutch should be fully locked up with 40 psi oil pressure supplied at the control pressure port.
2. Operate the fan clutch with 180 F (82 C) 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 the fan mounting hub is allowed to rotate freely while the clutch is
engaged.
The fan clutch rotation causes the pitot tubes to pump lubrication 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 ELECTRIC SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
24VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1
BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-1
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 when the engine is running.
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 those working in the areas of the deck, electrical cabinet, traction motors, and retarding grids. The
following procedures will ensure the electrical system is properly discharged before repairs are started.
D01033
Index
D1-1
TRUCK SHUTDOWN PROCEDURE

1. Reduce the engine speed to idle. Place the selector switch in NEUTRAL and apply the parking brake.
Be certain the parking brake applied indicator lamp in the overhead panel is illuminated.
2. Place the drive system in the rest mode by turning the rest switch on the instrument panel ON. Be
certain the rest warning lamp is illuminated.
3. Shut down the engine using the keyswitch. If, for some reason the engine does not shut down, use
the shutdown switch on the center console.
4. After approximately 90 seconds, verify the steering accumulators have bled down by attempting to
steer.
5. Verify the link voltage lights on the electrical cabinet and the DID panel in the cab are OFF. If they
remain on longer than 5 minutes after shutdown, the propulsion system must be inspected by a technician trained to investigate the cause.
6. Place the GF cutout switch, located in the information display panel at the left side of the electrical
control cabinet in the CUTOUT position.
AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR AND

ITS CIRCUITS TO DE-ENERGIZE.
Do not attempt to perform auxiliary blower motor or blower electrical circuit repairs until it has
been verified the system is de-energized.
D1-2
Index
D01033
SECTION D2
24VDC ELECTRIC 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
Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Battery Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Isolation Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6
24VDC Auxiliary Battery Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6
Battery Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7
D02025
24 VDC Electric Supply System
D2-1
NOTES
D2-2
D02025
24VDC ELECTRIC SUPPLY SYSTEM

ELECTRICAL SYSTEM DESCRIPTION
The Komatsu truck utilizes a 24VDC electrical system which supplies power for engine starting circuits
and most non-propulsion electrical components. The
24VDC engine starting circuit is supplied by four,
heavy duty type 8D, 12 volt storage batteries. Several components require 12VDC and are supplied by
circuits tapped off the starting batteries. Two, smaller,
12VDC batteries (type 4D) supply 24VDC for the
non-propulsion components; engine control system,
circuit relays, indicator lamps, etc.
The batteries are of the lead-acid type, each containing six 2-volt cells. With the engine off, power is supplied by batteries. During engine cranking, power is
supplied by the four engine cranking batteries only.
When the engine is running, power is supplied by an
engine driven high capacity alternator.
Do Not smoke or allow flame around a dead battery or during the recharging operation. The
expelled gas from a dead cell is extremely explosive.
Excessive consumption of water indicates leakage or
overcharging. Normal water usage for a unit operating eight hours per day is about one to two ounces
per cell per month. For heavy duty operation (24
hour) normal consumption should run about one to
two ounces per cell per week. Any appreciable
increase over these figures should be considered a
danger signal.
Troubleshooting
Lead-acid storage batteries contain sulfuric acid,
which if handled improperly may cause serious
burns on skin or other serious injuries to personnel. Wear protective gloves, aprons and eye protection when handling and servicing lead-acid
storage batteries. See the precautions in Section
A of this manual to insure proper handling of batteries and accidents involving sulfuric acid.
Two most common troubles that occur in the charging system are undercharging and overcharging of
the truck's batteries.
An undercharged battery is incapable of providing
sufficient power to the truck's electrical system.
Some possible causes for an undercharged battery
are:
Sulfated battery plates
During operation, the storage batteries function as an

electrochemical device for converting chemical
energy into the electrical energy required for operating the accessories when the engine is shut down.
Loose or corroded battery connections

Defective wire in electrical system
Loose alternator drive belt
A defective alternator
BATTERIES
Maintenance and Service
The electrolyte level of each cell should be checked
at the interval specified in Lubrication and Service,
Section P, and water added if necessary. The proper
level to maintain is 3/8 - 1/2 in. (10-13 mm) above the
plates. To insure maximum battery life, use only distilled water or water recommended by the battery
manufacturer. After adding water in freezing weather,
operate the engine for at least 30 minutes to thoroughly mix the electrolyte.
D02025
Overcharging, which causes overheating, is first indicated by excessive use of water. If allowed to continue, cell covers will push up at the positive ends
and in extreme cases the battery container will
become distorted and cracked.
Leakage can be detected by continual wetness of the
battery or excessive corrosion of the terminals, battery carrier and surrounding area. (A slight amount of
corrosion is normal in lead-acid batteries). Inspect
the case, covers and sealing compound for holes,
cracks or other signs of leakage. Check battery hold
down connections to make sure the tension is not
great enough to crack the battery, or loose enough to
allow vibration to open the seams. A leaking battery
should be replaced.
D2-3
To remove corrosion, clean the battery with a solution

of ordinary baking soda and a stiff, non-wire brush
and flush with clean water. Make sure none of the
soda solution is allowed into the battery cells. Be
sure terminals are clean and tight. Clean terminals
are very important in a voltage regulated system.
Corrosion creates resistance in the charging circuit
which causes undercharging and gradual starvation
of the battery.
NOTE: When washing batteries, make sure cell caps
are tight to prevent cleaning solution from entering
the cells.
Addition of acid will be necessary if considerable
electrolyte has been lost through spillage. Before
adding acid, make sure battery is fully charged. This
is accomplished by putting the battery on charge and
taking hourly specific gravity readings on each cell.
When all the cells are gassing freely and three successive hourly readings show no rise in specific gravity, the battery is considered charged. Additional acid
may now be added. Continue charging for another
hour and again check specific gravity. Repeat the
above procedure until all cells indicate a specific
gravity of 1.260-1.265 corrected to 80F (27C).
NOTE: Use 1.400 strength sulfuric acid when making
specific gravity adjustments. Acid of higher strength
will attack the plates and separators before it has a
chance to diffuse into the solution.
If the temperature of the electrolyte is not reasonably
close to 80F (27C) when the specific gravity is
taken, temperature should be corrected to 80F
(27C):
The rate of self-discharge of a battery kept at 100F

(38C) is about six times that of a battery kept at
50F (10C) and self-discharge of a battery kept at
80F (27C) is about four times that one at 50F
(10C). Over a thirty day period, the average self-discharge runs about 0.002 specific gravity per day at
80F (27C).
To offset the results of self-discharge, idle batteries
should receive a booster charge (not a quick charge)
at least once every thirty days. Batteries allowed to
stand 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 sulfated battery may be restored to
limited service by prolonged charging at a low rate
(approximately normal rate).
An undercharged battery is extremely susceptible to
freezing when allowed to stand in cold weather.
The electrolyte of a battery in various stages of
charge will start to freeze at temperatures indicated
in the table.
The temperatures in the table below indicate the
points at which the first ice crystals appear. Lower
temperatures must be reached for a solid freeze.
Solid freezing of the electrolyte may crack the battery
case and damage the positive plates. As will be
noted, a charged battery is in no danger of freezing,
therefore, a charge or better is desirable, especially
during winter weather.
For every 10F (5C) below 80F (27C), 0.004

should be SUBTRACTED from the specific
gravity reading.
Specific Gravity
Corrected to 80 F (27 C)
Freezing
Temperature
Degrees
For every 10F (5C) above 80F (27C), 0.004

should be ADDED to the reading.
1.280
-90 F (-70 C)
1.250
-60 F (-54 C)
1.200
-16 F (-27 C)
1.150
+5 F (-15 C)
1.100
+19 F (-7 C)
Idle batteries should not be allowed to stand unattended. If equipment is to stand unused for more
than two weeks, the batteries should be removed
and placed in a cool, dry place where they may be
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 is more pronounced in warm weather than in
cold.
D2-4
D02025
BATTERY SUPPLY SYSTEM
Battery Control Box
24VDC Battery Charging Alternator

Refer to Section D, Battery Charging Alternator for
information regarding the truck battery charging
alternator.
Battery Box
The truck batteries are located in an enclosure (1,
Figure 2-1) in the center of the truck behind the front
bumper. For access to the batteries, remove the two
covers by turning the cover handles counterclockwise until released. Lift eyes are attached to the
ends of the enclosure if the entire battery container
must be removed.
Four, type 8D batteries (2) are installed in the battery box and are used for the 24VDC engine cranking circuit and the 12VDC circuits. Two Type 4D
batteries (3) are installed to provide 24VDC for the
truck systems other than engine starting. A system
battery starter disconnect relay isolates these batteries from the engine starter circuit during engine
cranking.
The battery control box (4) is located near the right

corner of the front bumper. This box contains the
battery disconnect switches and other components
listed below.
Isolation Diodes
Schottky type isolation diodes are used to provide
isolation between the system and the starter battery
circuits, and in the dual starter motor start command
circuits. These devices control the direction of current flow in high current applications.
The battery system isolation diode (8) allows charging current from the battery charging alternator to
charge both system batteries, but prevents current
flow from the system batteries to the starter motors
when the engine is started.
The engine starter system isolation diode (4) provides current flow from the cranking batteries
through the engine start relay (described below) to
the starter motor engagement drives.
FIGURE 2-1. BATTERY BOX AND BATTERY CONTROL BOX

1. Battery Box
2. Engine Cranking Batteries
D02025
3. System Batteries
4. Battery Control Box
D2-5
Battery Disconnect Switches

The three battery switches provide a convenient
method of disconnecting the truck batteries from the
truck electrical circuits.
The rear disconnect switch (2) opens the starter battery circuit only, preventing engine start-up while still
allowing battery power to the 24VDC control system
circuits if desired.
The front switches are ganged to ensure both are
opened or closed at the same time. The middle
switch (3) disconnects the 24VDC circuit and the
front switch (4) controls the 12VDC circuit.
24VDC Auxiliary Battery Connectors
Two pairs of receptacles (5), located adjacent to the
battery disconnect switches are provided to attach
battery charger leads for charging the truck batteries.
In addition, these receptacles can be used for connecting external batteries to aid engine starting during cold weather. When external batteries are used,
they should be of the same type (8D) as the batteries
installed on the truck. Two pairs of batteries should
be used. Each pair should be connected in series to
provide 24VDC, with one pair connected to the top
receptacle and the other pair connected to the bottom receptacle on the truck.
FIGURE 2-2. BATTERY CONTROL BOX

1. Battery Control Box
2. Starter Circuit
Disconnect Switch
3. 24 VDC Circuit
Disconnect Switch
4. 12 VDC Circuit
Disconnect Switch
5. Auxiliary Battery
Connectors
6. 12 VDC Circuit
Breaker
7. Isolation Diodes
8. Battery Equalizer
NOTE: If both the truck cranking batteries and

the system batteries are discharged, the system
batteries must be recharged before attempting to
start the engine. The external starting batteries
provide additional current for starter motor operation only. The system batteries are disconnected from the external (auxiliary) batteries and
the truck mounted cranking batteries while the
engine starter is engaged.
Battery Equalizer
The majority of the accessory and control circuits
operate at 24VDC. Several components however,
require 12VDC (cab window regulator motors, cassette/radio, cigar lighter etc.).
A battery equalizer (8) system is utilized to obtain the
required 12VDC and ensure that all the truck batteries are charged and discharged equally.
A 50 amp circuit breaker (6) mounted in the box protects the 12VDC circuits.
D2-6
D02025
Troubleshooting
Normal battery maintenance procedures should be
followed according to the intervals specified in the
"Lubrication and Service" section of this manual.
Refer to the "Battery" information in this section for
detailed instructions regarding proper battery maintenance and service procedures. Prior to troubleshooting the battery equalizer system, inspect all battery
circuit connections for excessive corrosion, loose
cables, ground connections etc. Use the following
procedure to check the system if a problem occurs:
1. Check the 12VDC circuit breaker.
a. If the circuit breaker has opened, check circuits and repair cause.
4. If alternator voltage is outside above limits, refer

to Section D, Battery Charging Alternator, service information.
5. With the engine running, verify voltages at the
battery equalizer terminals.
a. Measure the voltage between the 24 volt and
12 volt terminals.
b. Measure the voltage between the 12 volt terminal and ground.
6. If the difference between the voltage measurements above exceeds 0.75 volts, the battery
equalizer is defective and should be replaced.
b. Reset circuit breaker.

2. Check other applicable circuit breakers to determine if one or more has opened. (Refer to Circuit Breaker Chart in the following Section for a
list of circuit breakers and the circuits involved.)
a. If the circuit breaker has opened, check circuits and repair cause.
b. Reset circuit breaker.
Always open main battery disconnect switches

prior to removing or connecting any wires or
cables on the battery equalizer terminals.
3. Check battery voltage with the battery equalizer

connected and the engine running.
a. Verify battery charging alternator output is
27.8 to 28.2 volts.
D02025
D2-7
NOTES
D2-8
D02025
SECTION D3
24VDC ELECTRICAL SYSTEM COMPONENTS
INDEX
24 VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
PASSENGER SEAT BASE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
TRUCK SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
Tail Light Resistor Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
5 Minute Idle Timer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
5 Minute Idle Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
5 Minute Idle Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
5 Minute Idle Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
5 Minute Idle Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
Brake Warning Buzzer (BWB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
Alarm Indicating Device (AID) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
Coolant Level/Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
Temperature and Latch Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6
Hot Switch Inverter Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6
Hot Switch Inverter Card (Slot 4) (Not Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7
Oil Level Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7
Temperature Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7
Diode Matrix (Without Sound) Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7
Diode Matrix (With Sound) Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7
Lamp Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7
Electrical Interface Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Lubrication System Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Lincoln Lube Delay Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Barometric Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
D03024
24 VDC System Components
D3-1
Pulse Voltage Modulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8

Power Distribution Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Truck Control Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Kontrol Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Circuit Breaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8
Diode Board - DB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10
Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10
Relay Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11
Relay Boards: RB1, RB2, RB3, RB4, RB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11
Relay Board Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-12
Relay Board Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-13
Installing Additional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-14
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
CIRCUIT BREAKER CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-17
D3-2
D03024
24 VDC ELECTRICAL SYSTEM COMPONENTS

PASSENGER SEAT BASE
COMPARTMENT
COMPONENTS
The 24 VDC electrical system components shown in

Figure 3-1 are accessed by unlatching the passenger
seat base lid and tilting the passenger seat forward.
The electrical schematics in Section R should be
used when troubleshooting problems with the following components.
Do not attempt repairs until the truck is properly

shut down. Dangerous voltage levels are present
in the propulsion system while the engine is running and for a period of time after shutdown.
Refer to the Section D Index for additional warnings.
TRUCK SHUTDOWN PROCEDURE

illuminated.
2. Place the drive system in the rest mode by
turning the rest switch on the instrument panel
ON. Be certain the rest warning lamp is illuminated.
console.
4. Verify the link voltage lights on the electrical
cabinet and next to the DID panel in the cab are
off. If they remain on longer than 5 minutes after
shutdown, the propulsion system must be
inspected by a technician trained to investigate
the cause.
position throughout test and troubleshooting
procedures. (See Figure 3-1, page E3-4, Propulsion System, for switch location.)
D03024
Tail Light Resistor Diode Assemblies

The tail light resistor diode assembly RD1, RD2 (2,
Figure 3-1) is a circuit designed to vary the intensity
of each of the stop/tail lamp bulbs.
With the tail lights on, a resistor in series with the
lamp reduces voltage supplied to the lamp, thereby
reducing the lamp intensity. When the service brakes
are applied and the stop lights are activated, current
flows from the stop light relay, through a diode,
bypassing the resistor and applies 24 VDC to the
lamp filament.
RD1 controls the left lamp and RD2 controls the right
lamp. No adjustments are available or necessary.
5 Minute Idle Timer Components
The 5 minute idle timer circuit automatically provides
approximately 5 minutes engine idle time before
actual engine shutdown occurs. This system allows
the engine cooling system to circulate coolant to
reduce and stabilize engine component temperatures, when engine power requirements are minimal,
resulting in extended engine life.
The circuit is controlled by a 3-position rocker switch.
Pressing the bottom of the switch will turn the circuit
off. The engine will shut down by use of the key
switch, console mounted engine shutdown switch, or
the ground level shutdown switch.
With the 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 immediately using
any one of the three switches described above.
When the top of the switch is depressed and held
momentarily, the idle timer circuit is activated. When
released, the switch will return to the ON (middle)
position, and the 5 minute idle timer circuit is latched
on through the switch. The engine will not shut down
with the key switch. Moving the key switch to the
OFF position, will cause the engine to shut down
after the 5 minute time delay is completed. The normal shutdown sequence will then occur.
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 console shutdown
switch is depressed, or the ground level shutdown
switch is activated, the engine will shut down immediately, followed by the normal shutdown of all systems.
D3-3
FIGURE 3-1. PASSENGER SEAT BASE COMPARTMENT

1. Seat Base
2. Tail Light Resistor/Diodes
(RD1/RD2)
3. Terminal Board (TB13)
D3-4
6. 5 Minute Idle Timer

7. 5 Minute Idle Contactor
8. Inclinometer
9. Hoist Control
10. Compartment Service Light
11. Brake Warning Buzzer (BWB)
12. 5 Minute Idle Relay

13. Connector (RP226)
16. AID Module
D03024
5 Minute Idle Timer
Brake Warning Buzzer (BWB)
The 5 minute idle timer (6) circuit is activated when

the operator presses the 5 minute idle timer engine
shutdown switch mounted on the instrument panel.
(This is a momentary switch that also latches the 5
minute idle timer in the energized position.) When the
timer is energized, internal contacts close and energize the relay and contactor described below.
The brake warning buzzer (11) provides an audible

alarm for the operator if a malfunction occurs in the
hydraulic service brake system. Refer to Section J for
additional operational details.
5 Minute Idle Relay

The relay (12) contacts close when the idle delay
timer is energized. When the contacts are closed, the
AID system indicator light circuit (12M) is grounded
through the "5 minute idle timer" indicator lamp on
the overhead display, turning the lamp on.
Alarm Indicating Device (AID) System

The alarm indicating device (16, Figure 3-1) used on
Komatsu trucks is a device which is connected in the
electrical accessories circuits to provide the operator
with a warning indication of a malfunction. This system consists of up to eight printed circuit cards,
located under the passenger seat in the operators
cab. The actual quantity of cards will depend on
options installed on the truck.
The contactor (7) energizes the idle timer and maintains current flow to the engine "run" circuit if the
operator turns the key switch off.
The AID system enables the indicating lights to be

flashing or constant. The AID also has the capability
of operating an audible alarm along with the light.
The eight printed circuit cards are (refer to Figure 32):
5 Minute Idle Circuit Test
Diode Matrix (With Sound) Card (Slot 1)
Check 5 minute idle timer circuits as follows:
Diode Matrix (Without Sound) Card (Slot 2)
1. With the key switch ON, press the engine shutdown switch firmly to the momentary position
and release (switch will return to the ON position).
Hot Switch Inverter Card (Slot 3)
Hot Switch Inverter Card (Slot 4) (Not Used)
Temperature Card (Slot 5) (Optional)
2. Turn the key switch OFF and verify the following:
Oil Level Card (Slot 6) (Optional)
Temperature and Latch Card (Slot 7)
Circuit 712 (to ground) remains 24 volts for

approximately 5 minutes. After 5 minutes, the
voltage drops to 0.
Coolant Level and Flasher Card (Slot 8)
5 Minute Idle Contactor
The 5 minute idle indicator lamp on the

overhead display is on when circuit 712 reads
24 volts.
3. Repeat step 1. While monitoring voltage at circuit 712, turn the key switch OFF. Turn the
engine shutdown switch OFF.
Verify voltage at circuit 712 drops to 0 when
the shutdown switch is turned to OFF.
NOTE: Each card is identified with a number which

corresponds with a mating number on the housing. If
cards are removed, make sure card numbers
correspond with housing numbers during installation
(See Figure 3-2).
The following briefly describes each card and its
function. Refer to Section R for circuit components
described below.
Coolant Level/Flasher
Inclinometer
The inclinometer is used by the on-board load weighing system to determine whether the truck is on a
level surface or tilted fore or aft. The information provided by the inclinometer is sent to the weighing system for use in calculating the payload. Refer to
Section M, Payload Meter, for detailed information on
the inclinometer and the on-board weighing system.
D03024
The coolant level and flasher card contains two separate circuits. The flasher circuit at the top of the card
has Q12 transistor biased to be saturated when no
malfunction is present, resulting in there being 24 volt
positive output on pin "H" of the card and on wire
12F. When a indicating circuit is activated, the ground
side of the circuit connected to card pin "K" is
grounded. Q12 will turn off initially and then after a
delay, adjusted by R20, will turn on and off to give the
intermittent 24 volt output.
D3-5
Temperature and Latch Card

The temperature and latch card has two circuits to
operate two different indicating lights. The temperature circuit is controlled by a coolant temperature
sensor which decreases electrical resistance as its
temperature increases. It will have a resistance of
approximately 1000 ohms at 185F (85C) and 500
ohms at 250F (122C). Normal setting is 204F
(96C).
When the temperature is low and the resistance is
high, Q1 is off and no high temperature indication
occurs. When the coolant temperature is excessive,
resistance decreases to a point where Q1 will turn on
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 resistor is installed to replace the
temperature sensor and disable the AID system
circuit.
FIGURE 3-2. AID SYSTEM CARD ENCLOSURE

1. Diode Matrix With Sound
2. Diode Matrix Without Sound
3. Hot Switch Inverter
4. Hot Switch Inverter
5. Temperature & Latch
6. Coolant Level & Flasher
The other half of the circuitry on the coolant level and
flasher card operates the coolant level light. The
water level probe connected to terminal B11 grounds
the 31L circuit when the coolant in the radiator is
above the probe position. The coolant saturates the
probe and electrically grounds the circuit. When the
circuit is grounded, Q6 transistor is off, resulting in no
indication. When the coolant level drops below the
probe, 31L is no longer grounded and Q6 turns on to
ground the flasher through D5, ground the coolant
level light through terminal D11, and ground the
alarm horn through D6. The light and alarm horn will
operate intermittently as their 24 volt supply is from
circuit 12F, the flasher output.
NOTE: Some electronic engine controls monitor
coolant level. If the engine controls monitor the
circuit, a 2K resistor is installed to replace the
probe and disable the AID system circuit.
D3-6
The latch circuit monitors the accumulator precharge

pressure switches. When one of the pressure
switches closes, Q5 will be turned off which supplies
power to the gate of SCR Q7. 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.
Hot Switch Inverter Card

The hot switch inverter card (slot 3) 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.
Transistor Q4 is turned on by this voltage and, in
turn, grounds the service brake Indicator Light. There
is no alarm horn operation with this card.
A second circuit on this card is used to operate and
test the retard speed control indicator light. When
RSC is turned Off, transistor Q7 is off and the 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.
D03024
Hot Switch Inverter Card (Slot 4) (Not Used)
Diode Matrix (With Sound) Card
Oil Level Card
The diode matrix with sound card works very much

like the other diode matrix card, except that it contains extra diodes to activate the alarm horn in addition to the flasher. The circuits connected to terminals
A1 through A8 operate in the same manner.
The oil level card (optional) is used to turn on the low

oil level indicator light to warn the operator engine oil/
hydraulic tank oil level is below acceptable levels.
The oil float is connected to a variable resistor. As the
oil level decreases, the resistance goes down causing Q3 to turn on, grounding the indicator light and
alarm horn.
Temperature Card
The temperature card (optional) is used to turn on
the high oil temperature indicator light. The indicator
light tells the operator hydraulic tank oil temperature
has exceeded acceptable levels. Normal temperature setting is 250F (121C). As the temperature
goes up the resistance in the probe decreases providing a ground path for the indicator light and alarm
horn.
Lamp Test Switch

All of the card circuits are connected to the lamp test
switch on the overhead display area. In normal operation, these circuits are open and not functional.
When the operator pushes the lamp test switch, it
activates all the indicator circuits by grounding them.
This is used to verify that all lamps are functional.
Diode Matrix (Without Sound) Card

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 grounds 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.
D03024
D3-7
Electrical Interface Cabinet
Truck Control Interface Panel
The electrical interface cabinet (1, Figure 3-3) is

mounted near the rear of the cab and on the left side
of the main electrical control cabinet. The cabinet
houses various components for the 24VDC circuits,
engine controls and the Truck Control Interface (TCI)
panel.
The Truck Control Interface Panel (TCI) (6, Figure 33) is the main interface between truck systems and
devices and service personnel. This panel is used in
conjunction with the Diagnostic Information Display
(DID) located in the operator's cab.
The following information describes the components

in the cabinet and their operation. Additional, detailed
information for operation and troubleshooting procedures not included below can be found in Section E
of this manual, the engine manufacturer's service
publications and the appropriate G.E. publications.
Refer to Section R in this manual for system schematics. Refer to Figure 3-3 for location of the following components.
The TCI panel provides the following functions:
Communicates with the Propulsion System

Controller (PSC) to exchange propulsion control
system status and control data and to provide
the PSC with truck systems status data.
Communicates with the Diagnostic Information

Display (DID) to exchange PSC and/or TCI
diagnostic and parameter data. Refer to Section
E for additional information.
Communicates with the auxiliary blower system

to exchange diagnostic data.
Communicates with a Portable Test Unit (PTU) to

exchange TCI PTU data.
Communicates with a modular mining dispatch

system to exchange truck status data.
Monitors engine control system, payload

information, ambient and propulsion system
temperature, operator control inputs etc.
Controls the engine start sequence.
Provides signals to activate many of the cab

mounted warning lamps and gauges. Controls
the park brake solenoid.
Processes front wheel speed signals for the

PSC.
Lubrication System Timer

Automatic lubrication system activation frequency
can be adjusted by removing the timer (4) 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,
Automatic Lubrication System for additional details.
Lincoln Lube Delay Timer
This 1 minute signal delay timer (22) allows the lube
system to attain normal grease pressure without activating the low pressure warning lamp on the overhead display.
Barometric Pressure Transducer
The barometric pressure transducer (9) monitors
barometric air pressure, providing a signal to the
Truck Control Interface panel (TCI) and Propulsion
System Controller (PSC).
Pulse Voltage Modulator
The Pulse Voltage Modulator (PVM) (2) receives a
load curve signal from the engine controls and converts it to a 0 to 10 volt signal for use by the Propulsion System Controller (PSC).
Power Distribution Terminals
A 24 VDC terminal (17) and a 12 VDC terminal (19)
are mounted on the left wall of the cabinet. These terminals distribute battery voltage and 12 VDC for
devices requiring reduced voltage. This 24 VDC terminal is a convenient test point for measuring battery
voltage during troubleshooting procedures.
D3-8
Kontrol Power Relay

The kontrol power relay (18) is energized when the
control power switch (located in the main electrical
cabinet) is turned on. This relay isolates the GE PSC
control power from the truck circuits and provides
power to non-propulsion system 24VDC components.
Circuit Breaker Panel

A panel (10) adjacent to the TCI panel in the electrical interface cabinet contains the cabinet service
lights on/off switch (1, Figure 3-4) and circuit breakers CB1 though CB12 (2). Refer to Circuit Breaker
Chart at the end of this section for functions and circuits.
D03024
FIGURE 3-3. ELECTRICAL INTERFACE CABINET

1. Cabinet Assembly
2. Pulse Voltage Modulator (PVM)
3. Relay Board (RB1)
4. Lincoln Lube System Timer
6. Truck Control Interface Panel
(TCI)
D03024
8. Cabinet Service Light

9. Barometric Pressure Transducer
10. Circuit Breaker Panel
15. Cable Entrance Panel

16. Diode Board (DB1)
17. 24 VDC Terminal
18. Kontrol Power Relay
19. 12 VDC Terminal
20. Cabinet Left Wall
21. Cabinet Right Wall
22. Lincoln Lube Delay Timer
D3-9
FIGURE 3-4. CIRCUIT BREAKER PANEL

1. Cabinet Service
Light Switch
2. Circuit Breakers
Diode Board - DB1

The diode board (16, Figure 3-3) contains replaceable diodes. Some of the diodes are used in the coil
circuit of various relays to suppress the resultant coil
voltage spike when power is removed from the circuit, preventing damage to other circuit components
(lamp filaments etc.). Other diodes are used to control the flow of current in a circuit as required. Resistors or diodes may also be installed in sockets P7
through P12 (3, Figure 3-5). Refer to the schematics
in Section R for specific circuits.
Diode board, DB1 contains 24 replaceable diodes.
The diodes are mounted on a plug-in connector for
easy replacement.
Diode Testing
Refer to the electrical schematic in Section R of this
manual for the specific circuit and diode to be tested.
If a diode failure is suspected, remove and check the
diode as follows:
1. Grasp the diode connector, compressing the
locking "ears" while pulling the connector off the
board. Note the connector "key" used to ensure
correct polarity.
NOTE: Some digital multimeters are designed to test
diodes. If this type is used, follow the manufacturer's
instructions for proper test.
D3-10
FIGURE 3-5. DIODE BOARD 1

1. Diode Board (DB1)
2. Connectors (P1-P6)
3. Sockets (P7-P12)
4. Diodes (D1-D23)
2. An analog ohmmeter can be used to test the

diode as follows:
a. Place the meter on the "x 100" scale.
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.
D03024
Relay Boards
Service
The electrical interface cabinet contains six relay

boards to provide control for many of the 24VDC circuits. Two types of boards are used; those containing
circuit breakers in addition to 24VDC relays and a PC
board for special functions, and a second type containing relays only.
To replace a relay:
All relays are interchangeable. The circuit breakers

are interchangeable, providing the circuit breaker
capacity is the same. Do not interchange or
replace any circuit breaker with one of a different
capacity than specified for the circuit. Serious
damage or a fire may result if the wrong capacity
breaker is used.
Relay Boards: RB1, RB2, RB3, RB4, RB5
Each relay board of this type is equipped with five
green lights (9, Figure 3-6) and one red light (7). Four
green lights are labeled K1, K2, K3, or K4. These
lights will be on only when that particular control circuit has been switched ON and the relay coil is being
energized. The light will not turn on if the relay board
does not receive the 24 volt signal to turn on a component. Each relay board has a 5th green light that
has a different function on each board.
The red breaker open light if (ON) indicates that a circuit breaker (on that relay board) is in the OFF position. A light on the overhead display will also
illuminate, informing the operator that a circuit
breaker is in the OFF position. The red breaker open
light will turn on whenever there is a voltage difference across the two terminals of a circuit breaker.
If a control switch has been turned ON and a green
(K) light is on, but that component is not operating,
check the following on the relay board for that circuit:
Check for a circuit breaker that is in the OFF
position or a red (breaker open) light is on. If
a circuit breaker is off, turn it ON. Check
operation of component. If it trips again,
check the wiring or component for cause of
overload.
The contacts inside the relay may not be
closing, or the contacts may be open,
preventing an electrical connection. Swap
relays and check again. Replace defective
relays.
Check the wiring and all of the connections
between the relay board and the component
for an "open" circuit.
NOTE: The relays are labelled to identify the

applicable circuits and components Also, refer to the
Circuit Breaker Chart 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 crossbar away.
3. Gently wiggle and pull outward to remove relay
(11).
4. Line up tabs and install new relay.
5. Place crossbar in original position and install
screw (10) that was removed and tighten both
screws.
To replace a circuit breaker:
NOTE: Always replace a circuit breaker with one of
the same amperage capacity as the one being
removed.
1. Place battery disconnect switches in the OFF
position.
2. Unplug all wiring harness(s) from relay board.
Remove four relay mounting screws and
remove relay board from truck.
3. Remove four hold down screws (3) (one in each
corner) in circuit breaker cover plate and all circuit breaker screws. Remove cover plate from
circuit breakers.
4. Remove nuts and star washer from back side of
circuit board that holds the breaker in place.
5. Lift out circuit breaker. Retain flat washers that
were between inner circuit breaker nut and
relay board.
6. Install one nut and two flat washers to each
pole on the circuit breaker. Nuts must be
adjusted to the same height as on the other circuit breakers. This is necessary so when cover
plate is installed, it will not press circuit breaker
into, or pull up on, the circuit board. Install new
circuit breaker of the same capacity rating as
the one removed.
7. Install star washer and nut to circuit breaker
poles (on the back side) and tighten nuts.
8. Install cover plate and all screws removed during disassembly.
Defective component. Replace component.

Poor ground at the component. Repair the
ground connection.
D03024
D3-11
To replace a circuit panel card
Relay Board Identification
DO NOT remove the small screws that hold the

cover plate to the circuit panel. Replace circuit panel
as a complete assembly.
The relay boards are identified as follows:

(Refer to Figure 3-3 for location.)
Relay Board 1 . . . . . . . . . Clearance/Turn Signal
Relay Board 2 . . . . . . . . . . . . . . . Payload Meter
2. Remove the two mounting screws (6, Figure 36) and carefully remove the circuit panel card
from the relay board.
Relay Board 3 . . . . Stop, Retard, Backup Lights
Relay Board 4 . . . . . . . . . . Parking Brake, Horn,

. . . . . . . . . . . . . . . . . Body-up, Engine Cranking
3. Line up the new circuit panel in slots and with

the socket on the relay board and install carefully.
Relay Board 5 . . . . . . . . . . . . . . . . . Head Lights
Relay Board 6 . . . . . . . . . . . . Engine Functions,

. . . . . . . . . . . . Mid/Full Load Signals to PSC,
. . Backup Lights & Horn, Park Brake Off Signal
Relay Board 7 . . . . Autolube Pressure Signals,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ether Start
1. Place battery disconnect switches in the OFF

position.
4. Install two mounting screws (6).
Refer to Circuit Breaker Chart for electrical circuit

identification numbers.
FIGURE 3-6. TYPICAL RELAY BOARD

(RB4 Shown)
1. Relay Board
2. Main Harness Connector
3. Screw
4. Circuit Breaker
5. Circuit Panel Card
6. Screw
7. Breaker Open Light (Red)
8. Bleed Down Light (Green) (Relay
Board 4 Only)
9. K1, K2, K3, K4 Lights (Green)
10. Screw
11. Relay
12. Circuit Harness Connector
13. Circuit Harness Connector
D3-12
D03024
Relay Board Functions

The following describes the components and functions of each relay board.
1 - rev light (green): This light is on whenever the

selector switch is in the REVERSE position, and the
key switch is in the ON position.
4 - 15 amp circuit breakers
Relay Board 1 (RB1)

1 - flasher power light (green): This light will be on
when the turn signals or hazard lights are activated.
>K1 light will be on during right turn signal operation
(CB16, CB17, CB18, CB19)

4 - relays
manual back-up lights relay (K1)
stop lights relay (K2)
retard lights relay (K3)
>K2 light will be on during left turn signal operation
slippery road relay (K4) (Not used)
>K3 light will be on when clearance lights are activated.
Relay Board 4 (RB4)
>K4 light will be flashing when the turn signals or

hazard lights are in operation.
1- steering pressure bleed down timer module card.
NOTE: If circuit breakers (CB13 & CB15) are in the

OFF position, no warning will be noticed until the
clearance light switch is turned ON.
1 - bleed down light (green): This light is on when the

bleeddown solenoid is being energized. The bleeddown timer will energize the solenoid for 90 seconds
after key switch is turned OFF.
1 - flasher module card.
2 - 5 amp circuit breakers (CB20, CB22)
3 - 15 amp circuit breakers (CB13, CB14, CB15)
1 - 15 amp circuit breaker (CB21)
4 - relays
4 - relays
right turn/clear light relay (K1)
park brake failure relay (K1)
left turn/clear light relay (K2)
engine cranking oil pressure interlock relay (K2)
clearance lights relay (K3)
horn relay (K3)
flasher relay (K4)
body up relay (K4)
Relay Board 2 (RB2)
Relay Board 5 (RB5)
1 - data storage module card.
1 - light display module card
1 - payload stored light (Green): This light is on for

one second when the payload meter actually stores
the load data into memory.
1 - lights control light (green): This light is on when 24

volts is being supplied to the battery terminal of the
light switch.
1 - 5 amp circuit breaker (CB29) (To payload meter)
5 - 15 amp circuit breakers

(CB23, CB24, CB25, CB26, CB27)
1 - 15 amp circuit breaker (CB28) (To payload lights

& relays)
4 - relays
4 - relays
left low beam relay (K1)
light relay 1 (Green) (K1)
right low beam relay (K2)
light relay 2 (Amber) (K2)
left high beam relay (K3)
light relay 3 (Red) (K3)
right high beam relay (K4)
light control relay (K4)
Relay Board 6 & 7 (RB6, RB7)
Relay Board 3 (RB3)

1 - light module display card
D03024
Relay boards 6 & 7 (Figure 3-7) do not contain circuit

breakers or modular cards. Additional circuits may be
added by utilizing a spare relay socket.
The following relays are installed on RB6:
D3-13
back-up lights & horn relay (K1)
Lincoln Lube low pressure relay (K3)
engine run/Ignition relay (K2)
engine start relay (K3)
Lincoln Lube pressure apply relay (K5)
engine retard speed relay (K4)
spare (K6)
engine run relay (K5)
spare (K7)
park brake off relay (K6)
spare (K8)
70% load signal to PSC relay (K7)
Installing Additional Circuits
full load signal to PSC relay (K8)
To add an additional circuit with a relay, connect the

wires as described below:
The control circuit for the relays are the "+" and "-"
terminals:
"+" terminal is for positive voltage.
"-" terminal is for grounding of the control circuit.
Either circuit can be switched "open" or "closed"

to control the position of the relay.
The terminals of the switched circuit from the relay

contacts are labeled as follows:
NC - Normally Closed
COM - Common
NO - Normally Open
>"COM" terminal is for the voltage source (protected

by a circuit breaker) coming into the relay which will
supply the electrical power for the component being
controlled.
>"NC" terminal is connected (through the relay) to
the "COM" terminal when the relay is not energized
(when the control circuit terminals "+" & "-") are not
activated).
>"NO" terminal is connected (through the relay) to
the "COM" terminal when the relay is energized (by
the control circuits "+" & "-") being energized).
FIGURE 3-7. RELAY BOARD 6 & 7
1. Relay Board
2. Terminal Strips
(TSI - TS8)
3. Relays (K1 - K8)

If relay board 6 or 7 must be removed and
replaced, be certain to note correct orientation of
board! Improper orientation will result in incorrect hookup to existing wire harness.
The following relays are installed on RB7:
ether start relay (K2)
D3-14
D03024
Body Up Switch
Adjustment
The body-up switch (3, Figure 3-8) is located inside

the right frame rail near the front of the body and
must be adjusted to specifications to ensure the
proper electrical signal is obtained when the body is
raised or lowered. The body-up switch is designed
to prevent propulsion in REVERSE when the dump
body is not resting on frame rails. The switch also
prevents forward propulsion with the body up unless
the override button is depressed and held.
Prior to adjusting the body-up switch, inspect body

pads for wear or damage and replace pads if
required. The body must be resting on the frame in
the normal body down position when adjustments
are made.
1. Loosen capscrews (2, Figure 3-8) and adjust
proximity switch bracket (3) to achieve an air
gap (dimension "A") between sensing area
(crosshatched area as marked on switch) and
actuator arm (4), of between 0.50 in. (12.7
mm) minimum and 0.62 in. (15.9 mm) maximum. Tighten capscrews after adjustment.
Operation
When the body is resting on the frame, actuator arm
(4) causes the electrical contacts in the magnetically
operated switch to close. When the body is raised,
the arm moves away from the switch, opening the
contacts. The electrical signal is sent to the control
system and the body-up relay.
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.
2. If necessary, loosen actuator arm mounting

capscrews (5), and position arm until centered
over sensing area of switch. Vertical set up
dimension ("B") should be 1.63 in. (41.5 mm).
Tighten capscrews after adjustment.
Service
Keep sensing area clean, free of metallic dust and
other debris that may damage or inhibit operation of
the proximity switch. If the switch is not functioning
or damaged, the unit must be replaced.
FIGURE 3-8. BODY-UP SWITCH ADJUSTMENT

1. Switch Mounting Bracket
2. Adjustment Capscrews
D03024
3. Proximity Switch
4. Actuator Arm
5. Adjustment Screws
D3-15
Hoist Limit Switch

The hoist limit switch (5, Figure 3-9) is located inside
the right frame rail above the rear suspension (near
the body pivot pin). The hoist limit switch is designed
to stop the hoist cylinders before reaching full extension, preventing possible damage to the dump body
or hoist cylinders.
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 components 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
With body raised and hoist cylinders within 6 in. (152
mm) of maximum travel, make the following adjustment.
1. Adjust limit switch to achieve an air gap (dimension "A") of 0.50 to 0.56 in. (12.70 to 14.30 mm)
between sensing area and actuator arm (3).
Retighten capscrews.
FIGURE 3-9. BODY LIMIT SWITCH ADJUSTMENT
Service
Keep sensing area clean, free of metallic dust and
other debris that may damage or inhibit operation of
the limit switch. If the switch is not functioning or
damaged the unit must be replaced.
D3-16
1. Body
2. Frame
3. Actuator Arm
4. Switch Mounting
Plate
5. Hoist Limit Switch
D03024
CIRCUIT BREAKER CHART

AMPS
DEVICE(S) PROTECTED
CIRCUIT
LOCATION
CB00
50
12 Volt Power Source
11B1
Battery Control Box
CB1
ECM Main Power
440
CB2
20
ECM Main Power
240M
CB3
20
ECM Main Power
241M
CB4
20
ECM Main Power
240R1
CB5
20
ECM Main Power
241R1
CB6
15
Engine Service Lights
11SL
CB7
10
Lincoln Lube Solenoids
68
CB8
10
Body-up Limit Switch/Solenoid
712H
CB9
10
Aux. Keyswitch Power
712A
CB10
10
Spare

CB11
15
Spare
CB12
Spare
CB13
15
Clearance Lights
11CL
RB1, Elect. Interface Cabinet
CB14
15
Turn Signals
11Z
CB15
15
RD1, RD2, & Tail Lights
41T
CB16
15
Dynamic Retard Lights
44C
CB17
15
Manual Back-up Lights
47B

CB18
15
Stop Lights
44A
CB19
15
Back-up Horn
79A
CB20
Control/Key Power, Kontrol Power Relay
439E, 712S, 71
CB21
15
Aux. Battery Power
11A
CB22
Control/Key Power, Engine Shutdown
23D
CB23
15
Low Beam Headlight, L.H.
11DL
CB24
15
Low Beam Headlight, R.H.
11DR
CB25
15
High Beam Headlight, L.H.
11HL
CB26
15
High Beam Headlight, R.H.
11HR
CB27
15
Headlight Switch
11D
CB28
15
Payload Meter
39J
CB29
15
Payload Meter
39G
CB30
15
Fog/Ladder Lights
11L
Power Distribution Module
CB31
15
Cab Heater/AC Blower Motor
12H
CB32
15
Warning Lights, A.I.D. Module
12M
CB33
Not Used
CB34
Not Used
CB35
Not Used
CB36
10
Cigar Lighter
CB37
10
Windshield Washer & Wiper
712W
CB38
Fuel, Engine Temperature, Oil Pressure, Voltmeter Gauges
712D
CB40A
Accessory Plug (12VDC)
12GE
CB40B
10
Radio/Cassette Player
11B4
CB41A
15
Cab Door Window, L.H.
11B6
CB41B
15
Cab Door Window, R.H.
11B7
CB42
15
Air Seat Compressor
712A

CB39
11B2
Not Used
CB43
10
Start Signal
21S
CB50
20
Communications Radio
SPR42/SPR46
CB51
20
Dispatch Radio
SPR43/SPR47
CB52
Not Used
CB53
Not Used
D03024
D3-17
NOTES
D3-18
D03024
SECTION D10
BATTERY CHARGING ALTERNATOR
INDEX
BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
BATTERY CHARGING SYSTEM (Niehoff) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5
TROUBLESHOOTING PROCEDURES (On-Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5
Equipment Required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
Regulator Bypass Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-7
ON VEHICLE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-9
ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage . . . . . . D10-9
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:. . . . . . . . . . . . . . . . . . . . . . . D10-9
CHARGE VOLT AND AMP VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-10
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-10
ADVANCED SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-11
Static Test - Engine OFF, Key ON, Battery Switch ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-11
Go To Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-11
Go To Regulator (If Required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-12
Go To Regulator Connector On The Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-12
ALTERNATOR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-13
ALTERNATOR DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-13
ALTERNATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-14
D10002
Battery Charging Alternator
D10-1
SERVICE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-15

ON-VEHICLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17
Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17
Preliminary Checks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17
Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-17
ON-VEHICLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-18
Bypass Test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-18
BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-19
STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20
Regulator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-20
Control Box Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-21
ALTERNATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-23
ASSEMBLY- ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-28
BF4822 STATOR SERVICE TOOL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-37
Stator Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-37
Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-38
D10-2
D10002
BATTERY CHARGING ALTERNATOR

ELECTRICAL SYSTEM DESCRIPTION
The Komatsu Truck utilizes a 24VDC electrical system which supplies power for all non-propulsion electrical components. The 24VDC is supplied by pairs of
12 volt storage batteries wired in series. The batteries are a lead-acid type, each containing six 2-volt
cells. With keyswitch ON and engine not operating,
power is supplied by batteries. When the engine is
operating, electrical power (non-propulsion) is supplied by a 24 volt alternator.
Excessive consumption of water indicates leakage or

overcharging. Normal water usage for a unit operating eight hours per day is about one to two ounces
per cell per month. For heavy duty operation (24
hour) normal consumption should run about one to
two ounces per cell per week. Any appreciable
increase over these figures should be considered a
danger signal. No water consumption may indicate
undercharging or sulphated plates.
Troubleshooting
BATTERY
During operation, the storage batteries function as an
electrochemical device for converting chemical
energy into the electrical energy required for operating the accessories when the engine is shut down.
Two most common troubles that occur in the charging system are undercharging and overcharging of
the truck's batteries.
An undercharged battery is incapable of providing
sufficient power to the truck's electrical system.
Some possible causes for an undercharged battery
are:
Sulfated battery plates
Loose or corroded battery connections
Lead-acid storage batteries contain sulphuric

acid, which if handled improperly may cause
serious burns on skin or other serious injuries to
personnel. Wear protective gloves, aprons and
eye protection when handling and servicing leadacid storage batteries. See the precautions in
Section A of this manual to insure proper handling of batteries and accidents involving sulphuric acid.
Maintenance and Service
The electrolyte level of each cell should be checked
at the interval specified in Lubrication and Service,
Section P, and water added if necessary. The proper
level to maintain is 3/8 - 1/2 in. (10-13 mm) above the
plates. To insure maximum battery life, use only distilled water or water recommended by the battery
manufacturer. After adding water in freezing weather,
operate the engine for at least 30 minutes to thoroughly mix the electrolyte.
DO NOT SMOKE or allow flame around a dead

battery or during the recharging operation. The
expelled gas from a dead cell or charging battery
is extremely explosive.
D10002
Defective wire in electrical system

Loose alternator drive belt
A defective alternator
A defective battery equalizer
Overcharging, which causes battery overheating, is
first indicated by excessive use of water. If allowed to
continue, cell covers will push up at the positive ends
and in extreme cases the battery container will
become distorted and cracked.
Leakage can be detected by continual wetness of the
battery or excessive corrosion of the terminals, battery carrier and surrounding area. (A slight amount of
corrosion is normal in lead-acid batteries). Inspect
the case, covers and sealing compound for holes,
cracks or other signs of leakage. Check battery hold
down connections to make sure the tension is not
great enough to crack the battery, or loose enough to
allow vibration to open the seams. A leaking battery
should be replaced.
To remove corrosion, clean the battery with a solution
of ordinary baking soda and a stiff, non-wire brush
and flush with clean water. Make sure none of the
soda solution is allowed into the battery cells. Dry off
battery. Be sure terminals are clean and tight. Clean
terminals are very important in a voltage regulated
system.
D10-3
Corrosion creates resistance in the charging circuit

which causes undercharging and gradual starvation
of the battery.
NOTE: When washing batteries, make sure cell caps
are tight to prevent cleaning solution from entering
the cells.
Addition of acid will be necessary if considerable
electrolyte has been lost through spillage. Before
adding acid, make sure battery is fully charged. This
is accomplished by putting the battery on charge and
taking hourly specific gravity readings on each cell.
When all the cells are gassing freely and three successive hourly readings show no rise in specific gravity, the battery is considered charged. Additional acid
may now be added. Continue charging for another
hour and again check specific gravity. Repeat the
above procedure until all cells indicate a specific
gravity of 1.260-1.265 corrected to 80F (27C).
NOTE: Use 1.400 strength sulphuric acid when
making specific gravity adjustments. Acid of higher
strength will attack the plates and separators before
it has a chance to diffuse into the solution.
If the temperature of the electrolyte is not reasonably
close to 80F (27C) when the specific gravity is
taken, temperature should be corrected to 80F
(27C):
For every 10F (5C) below 80F (27C), 0.004

should be SUBTRACTED from the specific
gravity reading.
For every 10F (5C) above 80F (27C), 0.004

should be ADDED to the reading.
The rate of self-discharge of a battery kept at 100F

(38C) is about six times that of a battery kept at
50F (19C) and self-discharge of a battery kept at
80F (27C) is about four times that one at 50F
(10C). Over a thirty day period, the average self-discharge runs about 0.002 specific gravity per day at
80F (27C).
To offset the results of self-discharge, idle batteries
should receive a booster charge (not a quick charge)
at least once every thirty days. Batteries allowed to
stand 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 sulfated battery may be restored to
limited service by prolonged charging at a low rate
(approximately 1/2 normal rate).
An undercharged battery is extremely susceptible to
freezing when allowed to stand in cold weather.
The electrolyte of a battery in various stages of
charge will start to freeze at temperatures indicated
in the table.
The temperatures in Table 1 indicate the points at
which the first ice crystals appear. Lower temperatures must be reached for a solid freeze. Solid freezing of the electrolyte may crack the battery case and
damage the positive plates. As will be noted, a 3/4
charged battery is in no danger of freezing, therefore,
a 3/4 charge or better is desirable, especially during
winter weather.
Table 10-1:
Specific Gravity
Corrected to 80 F (27 C)
Freezing
Temperature
Degrees
1.280
-90 F (-70 C)
1.250
-60 F (-54 C)
1.200
-16 F (-27 C)
1.150
+5 F (-15 C)
1.100
+19 F (-7 C)
Idle batteries should not be allowed to stand unattended. If equipment is to stand unused for more
than two weeks, the batteries should be removed
and placed in a cool, dry place where they may be
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 is more pronounced in warm weather than in
cold.
D10-4
D10002
BATTERY CHARGING SYSTEM (Niehoff)

General Description
The Niehoff model N1227 or C609 (Figure 10-1) is a
heavy duty, 24 VDC unit rated at 240 amps. A solid
state voltage regulator (6) mounted externally on the
end housing assembly provides voltage control during
operation. A single output connection (5) is located on
the face of the control unit (4) for connection to the
truck battery positive circuit. The ground circuit cable
can be attached to either of two terminals (10) located
on the front housing. A fan guard (7) protects maintenance personnel from the rotating fan when the
engine is operating.
TROUBLESHOOTING PROCEDURES
(On-Truck)
Most 24 volt charging system problems can be diagnosed with the alternator installed on the truck, operating under normal conditions. Many problems can be
attributed to loose or corroded cable connectors. It is
essential that all battery charging circuit cables are in
satisfactory condition and all connections are clean
and securely tightened.
Equipment Required:
Belt tension scale
Voltmeter, 0 - 40 volt range
Ammeter, 0 - 400 amp range
FIGURE 10-1. ALTERNATOR EXTERIOR
1. Belt Tension Adjustment Capscrew

2. Shaft Key
3. Pulley Bushing
4. Control Unit
5. Battery Positive Terminal
D10002
6. Voltage Regulator
7. Fan Guard
8. Cooling Fan Assembly
9. Mounting Lugs
10. Ground Terminals
D10-5
Test Procedure
Preliminary Checks
1. Check the drive belt tension as follows:
a. Apply 20.9 lbs. (9.5 kg) force at center of belt
span.
1. Start engine, accelerate to high idle and

observe meters.
b. Belt should deflect 0.50 in. (12.7 mm).

c. Adjust tension if necessary.
Insure that an undercharged battery condition has
not been caused by accessories having been left ON
for extended periods.
2. If a battery defect is suspected, check battery
as specified in Battery - Troubleshooting in this
section.
3. Inspect the wiring for defects. Check all connections for tightness and cleanliness. Remove and
clean battery cables.
4. If truck is equipped with a battery equalizer system, verify proper operation of equalizer and
individual battery voltages. Refer to Battery
Equalizer in Section D, 24VDC Electrical Supply System.
Test Setup
If voltmeter reading exceeds 30.5 volts, stop

engine immediately and refer to Table 2.
If batteries are sufficiently discharged, amps
should be "high" (220 amps 10%) and
voltage should be between 27.2 and 28.8
volts (normal range) or may be less than 23.7
volts if the batteries are significantly
discharged.
2. As the batteries approach full charge, the
amperage should fall as voltage rises.
3. When amps and volts readings stabilize, note
readings and refer to Table 2 to diagnosis system condition.
Table 10-2: TROUBLESHOOTING CHART
AMPS
VOLTS
DIAGNOSIS
HIGH
LOW
Charging system is OK. Batteries

are not yet fully charged. Wait for
charging system to bring to full
charge; amps should decrease
and voltage should stabilize
between 27.2 and 28.8 volts.
1. Discharge batteries sufficiently to insure adequate loading of alternator when engine is

operated during tests.
2. Open battery disconnect switch. Remove battery cable from alternator B+ terminal.
Refer to Figure 10-2 for the following steps. Meters
should be installed directly at the alternator as shown
to eliminate variations in readings due to cable
lengths etc.:
3. Install the ammeter (negative lead) to the battery positive cable removed in step 2. Install the
ammeter positive lead to the alternator B+ terminal.
HIGH
NORMAL Watch until amps decrease or
voltage exceeds 28.8 volts. If

amps decrease and volts remain
normal, system is OK. If voltage
exceeds 28.9 volts, regulator and/
or alternator defective. Go to
Static Test.
HIGH
HIGH
STOP TEST! Regulator and/or

alternator defective. Go to Static
Test.
LOW
LOW
1. Recheck voltmeter leads. If

connections are OK, alternator
and/or regulator defective.
4. Install a voltmeter between the alternator B+

terminal (positive lead) and the ground terminal
(voltmeter negative lead).
5. Secure all test equipment leads to prevent damage or short circuits when engine is started.
Reconnect battery disconnect switch.
2. Perform Regulator Bypass Test

per instructions on following page:
a. If volts and/or amps increase,
alternator is OK but regulator is
defective.
b. If no effect, replace alternator
LOW
LOW
NORMAL Charging system is OK.

HIGH
STOP TEST! If battery and voltmeter check is OK, regulator and/

or alternator defective.
The following tests require working near the

engine when running. Use caution when working
near engine fan, alternator fan and belt.
D10-6
D10002
FIGURE 10-3. REGULATOR BYPASS TEST

FIGURE 10-2. TEST METER HOOKUP
1. Alternator Under Test
2. 0 to 400 AMP Ammeter
3. 0 to 40 VDC Voltmeter
4. Alternator B+ Terminal
5. Alternator Ground Terminal
6. Truck Batteries
1. Alternator Control Unit

2. R Terminal (Relay)
3. E Terminal (Energize)
4. Alternator B+ Terminal
5. Alternator / Voltage Regulator
Harness Plug
Regulator Bypass Test

If the test procedure outlined on the previous page
indicates low current output and low voltage output, perform the following test to determine if the
voltage regulator is defective or if the alternator is
defective.
1. Disconnect alternator/regulator harness plug
(3, Figure 10-3).
2. Momentarily touch the "F-" connector pin on the
alternator connector to ground.
3. Observe meter readings:
If voltage or amperage rises, the alternator is
OK. The regulator is defective and should be
replaced.
If grounding the harness male pin has no
effect, the alternator is defective and should
be replaced.
D10002
D10-7
FIGURE 10-4. PARTS ILLUSTRATION

1. Locknut
2. Flat Washer
3. Drive Pulley
4. Pulley Bushing
5. Retainer Ring
6. Front Bearing
7. Capscrew & Washer
8. Cover Plate
9. Control Unit Cover
D10-8
10. Screw
11. Control Unit
12. Screw
13. Rotor
14. Shaft & Core
15. B+ Bolt Assembly
16. Retainer Ring
17. Nut
18. Front Stator
19. Stud
20. Shell
21. Pan Head Screw
22. Field Coil
23. Rear Stator
24. Rotor
25. Rear Bearing
26. Screw
27. Voltage Regulator
28. End Housing

29. Nut
30. O-Ring
31. Retainer Ring
32. Cooling Fan
33. Hardened Washer
34. Locknut
35. Socket Head Screw
36. Fan Guard
D10002
ON VEHICLE TROUBLESHOOTING GUIDE

ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage
PRELIMINARY PROCEDURES
HIGH VOLTAGE OUTPUT
Common problems, all applications:
Causes of high voltage:
Check alternator drive belt (s).
Wrong regulator.
Check alternator positive connection
High regulator set point.
Check alternator ground connection on alternator.
Defective regulator.
Defective alternator.
Check condition of connector between regulator

and alternator.
Identify model of alternator_______________
NO VOLTAGE OUTPUT
Identify model of regulator________________
Causes of no voltage output:
Record voltage regulator set points stated on

regulator tag:
1)_______ 2)_______ 3)_______ (if applicable)
No drive belt.
No battery (B+) voltage at alternator's "B+" terminal (except isolator type systems).
No "link" from "R" terminal to energize ("E") terminal on alternator when engine operating.
TOOLS AND EQUIPMENT:
Defective regulator.
1 - Voltmeter (Digital type preferred.)

1 - Ammeter (Digital, Inductive type preferred.)
1 - 12 gauge lead, 12 inches long, with alligator clip
at each end.
LOW VOLTAGE OUTPUT
Loose drive belt.
Maintenance type:
Low state of charge of battery.

Current load on system greater than alternator
can produce.
Low regulator set point.
Defective voltage regulator.
BATTERY CONDITIONS AND CHARGE

VOLTAGE REACTIONS:
NOTE:
Until
electrical
system
component
temperatures stabilize, these conditions may be
observed during cold start voltage tests.
Causes of low voltage:
Defective wiring or poor ground path.
Immediately after engine start, system volts are

lower than regulator set-point with medium
amps.
3-5 minutes into charge cycle, higher system
volts and reduced amps.
5-10 minutes into charge cycle, system volts are
at, or nearly at, regulator set point, and amps
are reduced to a minimum.
Low Maintenance types:
Same as above, except cycle times may be
longer.
D10002
D10-9
Maintenance Free types:

Immediately after engine start, system volts are
lower than regulator set-point with low amps.
15-30 minutes into charge cycle, still low volts
and low amps.
15-30 minutes into charge cycle, volts rise several tenths, amps increase gradually then
increase quicker to medium to high amps.
20-35 minutes into charge cycle, volts rise to
set-point and amps lower.
High-Cycle Maintenance Free Types:
These types respond much better than standard
maintenance free types. The charge acceptance
of these batteries may display characteristics
similar to standard, maintenance type batteries.
CHARGE VOLT AND AMP VALUES

Voltage and amperage levels are functions of battery
state of charge. If the batteries are charged 95% or
higher when the engine is cranked, the charge voltage will be near regulator set-point and the amps will
taper quickly from medium to low. True battery voltage is obtained AFTER removing any surface charge
from the battery or after 24 hours of non-use.
DEFINITIONS
NOTE: Charge voltage and amp rates vary from
battery type to battery type, based on battery
construction technology and physical size of battery.
Low amps are the necessary amps that a battery will take continuously over a period of time
without damage to the battery when the battery
is in an operating system and is constantly
cycling. Batteries such as the Group-8D may
accept rates up to 15 amps over several hours
without raising their internal temperature more
than a few degrees. Group-31 batteries may
accept rates up to 5 amps over several hours
with minimal temperature rise.
D10-10
Medium amps are defined as some multiple of

the low amp value, perhaps 30 amps for the
Group-8D and 10-15 amps for the Group-31.
This rate of amperage will cause a rise in battery temperature over a long period of time (4-8
hrs) and may lead to an overcharge condition if
temperature elevates too high.
High amps would be 50 to 75 amps for a Group8D, and 25 to 35 amps for a Group-31 size.
High amperage rates over a short period of time
(2-3 hrs.) can severely damage any battery by
overheating the battery and causing thermal
runaway. The battery, in effect, forgets its state
of charge and will accept all amps offered. The
electrolyte solution is boiled off as the battery
moves into an excessive gassing stage.
Charge voltage is the voltage delivered to the
battery when the alternator and regulator are
operating properly. This charge voltage value is
the voltage regulator's set-point. At times the
charge voltage value may be less than the regulator's set-point but it will never be higher than
that set-point.
Battery voltage is the steady state voltage of the
battery. The value of this voltage relates directly
to state of charge.
B+ voltage is battery positive voltage, but does
not refer to a specific value as does battery voltage.
Surface charge is a higher than normal terminal
voltage a battery has when it comes off a
charger or after extended time in vehicle operation. The surface charge must be removed to
determine true battery voltage.
D10002
ADVANCED SYSTEM TROUBLESHOOTING

NO ALTERNATOR OUTPUT
Static Test - Engine OFF, Key ON, Battery Switch
ON.
Identify and locate "B+", "E", and "R" and ground
("B-") terminals on alternator and check for link from
terminal "R" to "E".
Go To Alternator
DAMAGE WILL OCCUR IF UNIT IS OPERATED

WITH STRAP CONNECTED AND B+ APPLIED!
Hold a steel wrench or screwdriver near alternator
drive pulley: wrench or screwdriver held near drive
pulley will be attracted to pulley by magnetism.
If there is no magnetic attraction, alternator
may not be turned on. Go to "Regulator Test"
that follows and continue test.
Test for battery B+ voltage (__________V) at "B+" terminal on alternator:

If there is no B+ voltage on "B+" terminal,
repair VEHICLE wiring as necessary. Continue
test.
If B+ voltage is present on "B+" terminal, continue

test.
Remove strap between "R" and "E" terminal.

Connect a 12 gauge jumper wire from the "B+" terminal on alternator to the "E" terminal on alternator.
D10002
If there is magnetic attraction alternator is good

and regulator should be considered good.
Alternator will produce electricity because
regulator is on. This test only shows regulator as
either on or off.
NOTE: Alternator may not be turned on when engine

is operating. Go to "R" terminal test next, to prove if
vehicle "E" circuit will turn alternator on.
D10-11
Go To 'R' Terminal On The Alternator
Go To Regulator (If Required)
With engine running, measure value of AC voltage

from "R" terminal to "Ground".
Disconnect voltage regulator from alternator. There

are no static tests available for the regulator. Continue test.
If no AC volts are present, alternator is not

capable of turning on regulator.
NOTE: On a new, first time start up of an
alternator, the alternator may test at less than 5
volts on "R" terminal. The cause of this problem
may be loss of residual magnetism within the
alternator during shipping and handling of the
alternator. To restore the residual magnetism:
With engine off and battery switch on,
momentarily (1-2 seconds) connect a jumper wire
from 'B+' terminal to 'E' terminal. (May spark this is OK.) Remove jumper and restart engine.
Alternator should generate properly once the
residual magnetism is restored.
If AC voltage is approximately 14 Volts, alternator

is properly turned on and output of alternator will
be approximately 28 Volts.
If AC voltage is 3 Volts to 5 Volts, alternator is
NOT turned on (regulator is OFF) but
alternator is capable of turning on a good
regulator. NOTE: This test shows only if
alternator is capable of energizing regulator.
To check harness from alternator to regulator
go to "Regulator Connector On Alternator"
test.Continue testing.
Vehicle Charging Circuit Test Is Now Complete:

Remove all jumper wires from alternator used to test
charging circuit.
Re-test Charging Circuit For Operation With The

Engine Running:
Check charging system voltage with engine running.
If no charge voltage, test for voltage at "E"
terminal of alternator, with engine running.
If no voltage on "E" terminal, shut engine
down and inspect link from "R" terminal to
"E".
Go To Regulator Connector On The Alternator

Connect a jumper wire from ground on alternator into
"F-" pin of connector attached to alternator.
B+
F-
B-
METRI-PACK Connector
Hold a steel wrench or screwdriver near alternator
drive pulley; wrench or screwdriver held near drive
pulley will be attracted to pulley by magnetism.
If there is no attraction, alternator field is

defective. Replace alternator.
If there is magnetic attraction, alternator field is

good. Continue test.
With jumper still connected between "B+" terminal

and "E" terminal on alternator: Insert "+" probe of
voltmeter into "E" terminal of connector, and Ground
negative probe of voltmeter to alternator ground terminal.
If meter shows no voltage, alternator is

If meter shows battery voltage, circuit is good.

Continue test.
Insert "+" probe of voltmeter into "B" pin in connector.

Insert negative probe of voltmeter into "B-" pin in
connector. (This is power circuit for voltage regulator.)
If circuit shows open (no voltage), alternator is

If circuit shows B+ voltage, regulator

defective. Replace the regulator, only.
is
NOTE: Turn key and battery switch OFF before

installing new regulator. Turn battery switch and key
back on AFTER installing new regulator. Continue
test.
Run engine and re-test charging circuit.

Remove all jumper wires from alternator used to test
charging circuit.
Reconnect link from "R" terminal to "E" terminal
D10-12
D10002
ALTERNATOR OVERHAUL
ALTERNATOR DIMENSIONS
1. Mounting Bolt - 1/2 UNC
2. Mounting Bolt - 12/50 Dia; 65 ft.lbs. (88 N.m) torque
3. Ground Bolt, 3/8 - 16; 11 ft.lbs. (15 N.m) torque
Either Side; R.H. side shown
4. Locknut (5/16 - 18 UNF-2B) & Washer (to secure Pulley)
6. Fan Nut; 50 ft.lbs. (68 N.m) torque

7. Slip Bushing
8. Allowable Mounting Bracket Dimensional Span
9. F+ Stud (NOTE: F+ Stud Not On All Models)
FASTENER DESCRIPTION
TORQUE SPECIFICATIONS
SAE
METRIC
Pulley Nut
120 ft. lbs
163 Nm
Heat Sink, Cover Plate, Control Box Hold Down & Relay Terminal Screw
20 in. lbs.
2 Nm
Phase Terminal Screw
20 in. lbs.
2 Nm
Ground Bolt
11 ft. lbs.
15 Nm
Front & Rear Housing Hold Down Nut
18 in. lbs.
2 Nm
Tension Adjust Bolt
18 ft. lbs.
24 Nm
Rotor Hold Down Screws
45 ft. lbs.
61 Nm
Output Lead Bolt
11 ft. lbs.
15 Nm
Output Nut
20 - 22 ft. lbs.
27 - 30 Nm
Energize Terminal Nut
60 - 70 in. lbs.
7 - 8 Nm
Regulator Hold Down Screw

(for taptite screws)
32 in. lbs.
45 in. lbs.
4 Nm
5 Nm
Fan Nut
50 ft. lbs.
68 Nm
Field Coil Screw
9 in. lbs.
1 Nm
D10002
D10-13
ALTERNATOR SPECIFICATIONS
VOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC
AMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
GROUND . . . . . . . . . . . . . . . . . . . . . . . . .NEGATIVE
REGULATOR STEPS. . . . . . . . . . . . . . . . . . . . . . . .2
REGULATOR SETTINGS. . . . . . . . . . . . . 27.6 / 28.6
WEIGHT . . . . . . . . . . . . . . . . . . . . . . 65 lbs. / 29.3 kg
1. Measurements listed on the curves are for a
stabilized machine at maximum output at temperatures indicated for each curve.
2. A link between "E" and "R" terminal must be
used in order to provide self energizing. If residual magnetism is lost, self energizing will not
occur until magnetism is reestablished. This is
done by disconnecting the link and applying
24V momentarily to the E terminal while the
alternator is operating. After disconnecting the
+24V signal from "E" terminal, connect the link
between the "R" and "E" terminal.
D10-14
D10002
SERVICE PARTS
Ref
No.
1
2
3
4
5
6
7
8
9
9.a
10
11
12
13
14
15
16
17
18
19
20
20.a
20.b
20.c
21
22
23
24
25
25.a
25.b
25.c
25.d
25.e
25.f
26
27
28
29
30
31
32
33
34
35
36
37
Part No.
Qty.
Description
BF3715
BF1997
EF3527
BF1966
BF1989
BF1968
BF1988
BF1990
BF1970
BF3712
BF2002
BF1969
BF1972
BF1971
BF3716
BF1995
BF1996
BF3717
BF3718
BF3720
BF1973
BF1974
BF1975
BF3713
BF1992
BF1991
BF3719
BF3721
BF1976
BF1977
BF1980
1
1
1
1
1
1
1
15
1
1
18
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
12
9
1
1
9
1
1
1
1
18
9
1
1
2
1
1
1
1
1
1
3
LOCKNUT (1)
FLAT WASHER (1)
PULLEY
BUSHING, PULLEY
RING, RETAINER (1)
BEARING, FRONT
RING, RETAINER (1)
SCREW, PAN HEAD - #8 - 32NC X 3/8" (1)
PLATE, COVER
HOUSING, FRONT
NUT - (SPECIAL)
COVER, CONTROL UNIT
TERMINAL, OUTPUT
CONTROL UNIT
BOLT (+) - 5/16" - 18NC X 3/4"
LOCKWASHER - 5/16" (1)
FLAT WASHER (1)
LOCKWASHER (1)
CAPSCREW - 1/2" - 13NC X 1" (1)
KEY WOODRUFF (1)
SHAFT/CORE/ROTOR ASSEMBLY
ROTOR ASSEMBLY
SHAFT/CORE ASSEMBLY
RING, RETAINING
LOCKWASHER (1)
CAPSCREW - 3/8" - 16NC X 5/8" (1)
CAPSCREW - #10 - 32NF X 1/2" (1)
NUT - #8 - 32NC (1)
SHELL/STATOR/FIELD ASSEMBLY
STATOR, FRONT
STUD
SHELL (2)
BUSHING, TENSION
COIL
STATOR, REAR
SCREW, PAN HEAD - #6 - 32NF X 3/8" (1)
NUT - #8 (1)
HOUSING, END
BEARING, REAR
SCREW, LOCK - #10 - 32NC X 5/8" (1)
REGULATOR
O-RING
FAN
FLAT WASHER (HARDENED) (1)
LOCKNUT - 1/4" - 20NF (1)
GUARD, FAN
SCREW, SOCKET HEAD - #10 - 32NF X 7/8" (1)
BF1981
BF1978
BF1979
BF3722
BF3723
BF1982
BF1983
BF3724
BF1962
BF3714
BF1985
BF2003
BF2004
BF1961
BF3725
NOTE: (1) NOT SERVICED SEPARATELY - SUPPLIED ONLY IN BF1986 KIT.NOTE: (2) NOT SOLD
SEPARATELY
D10002
D10-15
ALTERNATOR PARTS
Refer to previous page for Parts List.
D10-16
D10002
ON-VEHICLE TEST
Equipment:
Belt Tension Gauge
Voltmeter, 0 - 40 Volt range
Ammeter, 0 - 400 Ampere range
Preliminary Checks:
1. Check Belt Tension. Use Belt Tension Gauge to
measure belt tension: Poly V Belt Adjustment
(20 lbs./strand): 240 lbs. maximum for 12
groove Poly V-belt.
2. Check Battery.Batteries must be in good condition and fully charged. If any battery condition is
marginal, it should be replaced with one known
to be in good condition.
For split battery pack, dual voltage systems,
battery rest voltages should agree within 0.3 V.
When "12V" battery voltage is more than 0.3 V
lower than "24V" battery voltage, check the
"12V" battery circuit to verify adequate charge.
Polarity of battery and alternator must agree;
reverse polarity will damage the alternator. The
alternator is NEGATIVE ground.
3. Check electrical connections in charging circuit.
Make sure all connections are clean, tight, and
free of corrosion. Battery connections are especially important.
4. Check Energize circuit.If alternator is not charging, check for voltage at the alternator energize
terminal. Refer to Figure 10-5 for energize terminal location on the outside of the control box.
Check for battery voltage at the "E" terminal
with engine running.
FIGURE 10-5.
1. Alternator
2. Voltmeter
3. Ammeter
4. Battery
7. Attach meters as indicated by Figure 10-5, be

sure to measure voltage and amperage at alternator, not at batteries or intermediate point.
If an in-line ammeter is used, disconnect battery
ground cable before connecting ammeter. Then
reconnect battery ground cable. Ammeter connections must carry rated output of alternator.
Test Procedure
Test Set-up
8. Start engine. Accelerate to high idle.
5. Discharge Battery as Follows:

d.Disable fuel system.
e.Turn all lights and accessories "ON". Crank
the engine for 10 - 15 seconds to discharge
battery, then stop cranking engine.
f. Turn all lights and accessories off.
g.Enable fuel system.
6. Determine setpoints of regulator. The setpoint
of the alternator is 28V. "Normal" range is within
0.2V of setpoint.
D10002
If voltmeter reading exceeds 32V for 24V system,

stop engine immediately and refer to Table 10-3.
9. Watch meter reading.If battery is sufficiently discharged, amps should be high within 10% of
output specified by performance curve (refer to
SPECIFICATIONS, alternator RPM = engine
RPM x pulley ratio). Volts should be within or
below the "normal" range as battery
approaches full charge. Amps should fall as
Volts rise. When amps and volts stabilize, note
readings and refer to Table 10-3.
D10-17
Table 10-3: TROUBLESHOOTING

AMPS
VOLTS
DIAGNOSIS
HIGH
LOW
Charging system is OK. Battery is

not yet fully charged. Wait for
charging system to bring to full
charge: AMPS should fall and
VOLTS should stabilize within normal range.
HIGH
NORMAL Watch until AMPS fall, or VOLTS

exceed normal range. If AMPS fall
and VOLTS remain normal, charging system is OK. If VOLTS
exceed normal, regulator and/or
field coil should be replaced (Go to
Static Tests).
HIGH
HIGH
Stop test. Regulator and/or field

coil should be replaced. (Go to
Static Tests.)
LOW
LOW
Make sure voltmeter leads are

attached at alternator. If connections are OK, alternator and/or
regulator must be repaired or
replaced. Bypass regulator (See
Figure 10-3). If VOLTS and/or
AMPS rise, alternator is OK and
regulator should be replaced. If no
effect, repair alternator. (Go to
Static Tests.)
LOW
NORMAL Charging system is OK.
LOW
HIGH
Stop test. If battery and voltmeter

check OK, regulator and/or field
coil must be replaced.
System voltage may rise above 32 volts on a 24 volt

system, during regulator bypass test. Possible damage to sensitive electronic components could occur.
Refer to the "On Vehicle Troubleshooting Guide" for
an alternative to the bypass test.
FIGURE 10-6. VOLTAGE STEP ADJUST

1. Low
2. Medium
3. High
CAUTION! USE HIGH SETTING ONLY FOR:
EXTREME COLD
INTERMITTENT SERVICE
MAINTENANCE - FREE BATTERIES
CHECK BELT TENSION BEFORE ADJUSTING

VOLTAGE. TO ADJUST VOLTAGE, MOVE LINK TO
OTHER POST.
System voltage may rise above 32 volts on a 24

volt system during bypass test. Possible damage
to sensitive electronic components may occur.
Refer to the "On Vehicle Troubleshooting Guide"
for an alternative to the bypass test.
Table 10-4: VOLTAGE REGULATOR

SYSTEM
VOLTAGE
FACTORY
SETTING
NORMAL
RANGE
27.5
27.2 - 27.8
28.0
27.7 - 28.3
24
ON-VEHICLE TEST
Bypass Test:
Disconnect plug between alternator and regulator
and momentarily touch "F-" terminal from alternator
plug to ground.
FIGURE 10-7.
1. F+ Stud (some units have F+ Stud & Phase taps)
D10-18
D10002
BENCH TEST
TEST 2 - Full Load Test
Results of on-vehicle test should be confirmed

by these bench tests, if possible. When it is not
possible to perform on-vehicle test, alternator
performance can be checked quickly by referring
to these bench tests.
With load set to rated output (nameplate) 10%, run

alternator at 5000 rpm. Refer to Table 10-6.
Equipment:
Test Bench, with 15 - 20 Hp motor set up to drive

alternator to 7000 RPM.
Voltmeter, 0 - 40 Volt Range
Ammeter, 0 - 400 Amp Range
Table 10-6: FULL-LOAD TEST

AMPS
VOLTS
DIAGNOSIS
HIGH
LOW
Test bench battery is discharged (or defective). Allow to

charge or replace.
HIGH
Mount alternator on test bench according to the

bench manufacturer's instructions. Refer to Figure
10-5 for set-up to measure voltage and amperage
produced by alternator. Voltage within 0.2V of regulator setpoint is "normal". Amperage within 10% of
rated output at 5000 rpm is "high".
NORMAL Charging system OK.
HIGH
HIGH
Stop test. Regulator and/or

field coil should be replaced.
(Go to Static Tests.)
LOW
LOW
Alternator and/or regulator

must be repaired or replaced.
Go to Test 3.
LOW
NORMAL Increase load.
LOW
HIGH
Stop test. Bench malfunction or

wiring error.
TEST 1 - No Load Test

Without electrical load but with battery connected,
run alternator at 5000 rpm. Refer to Table 10-5
below.
Table 10-5: N0-LOAD TEST
AMPS
VOLTS
DIAGNOSIS
HIGH
LOW
Test bench battery is discharged (or defective). Allow to

charge or replace.
HIGH
HIGH
LOW
LOW
LOW
NORMAL Give time to stabilize while

monitoring VOLTS. If VOLTS
rise above normal range (Table
13-2) regulator and/or field coil
must be replaced. If AMPS fall,
charging system is OK.
HIGH
LOW
Stop test. Regulator and/or

field coil should be replaced.
(Go to Static Tests.)
TEST 3 - Regulator Bypass Test

Perform this test only when suggested by other tests.
Alternator connections and load same as test 2.
Bypass regulator as shown in Figure 10-7. Note
whether amps rise to within 10% of output rating
when connecting F- terminal to ground. Note whether
amps fall when disconnecting F- terminal. Then refer
to Table 10-7 below.
Limit terminal connection to a few seconds to

protect charging system from excessive voltage.
Table 10-7: REGULATOR BYPASS TEST
CONNECT
DISCONNECT
DIAGNOSIS
Amps Rise
Amps Fall
Alternator is OK.
See note, replace
regulator only if low
AMPS/low VOLTS
indicated in Test 1
and/or Test 2.
No Change
No Change
Alternator must be
repaired. Go to
Static Tests.
Alternator and/or regulator

must be repaired or replaced.
Go to Test 3.
NORMAL Regulator OK. Go to Test 2.

HIGH
Stop test. Bench malfunction or

wiring error.
Note: Before replacing regulator, check continuity of

energize circuit (refer to Static Tests, Test 5).
D10002
D10-19
STATIC TESTS
TEST 2 - Check Function Of Clamping Diode
Static tests are performed on the partially disassembled alternator to confirm component failure
indicated by on-vehicle test or bench tests.
Set ohmmeter to x100 scale and make sure ohmmeter is zeroed. Using the regulator connector plug,
connect one ohmmeter lead to terminal "F-", connect
the other lead to terminal "B-" and observe ohmmeter
reading. Reverse leads and observe meter reading.
In one direction the ohmmeter should read less than
600 ohms. In the other direction the ohmmeter
should read very high. If the ohmmeter reads less
than 600 ohms in both directions (short) or very high
in both directions (open) clamping diode is defective
and regulator must be replaced.
Equipment:
Ohmmeter, Simpson 260 or equivalent
Regulator Tester, or Ohmmeter
Diode Tester or Ohmmeter
Remove control box cover and drive pulley. Disconnect regulator from control unit. Remove cover plate.
Disconnect all phase leads attached to the front
housing ("P1" through "P6" in Figure 10-10).
Note: If regulator failure is indicated, field coil failure

must also be suspected.
NOTE: Refer to disassembly procedures in

Alternator Disassembly section of this manual.
Before repairing the alternator, perform all static
tests.
Field Coil Tests
Regulator Tests
TEST 3 - Check For Open Field Coil
The regulator is normally checked using a regulator

tester. If a regulator tester is used, make connections
to regulator plug as follows (see Figure 10-4 for wire
assignments):
Set ohmmeter to x1 scale and make sure ohmmeter

is zeroed. Connect one ohmmeter lead to "B+" output stud. (NOTE: On unit with "F+" stud, connect
ohmmeter to "F+" stud). Connect the other lead to
terminal "F-" of control unit harness. Ohmmeter
should read less than 3 ohms. If ohmmeter reads
above the specified limit, the field coil is open and
must be replaced (replace or repair Stator & Shell
Assembly).
NOTE: Terminal locations differ on SAE and metripack connectors.
Wire 1 to "Field Coil (-)"
Wire 2 to "Ground"
Wire 3 to "Field Coil (+)" or "B+"
Wire 4 to "Ignition" or "B+"
Refer to regulator tester manufacturer's instructions

for test procedure.
If regulator tester is not available, it is difficult to test
regulator for open output transistor. However, most
regulator failures are caused by shorted output transistor, so the following procedure utilizing an ohmmeter, will often suffice when a regulator tester is not
available.
TEST 1 - Check For Shorted Output Transistor
Set ohmmeter to x100 scale and make sure ohmmeter is zeroed. Using the regulator connector plug,
connect one ohmmeter lead to terminal "F-", connect
to other lead to terminal "B-", and observe meter
reading. Reverse leads and observe meter reading.
In one direction the meter should read less than 600
ohms. In the other direction the ohmmeter should
read very high. If ohmmeter reads zero in both directions, output transistor is shorted and regulator must
be replaced.
D10-20
FIGURE 10-8.
1. Ignition (E)
(Harness Lead #4)
2. Relay (R)
3. Terminal Block
4 F- (Harness Lead #1)
5. F+ (Harness Lead #3)

6. Ground Wire
from Regulator
(Harness Lead #2)
7. B+ Buss Leads to
Rectifier
D10002
TEST 4 - Check For Grounded Field Coil

Set ohmmeter to x10K scale and make sure ohmmeter is zeroed. Connect one ohmmeter lead to terminal
"F-" of the control unit harness. Connect the other
ohmmeter lead to the front housing ground stud. The
ohmmeter should read very high. If the ohmmeter
reads less than 100K ohms, the field coil is grounded
and must be replaced (replace or repair Stator &
Shell Assembly).
Move ohmmeter lead from "F-" to "F+" (if so
equipped), or to "B+" and repeat test. The ohmmeter
should read very high. If the ohmmeter reads less
than 100K ohms, the field coil is grounded and must
be replaced (replace or repair Stator & Shell Assembly).
Metri-Pack Connecter
SAE Connecter
FIGURE 10-9.
Control Box Tests

Note: Needle point probes may be required to penetrate the potting compound in the control box.
Refer to Figure 10-8 for location of control box terminal strip connections. Refer to Figure 10-7 for location of control box external connections to regulator
and ignition circuit.
TEST 6 - Diode Heat Sink Tests

Check to make sure that all phase leads are disconnected from the heat sink (refer to Figure 10-10).
TEST 5 - Check Continuity Of Terminal Strip Connections

Set ohmmeter scale according to Table 10-8 and
make ohmmeter connections between the terminal
strip inside the control box and control box terminals
located on the outside of the control box.
Table 10-8:
CONTROL BOX CONTINUITY CHECKS
OHMETER
SCALE
TERMINAL
STRIP
CONNECTION
CONTROL
BOX
EXTERNAL
CONNECTION
(Figure 10-5)
READING
x 10K
F-
GND* (B-)
VERY
HIGH
x1
F-
(F-) PIN
ZERO
x1
F+
(F+)
TERMINAL
ZERO
*GND connections are made to ground terminal

located on outside of front housing.
With regulator disconnected, test for continuity from
"E" terminal on control unit to connector Energize
("E") pin on regulator harness (See Figure 10-9).
D10002
FIGURE 10-10.
1. Positive Diode Studs
2. S Phase Terminal
NOTE: Heat sink diodes are de-rated for heavy duty

performance. If diode failure is detected, the entire
charging system should be examined for loose
connections (especially battery). If diode failure is
indicated, stator failure must also be suspected.
D10-21
Note: Do not allow sleeving on leads to slide down

leads; phase terminal without sleeves can short
against alternator body.
The diode heat sink assembly is normally checked
using a diode tester. If a diode tester is used, refer to
manufacturer's instructions for proper connections.
When a diode tester is not available, use an ohmmeter and refer to the following procedure.
Note: Do not use an AC Device such as a leakage
tester to check the diode heat sink.
TEST 7 - Check Positive Diodes

Refer to Figure 10-10. Set ohmmeter to x100 scale
and make sure ohmmeter is zeroed. Connect one
ohmmeter lead to the "B+" output stud, connect the
other ohmmeter lead to each of the six heat sink
phase terminals "S". All six readings should be nearly
alike; either less than 600 ohms or very high. If all six
readings are not alike, the diode rectifier assembly is
defective and front housing assembly must be
replaced.
TEST 9 - Check Front & Rear Stator

Set ohmmeter to x1 scale and make sure ohmmeter
is zeroed. Check for open stator winding by connecting ohmmeter between each successive pair of stator
phase leads (Refer to Figure 10-10: "P-1" - "P2"; "P2"
- "P3"; "P1" - "P3"; "P-4" - "P5"; "P5" - "P6"; & "P4" "P6").
Note: It may be necessary to probe under the
sleeves of the phase leads in order to make electrical
contact. Ohmmeter should read less than 1 ohm
between each pair of stator phase windings. If
ohmmeter reads very high, the stator is open and
must be replaced (replace or repair stator or stator /
shell assembly).
Set ohmmeter to x10K scale and make sure ohmmeter is zeroed. Check for shorted stator windings by
connecting ohmmeter between each phase lead
("P1", "P2", "P3", "P4", "P5", & "P6") and the ground
terminal located on the outside of the front housing.
Ohmmeter should read very high. If ohmmeter reads
zero for the related test point, the stator is grounded
and must be replaced (replace or repair stator or stator / shell assembly).
Note: Grounded stator is difficult to confirm by static
test. Examine stator for burnt insulation or loose coil.
TEST 8 - Check Negative Diodes

Refer to Figure 10-6, set ohmmeter to x100 scale,
and make sure ohmmeter is zeroed. Connect one
ohmmeter lead to "B-" terminal located on the outside of the front housing, connect the other ohmmeter lead to each of the six heat sink phase terminals
"S". All six readings should be nearly alike; and all
should read very high. If all six readings are not alike
the diode rectifier assembly is defective and the front
housing assembly must be replaced.
Reverse ohmmeter leads, and again observe resistance between "B+" terminal and each of the six heat
sink phase terminals "S". All six readings should be
very high. If any reading is not alike, the diode rectifier assembly is defective and the front housing
assembly must be replaced.
Stator Tests
NOTE: The front stator related Phase leads are "P1",
"P2", & "P3"; The rear stator phase leads are "P4",
"P5", & "P6"
The Alternator has two separate assemblies that will
be checked individually. Make sure all phase leads
are disconnected from the heat sink (Refer to Figure
10-6).
D10-22
D10002
ALTERNATOR DISASSEMBLY
Regulator Removal
Notes: Disassemble alternator only as far as

necessary to replace defective part(s).
For stator removal, refer to BF4822 Stator Service
Tool Instructions.
1. Disconnect regulator from alternator harness.

2. Remove mounting hardware from regulator
mounting feet (Figure 10-12).
3. Remove regulator.
In this publication, Front Housing refers to the Drive

End Housing, and Rear Housing refers to the
opposite end housing.
Fan Removal
1. Remove fan guard.
2. Use a 3/4" socket wrench to loosen nut attaching fan to alternator. Keep shaft from rotating by
holding the pulley in a vise, jaws padded with
brass or aluminum (Figure 10-11).
3. Remove nut and hardened washer.
4. Remove fan assembly from alternator.
FIGURE 10-12.
FIGURE 10-11.
Pulley Removal
1. Use a 15/16" socket wrench on the pulley nut.
Clamp the pulley in a vise, jaws padded with
brass or aluminum, and loosed pulley nut (Figure 10-13).
2. Remove pulley nut and hardened washer.
3. With a gear puller remove the pulley from the
shaft.
4. Remove woodruff key from shaft.
5. Remove pulley bushing from shaft.
FIGURE 10-13.
D10002
D10-23
End Housing Removal

1. Remove nine flanged locknuts from stator-tube
assembly studs at rear of end housing.
2. With a gear puller, remove end housing from
alternator (Figure 10-14).
FIGURE 10-16.
1. Machine Screws
2a.Use three 10-32 UNF x 2" long machine

screws as jacks in the three threaded holes
of rotor end plate (Figure 10-16). Pull rotor
off of core gradually by working screws
against core in sequence. If rotor resists
movement, see alternate method below.
FIGURE 10-14.
Alternate Method
Rear Rotor Removal
1. Remove six flanged locknuts from core studs or
six self tapping screws (1, Figure 10-15). Scribe
location of stud or screw holes on rotor face
plate.
2b.Using an air hammer (air chisel) with a blunt

tipped tool, vibrate the area around the
rotor element to rotor core attaching studs.
The vibrations should loosen any built up
rust in that area. Remove the rotor element. If resistance is still felt, use the
method described in "2a.", plus the air
hammer.
Rear Bearing Removal

There are two types of rear bearing systems in
use:
1. For press fit rear bearings, support end housing on blocks with rear side facing up. Use a
proper tool and press to remove rear bearing
and seal.
FIGURE 10-15.
2. The loose fit rear bearing is retained on the

shaft and core assembly and can be removed
with a pulley puller.
1. Self Tapping Screws
D10-24
D10002
Front Housing Removal

Note: All control box and front housing connections
are coated with RTV Silicone Rubber. Remove RTV
Silicone Rubber as alternator is disassembled.
1. Remove five screws from control box cover.
2. Remove control box cover (Figure 10-17 A).
3. Loosen terminal strip screws and disconnect 2
field leads (white wires) from control box terminal strip.
4. Remove six screws from front housing cover
plate (Figure 10-17 B).
5. Remove front housing cover plate.
6. Remove the six nuts holding phase leads (black
wires) to diode studs (Figure 10-17 C).
7. Remove the six phase leads from the diode
studs and push the phase leads back through
the large openings in front housing (this will
facilitate separation of front housing from tube).
8. Remove nine flanged locknuts from stator/tube
assembly studs at front of front housing.
Note: The Front housing is attached to the rotor/shaft
core assembly.
9. Separate front housing with the rotor/shaft/core
assembly from the stator/tube assembly. Light
taps with a soft faced mallet will help in the separation of parts.
FIGURE 10-17.
1. Cover
2. Field Leads
(white wires)
3. Front Cover Screw
10. Support front housing on wood blocks. Using a

press, press shaft through front housing bearing.
D10002
D10-25
Control Unit
(These instructions may be used with control unit
assemblies having SAE or Metri-Pak connector.)
Refer to Figures 10-18 and -19 for the following
steps:
1. Remove the top cover of the control unit
assembly (Five screws).
Before removing the old control unit assembly,

observe wire position by wire function, not wire
color. Wire connections on some units are not
color coded.
2. Remove bolt and lock washer attaching "B+"
buss from the rectifier assembly to "B+" output
terminal.
3. Remove four attaching screws from the front of
the control unit assembly. Pull control unit - face
plate forward to permit easy disconnection of
wire ends from "R" (or phase terminals) and
"B+" terminals. Leave the regulator harness
with grommet resting on frame while sliding
face plate up and off grommet.
FIGURE 10-18. TYPICAL CONTROL UNIT

1. Ignition (E)
(Harness Lead #4)
2. Relay (R)
3. Terminal Block
4. F- (Harness Lead #1)
5. F+ (Harness Lead #3)

6. Ground Wire from Reg.
(Harness Lead #2)
7. B+ Buss Leads to
Rectifier
4. Remove the phase lead wire from "R" terminal

(or phase terminals) on the face plate. Be careful not to move or reroute the phase lead.
5. Disconnect the field leads from "F-" terminal
and "B+" terminal of the terminal block.
6. Disconnect the regulator harness ground wire
from the end housing. (lead #2)
7. Remove the terminal block from the housing.
NOTE: Two nuts are used as spacers underneath the
terminal block on attaching screws.
8. Desolder "B+" lead from the terminal block.
Take care to position "B+" lead coming from the
rectifier assembly.
FIGURE 10-19.
1. Cover Screws (TOP)
Do not cut "B+" lead at terminal block. "B+" lead
does not have slack.
9. Discard the old face plate assembly with regulator connector harness assembly.
2. Control Unit Screw
11. Inspect leads from field coil and rectifier assembly for chaffing, and repair as necessary.
10. Clean old RTV from the top and the face of control unit area of the housing.
D10-26
D10002
Front Bearing Removal

1. Remove retaining ring (1, Figure 10-27) from
front outer side of front housing.
2. Remove retaining ring (3, Figure 10-27) from
rear inner side of front housing.
3. Support front housing on blocks and with a
press, remove front bearing (4, Figure 10-27)
from front housing. Use Tool BF4818 (Figure
10-28).
Front Rotor Removal
1. Remove six flanged locknuts from core studs or
six self tapping screws (Figure 10-20).
FIGURE 10-21.
1. Jack Screws
FIGURE 10-20.
1. Flanged Locknuts or Screws
2a.Use three 10-32 UNF x 2" long machine
screws as Jacks in the three threaded
holes of rotor end plate (Figure 10-21). Pull
rotor off core gradually by working screws
against core in sequence.
Alternate Method
2b.Using an air hammer (air chisel) with a blunt
tipped tool, vibrate the area around the
rotor element to rotor core attaching studs.
The vibrations should loosen the built up
rust in that area. Remove the rotor element. If resistance is still felt, use the
method described in "2a." above, plus the
air hammer.
Field Coil Removal
Do not attempt to repair field coil. Replace the whole
assembly.
1. Mark the position of field coil leads (white wires
with spade terminals) on stator. New fields will
be positioned in same opening in stator assembly, as the old field leads.
D10002
FIGURE 10-22.
1. Bobbin Removal Tool
(BF4820)
2. Stator & Shell

Assembly
2. Remove the screws attaching field coil bobbin

to stator tabs (Figure 10-22).
3. Use tool BF4820 to rotate field coil bobbin
about 20 degrees to disengage bobbin ears
from stator tabs.
Note: Some force may be required to break the
perma-fill coating on the tabs.
D10-27
4. After rotating field coil bobbin, remove field coil

through back of stator and shell assembly (end
away from leads) while allowing field leads to
slide through opening in front stator assembly.
Notes: As field coil is removed from stator and shell
assembly note and mark position of leads relative to
drainage holes in shell for reassembly (Figure 1023).
ASSEMBLY- ALTERNATOR
Field Coil Assembly
1. Lay stator and shell assembly on its side,
phase leads to the left (Figure 10-24).
2. Insert field coil from right hand side of stator
and shell assembly, field leads (white wires with
spade terminals) facing toward phase leads.
Loctite should be used on all screws and nuts as

machine is assembled, except where told otherwise.
For stator installation, see BF4822 Stator Service
Tool Instructions.
FIGURE 10-24.
1. Field Leads
FIGURE 10-23.
D10-28
2. Remove or insert
field coil from this
end.
3. As field coil is inserted into stator and shell

assembly thread the field leads through the
proper openings between the front stator windings.
D10002
4. Seat field coil bobbin ears over stator tabs (Figure 10-25) by inserting field winding and rotating about 20 degrees after insertion with tool
BF4820. Align screw holes in bobbin ears with
screw holes in stator tabs.
Note: Bobbin ears go over stator tabs as viewed from
both ends of tube assembly.
5. Make sure field coil leads (white spade terminals) are pulled through proper stator openings
with no slack at the field coil and that neither
wire is pinched by the bobbin ears.
6. Using eighteen screws coated with loctite, fasten field coil bobbin ears to stator tabs (Figure
10-26). Tighten screws to 8-10 lb-in. (0.9- 1.1
Nm) torque.
Note: If field coil leads cannot be threaded through
stator openings with the terminal attached, unsolder
terminals, remove sleeving and then insert leads.
After field coil is in place slip sleeving on field leads,
solder terminals to wires and slip sleeving back over
terminal.
Front Bearing Assembly

1. Clean bearing I.D. surface of front housing.
2. Install retaining ring in rear inner groove of front
housing.
Note: This retaining ring has two flat sides (3, Figure
10-27).
3. Coat outer race of front bearing (4, Figure 1027) with thin coat of loctite.
FIGURE 10-25.
1. Field Coil Bobbin Ear
FIGURE 10-27.
1. Retaining Ring
(Tapered)
2. Front Housing
3. Retaining Ring
(Flat, both sides)
4. Bearing - Outer Race
FIGURE 10-26.
D10002
D10-29
4. Using tool BF4818 and a press, press front

bearing into front housing until bearing seats
against retaining ring (Figure 10-28). Outer ring
will be installed after housing is placed on shaft.
FIGURE 10-28.
1. Tool (BF4818)
Front Rotor Assembly
FIGURE 10-29.
1. Position rotor assembly on front end of shaft

and core assembly.
1. Shaft
2. Stud
Note: Front end of shaft and core assembly has

woodruff key slot in shaft (Figure 10-29).
3. SLot
2. Using six flanged locknuts or self tapping

screws, fasten rotor assembly to shaft and core
assembly. (Loctite should be applied to studs or
screws before installing). Torque flanged locknuts to 45 in. lbs., 5.0 Nm, screws to 65 lb-in,
7.3 Nm.
Note: Center studs or holes of core in the center of
slot in rotor plate.
Front Housing - Rotor, Shaft & Core Assembly
Note: When replacing shaft and core assembly,
(using ring seal) refer to Figure 10-39 before
proceeding with assembly.
1. Support rotor, shaft and core assembly on
blocks with the rear bearing end down.
2. Position bearing in front housing assembly onto
shaft, drive side of housing facing up.
3. Using tool BF4810 press bearing on shaft until
bearing inner race seats on shaft shoulder (Figure 10-30).
4. Install tapered retaining ring with tapered side to
front outer side, in front outer groove of front
housing (2, Figure 10-27).
D10-30
FIGURE 10-30.
1. Arbor Press
2. Tool (BF4810)
D10002
Front Housing - Rotor, Shaft & Core Assembly

1. Support stator, field coil & shell assembly on
blocks, with the six phase leads (black wires)
and the two field leads (white wires) pointing
up.
Note: Care must be used when setting stator, field
coil & shell assembly on blocks that neither the stator
windings nor the studs are damaged.
2. Set the front housing-rotor, shaft & core assembly into the stator, field coil & shell assembly
(core goes through the field coil bobbin). Align
mounting foot of front housing with mounting
foot on shell (Figure 10-31). As the shell studs
come through the holes in the front housing,
guide the six phase leads (black wires) and two
field leads (white wires) through the large openings in the front housing (Figure 10-31).
5. Route the two field leads (white wires) through

the hole in the front housing to the control box.
Connect the field leads to the control box terminal strip; one lead to the "B+" terminal the other
lead to the "F" terminal (Figure 10-32, Figure
10-8).
Note: Do not allow sleeving on leads to slide down
leads; phase terminal without sleeves can short to
front housing.
3. Make sure that shell and front housing are

seated together completely.
4. Fasten front housing to shell by installing nine
flanged locknuts on shell studs (apply Loctite to
studs before installing locknuts). Torque flanged
locknuts to 18 in. lbs. (2.0 Nm) maximum.
FIGURE 10-32.
1. Field Leads
2. Phase Leads
6. Using 6 nuts (coat with Loctite) attach the six

phase leads (black wires) to diode studs.
Note: Insulator and washer placed over positive
diode stud before securing phase terminal for
positive diode locations. Refer to Figure 10-33. If
insulator or washer were lost during disassembly,
replace before attaching phase lead.
7. Rotate shaft and make sure rotor does not contact wires.
8. Coat the six phase terminals and the two field
terminals with RTV Silicone Rubber, type 3141
(flowable type). If control unit assembly requires
a replacement, skip step 9 and proceed to Control Unit Assembly Replacement.
FIGURE 10-31.
1. Mounting Foot
2. Phase Leads
D10002
3. Field Leads
4. Drain Holes
9. Use five screws (coat with Loctite) to attach

control box cover to control box. Torque screws
to 20 in. lbs. (2.2 Nm).
D10-31
1. Field Leads
FIGURE 10-33.
2. Phase Leads
Control Unit Assembly Replacement

Refer to Figures 13-34 and 13-35 for the following
steps:
1. Hold the new regulator connector harness in its
approximate installation position and bend
wires into their proper position.
2. Solder both the regulator connector lead "3",
and the output lead from "B+" buss, to the terminal block, "B+" position. (right of center)
FIGURE 10-34.
1. Ignition (E) (Harness Lead #4)
2. Relay (R)
3. Terminal Block
4. F- (Harness Lead #1)
5. F+ (Harness Lead #3); 10 in. lbs. (1.3 Nm)
torque
6. Terminal Block Screw; 30 in. lbs. (3.5 Nm)
torque
7. Ground Wire from Regulator
(Harness Lead #2)
8. 24 in. lbs. (2.7 Nm) torque
9. B+ Buss Leads to Rectifier
10.When replacing output stud only; tighten to
12-15 ft.lbs. (16-20 N.m) torque, coat with
epoxy.
10. Solder here.
10. Apply RTV here.
10. Tighten to 180 in.lbs. (20 N.m) torque.
3. Position nuts on the terminal block attaching

screws about 2 threads from the tip of the
screw.
NOTE: These nuts are used as spacers.
4. Attach the terminal block to the alternator housing.
CAUTION: Thread both screws in evenly so as
not to cock the terminal block. Failure to keep the
terminal block parallel to the housing may break
the terminal block.
5. Attach the ground lead from the regulator harness (lead "2") to the housing.
6. Route the regulator harness under B+ buss
leads. Care should be taken to keep the regulator connector flat with A pin properly positioned.
NOTE: Wires in steps 7 & 8 should slant away from
both "E" & "R" terminals (down and left, as viewed
from outside).
D10-32
FIGURE 10-34.
1.Cover Screws (TOP)
2. Control Unit Screw
NOTE: Tighten nine screws to 20 in.lbs.

(2 Nm) torque.
D10002
7. Position the insulating sleeving over wire terminals prior to attaching ring terminals to "E" & "R"
(or phase terminals) studs.
NOTE: Assembly sequence for "E" & "R" terminal (or
phase terminals) is: insulator-flatwasher-terminal-nut.
8. Position the control unit-face plate and attach
the regulator harness lead "4" to "E" terminal on
the face plate.
9. Attach the alternator phase lead to "R" terminal
(or phase terminals) on the face plate.
10. Use RTV #732 on the face of the housing. Use
Loctite in mounting screw holes for the face
plate.
11. Install the face plate onto the housing while sliding slot in the face plate onto grommet on regulator harness. Attach the face plate to the
housing with 4 screws.
12. Attach "B+" buss leads from rectifier to the back
of "B+" terminal.
13. Position "B+" buss leads from rectifier so that
the leads will not contact inside ends of "E" or
"R" terminals (or phase terminals).
14. Attach leads from the field coil to the terminal
block at "F" and "B+" positions.
15. Use RTV #732 to reseal the housing where the
field coil leads enter the housing.
16. Use RTV #3140 on inner ends of "R" (or phase
terminals) and "E" terminals, on the terminal
block, and all exposed wires on inner end of
"B+" stud to prevent corrosion.
17. Apply RTV #732 on the top of the housing.
18. Use five screws (coat with Loctite) to attach
control box cover to control box. Tighten screws
to 20 in. lbs. (2.2 Nm) torque.
Rear Rotor Assembly

1. Place rotor assembly on shaft and core assembly inside stator, field coil and shell assembly
(Figure 10-36).
D10002
FIGURE 10-35.
1. Studs or Screws
NOTE: Align stud or screw holes of core with scribe
marks on rotor, or center studs or screw holes of core
in the center of slots in rotor plate as shown in Figure
10-36.
2. Use six flanged locknuts or self tapping screws
to fasten rotor assembly to shaft and core
assembly (Apply Loctite to studs before installing locknuts). Torque flanged locknuts to 45 in.
lbs. (5.0 Nm), screws to 65 in. lbs. (7.3 Nm).
End Housing Assembly
1. Stand alternator on front end.Observe extra
care when installing housing if rotor shaft is
equipped with dust cap and ring seal carrier, as
ring seal must compress to enter into housing
bore.
NOTE: If shaft has ring seal, rear housing must have
chamfer on bearing bore. Studs from stator, field coil
and shell assembly will come through holes in end
housing.
2. Ring Seal Conversion The fan and shaft/core
assemblies have been modified to accommodate a new bearing ring seal design (Figure 1037). These changes affect alternators manufactured after January 1996. The changes affect
the shaft and fan hub diameters on full units and
service parts. When new service parts are used
to repair units manufactured before January
1996, the ring seals and lip seals must be
removed.
D10-33
Shaft/Core Replacement
Remove old shaft/core assembly. Remove the
shaft/core assembly from alternator (as directed
in this publication). Remove the front seal from
the old end housing.
Install New Shaft/Core Assembly
(Figure 10-39)
Remove the ring seal from the new shaft/core
assembly, if present.Install the shaft/core
assembly into the alternator (as directed in this
manual).
FIGURE 10-36.
1. Ring Seal Groove
2. Ring Seal
3. Bearing
4. O-Ring
5. Ring Seal
6. Ring Seal Groove
7. Fan Mounting
Hardware
8. Fan Guard Screws
To use new service parts on product manufactured before the modification date, follow these
instructions:
Fan Replacement (Fan with Ring Seal)
Remove the fan and rear bearing seal. Remove
the old fan assembly from the alternator.
Note: On older units a puller may be required to
remove the old fan from shaft. Using a pry bar or
large screwdriver, remove the rear bearing seal from
end housing. Do not remove bearing.
Installation Of New Fan On Old Assembly
(Figure 10-38).
FIGURE 10-38.
1. Ring Seal Groove
2. Bearing
3. Bearing Seal
4. Fan Mounting
Hardware
5. Fan Guard Screws
3. Apply Loctite to studs, then install nine flanged

locknuts on studs.Torque flanged locknuts to 18
in. lbs. (2.0 N.m) maximum.
4. Install cover plate on front housing with six
screws.
Remove the ring seal from the new fan, if

present.Install the new fan onto the shaft and
slide into position. Place fan nut and washer
onto the shaft and tighten to 55 ft.lbs (75 N.m).
FIGURE 10-37.
1. Bearing Seal
2. Bearing
3. Ring Seal Groove
4. Fan Guard Screws

5. Fan Mounting
Hardware
FIGURE 10-39.
1. Insertion Tool (BF4821) placed here.
D10-34
D10002
Regulator Assembly
Rear Bearing Assembly

1. Assembly alternator, including end housing, but
leave out rear bearing and fan. Make sure
mounting feet are aligned.Install front pulley
bushing on shaft.
2. There are two types of rear bearing systems
used: press fit and loose fit.
1. Set regulator on rear housing with regulator

plug toward control box.
2. Using mounting hardware (coated with Loctite),
attach regulator to end housing (Figure 10-42).
Torque screw to 32 in. lbs. (3.6 N.m) maximum.
3. Connect regulator to regulator harness from
control unit.
Press Fit Bearings

Stand alternator on front end, in a press, supporting
the front bearing bushing. Insert bearing over rear
end of shaft. Place bearing insertion tool (part of
BF4821 package) over bearing and press until inner
race of bearing is seated onto shaft shoulder (Figure
10-41). Use caution when bearing outer race begins
to enter end housing bore because misalignment at
this point can damage housing.
FIGURE 10-41.
FIGURE 10-40.
1. Ball Bearing
2. Shaft
3. Support
4. Bushing
5. Front Housing
6. End Housing
7. BF4821 Insertion
Tool
Loose Fit Bearings

Before starting installation of loose fit rear bearings,
check that O-ring is greased (grease with Amoco
Rykon or equivalent) and properly installed in O-ring
groove in housing bore. Continue with bearing installation as above.
3. Turn shaft by hand to make sure it spins freely.
Fan and fan hardware can now be installed.
D10002
D10-35
Pulley Assembly
Fan Assembly
1. Place fan assembly on shaft (Figure 10-43).
Note: If fan hub has ring seals and carrier as ring
seal must compress ring enters housing.
NOTE: Do not hold fan to prevent shaft rotation. Fan

damage may result.
1. Install pulley bushing on shaft.
2. Press Woodruff Key into shaft.
3. Position pulley on shaft.
4. Install pulley nut and hardened washer on shaft.
Place alternator and pulley into vise. With a 15/
16" socket on the pulley nut (Figure 10-44).
Torque pulley nut to 120 ft. lbs. (162.7 N.m).
Note: Brass or aluminum jaw protectors must be
inserted into vise jaws to prevent damage to pulley.
FIGURE 10-42.
When repairing units manufactured before June
1994, the ring seal and contact seal must be
removed before installing the fan (Refer to Figure 10-38).
2. Use hardened washer and locknut to fasten fan
to alternator. Place alternator and pulley into
vise. With a 3/4" socket, tighten fan nut (Figure
10-43). Torque fan nut to 50 in. lbs. (68 N.m).
Note: Brass or aluminum jaw protectors must be
inserted into vise jaws to prevent damage to pulley.
D10-36
FIGURE 10-43.
D10002
BF4822 STATOR SERVICE TOOL INSTRUCTIONS

Function of Service Tool
This tool has been designed to remove and install
stators in alternators. The user of this tool must be
familiar with basic disassembly and reassembly techniques of dual stator alternators. Proper assembly
and use of this tool will result in correct placement of
stators inside the shell (indexing of stator, with
respect to stator leads). Read through these
instructions to familiarize yourself with the
names of various tool components prior to
attempting stator removal or installation.
Stator Removal And Replacement
Shell Assembly Preparation (Refer to Figure 10-45)
The field coil and shell studs must be removed from
the shell assembly before a stator can be removed.
REMINDER: A narrow, 1 - 3" wide, support ring is in
the tool package (not pictured). This ring is used
when necessary, to provide additional tool height to
prevent the jack screw from protruding through the
bottom thrust plate and preventing proper tool use.
1. Position the bottom thrust plate in work area.
2. Place the first support ring on the bottom thrust
plate.Make sure the support ring seats in the
mating groove in the bottom thrust plate.
3. Place the shell assembly on the support ring
with the stator to be removed, facing up.
4. Place the second support ring on top of the
shell assembly.Reach inside the support ring
and position the stator leads inside and away
from the top of the shell assembly.
Pressure Plate Set-up (Refer to Figure 10-46)
5. Thread the 3/8" diameter guide pin into the
pressure plate, from the hub side of the pressure plate. The threaded hub on the pressure
plate faces up, toward the top thrust plate.
6. Lay the top thrust plate on the pressure plate as
you pass the guide pin through the curved slot
in the top thrust plate.
7. After properly placing the thrust washer (not
shown on drawing) on the jack screw, insert the
jack screw through the top thrust plate and
thread the jack screw into the pressure plate
about 1".
8. Lift the top thrust plate up and off the guide pin.
Turn the top thrust plate so that the guide pin
does not re-enter the slot.Lower the top thrust
plate and allow it to rest on top of the guide pin.
D10002
9. Lubricate approximately 1" of the jack screw

where it enters the pressure plate with white
lube or a wheel bearing type of grease. Also
place a dab of this grease on both sides of the
thrust washer that is placed under the hex head
of the jack screw.
10. Position the stator leads so that they will not
snag on the pressure plate when the pressure
plate is being inserted into, then through, the
stator. Bend the stator leads over the top of the
support ring (this will help to eliminate interference).
11. Wrap a clean shop towel around the jack screw
and lift the pressure plate/jack screw/top thrust
plate assembly. Insert the pressure plate into
and through the top stator assembly. Position
the pressure plate in the space between the two
stators, where the field coil had been. Turn the
pressure plate to align the poles of the pressure
plate with the poles of the stator. This is easily
done by grasping both the jack screw and guide
pin and twisting. The pressure plate will then
rotate. Before releasing the assembly, make
sure the top thrust plate will once again rest on
the end of the guide pin, not the support ring.
12. Position the stator leads inside the support ring.
Firmly grab the top thrust plate at the outer
edge, twist slightly until the guide pin enters the
curved slot. Lower the top thrust plate onto the
support ring. The top of the support ring should
enter the mating groove in the top thrust plate.
13. Thread the jack screw in, until the head of the
jack screw contacts the top thrust plate.
14. Look through the large diameter holes (torque
arm holes) in the thrust plate to confirm the
proper seating of the pressure plate steps
against the stator. Adjust the pressure plate as
necessary.
NOTE: The pressure plate is properly seated when
the outer edge of the pressure plate presses against
the field coil mounting tabs on the stator. Make sure
that ALL field coil mounting tabs are in contact with
the pressure plate.
15. Continue threading the jack screw in, until significant resistance is felt. Check position of the
pressure plate again.
D10-37
16. If the tool assembly attempts to rotate after significant resistance is felt, insert torque arm into
the large diameter holes in top thrust plate and
use torque arm to prevent tool assembly from
rotating. Continue threading jack screw in until
stator is removed from shell, observe caution
below.
CAUTION: The movement of the stator should be
checked often during stator removal process.
Use the exposed portion of the guide pin as an
indicator of stator movement. Tension on the
removal tool will abruptly cease when the stator
is free of the shell. The service technician may be
startled by this abrupt looseness, exposing the
technician to potential injury. Keep the stator service tool vertical. Do not use the tool laying on its
side.
4. Place a support ring on the bottom thrust plate.

Make sure the support ring is seated in the mating groove in the bottom thrust plate.
5. Position the shell assembly on the support ring.
Shell bore to receive new stator must be facing
down.
6. Insert 3/8" diameter locating pin, from outside of
shell, into and through, center drain hole in the
shell assembly. Pass locating pin through shell
assembly and into correct hole in locating rod.
The locating pin must be in both shell and locating rod to maintain stator alignment during stator installation.
7. Place second support ring on shell/stator
assembly.
Stator Installation
(Refer to Figure 10-45)
Shell Assembly Preparation
The bore that is to receive the new stator should be
clean and free from burrs.
1. Position the bottom thrust plate in the work
area.
2. Place the pressure plate, threaded hub facing
down, on the bottom thrust plate. Align the
smooth bored hole in the pressure plate with
the keyed hole in the bottom thrust plate. Insert
the correct length locating rod through the pressure plate and into the bottom thrust plate.
NOTE: The correct length locating rod is a rod that
has a hole that will allow the locating pin to pass
through both the locating rod and shell drain hole.
3. Place new stator on the stator indexing pins on
the bottom thrust plate.
NOTE: Proper placement of the stator is achieved
when the single stator lead aligns with a stator slot
next to the other stator's single lead. The finished
shell assembly will have a slot arrangement of two
leads-space, two leads-space, two leads-space.
The front stator is placed on the stator indexing
pins with the leads pointing down.
FIGURE 10-44.
1. Bottom Thrust Plate
2. Stator Index Pins
3. Guide Pins
4. Jack Screw
5. Locating Rod (Long)

6. Locating Pin
7. Locating Rod (Short)
8. Pressure Plate
The rear stator is placed on stator indexing pins

with leads pointing up.
Position the stator leads so they will not be
damaged during stator installation.
D10-38
D10002
Pressure Plate Setup (Refer to Figure 10-46)

8. Place thrust washer on jack screw. Lube the
jack screw for 1", about 1" from the tip of the
jack screw. Lubricate approximately 1" of the
jack screw where it enters the pressure plate
with white lube or a wheel bearing type of
grease. Also place a dab of this grease on both
sides of the thrust washer that is placed under
the hex head of the jack screw.
Insert the jack screw through the top thrust
plate. Screw jack screw into the pressure plate
about 5 turns. Place a dab of lube on both sides
of the thrust washer under hex head of the jack
screw. Screw jack screw into the pressure plate
until contact is make between head of the jack
screw and top thrust plate.
9. Continue threading the jack screw in, until stator contacts shell/shell assembly. Measure from
top of locating pin to the top of the top thrust
plate. Record this measurement as starting
point to be used later.
10. Check the position of stator leads by looking
through the large torque arm holes in the top
thrust plate. Turn jack screw until significant
resistance is encountered.
NOTE:If the tool assembly starts to rotate, insert
torque arm into holes in the top thrust plate for
additional leverage.
11. Check the distance the stator has been inserted
into the shell by measuring from the top of the
locating pin to the top of the top thrust plate
(first measurement taken in step 9, above). This
measurement should increase, which indicates
the stator is entering the shell.
FIGURE 10-45.
1. Top Thrust Plate
2. Support Ring
3. Stator & Shell
Assembly
4. Support Ring
5. Bottom Thrust Plate

6. Torque Arm
7. Front Stator
8. Rear Stator
12. After the stator has been properly seated, disassemble the tool. Pull the stator leads through
the correct slots. Continue with the alternator
assembly as per instructions in this manual.
D10002
D10-39
NOTES
D10-40
D10002
SECTION E
ELECTRICAL PROPULSION SYSTEM
INDEX
ELECTRIC PROPULSION SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-1
NOTE: Propulsion system electrical schematics are located in Section R of this manual.
E01012
Index
E1-1
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 when the engine is running.
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 Truck Shutdown Procedures,
this Section, for additional propulsion system safety checks to be performed by a technician
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.
THE LINK VOLTAGE LIGHTS MUST NOT BE ILLUMINATED WHEN TEST OR REPAIRS ARE INITIATED. It requires approximately 5 minutes after the truck is shut down before the Link Voltage has dissipated.
AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED FOR THE AUXILIARY BLOWER MOTOR

AND ITS CIRCUITS TO DE-ENERGIZE. Do not attempt to perform Auxiliary Blower Motor or
Blower electrical circuit repairs until the Red warning lights on the Blower Control Panel have
turned off and it has been verified the system is de-energized.
BEFORE WELDING ON THE TRUCK; Disconnect all electrical harnesses and the ground wire
from the Engine Control System (ECS - MTU engine). If equipped with DDEC or Komatsu
engine, disconnect ECM harnesses. In the PSC and TCI enclosures, pull cards forward far
enough to disconnect the card connector from the backplane connector. Disconnect the battery charging alternator lead wire and open the battery disconnect switches. 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. Avoid
laying welding cables across or near truck wiring harnesses or power cables; voltages can be
induced in adjacent cables, damaging electrical components.
E1-2
Index
E01012
SECTION E2
ELECTRICAL PROPULSION SYSTEM COMPONENTS
INDEX
ELECTRICAL PROPULSION SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-3

GENERAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-3
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-5
Auxiliary Blower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-5
Propulsion System Controller (PSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-5
TRUCK CONTROL INTERFACE PANEL (TCI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-6
Diagnostic Information Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-7
DID PANEL EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-7
PSC SOFTWARE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-32
Input Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-32
STATE MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-32
State Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-32
Transitions Between States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-33
DC Link State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-35
Powering the Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-35
De-Powering the Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-35
Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-35
Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-35
ALTERNATOR FIELD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-36
Desired Three-Phase Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-36
Desired DC Link Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-36
Self-load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-36
Propel Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-37
Retard Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-37
Wheel Slide Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-37
E02014 01/02
Electrical Propulsion System Components
E2-1
Resistor Grid Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-38

Chopper Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-38
AUXILIARY BLOWER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-38
EVENT PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-38
Event Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-38
Power On Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-38
Initiated Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-39
Periodic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-39
EVENT RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-39
EVENT LOGGING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-39
Event History Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-40
Data Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-40
To Record and Save a Data Pack to a Floppy Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-40
Event Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-41
SERIAL DATA COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-42
PSC - TCI Communications processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-42
PSC - PTU Communications Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-42
Inverter Communications Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-42
OUTPUT PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-43
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-43
Fast Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-43
Engine Shutdown/Engine Not Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-43
Limp Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-43
Entering/Exiting Limp Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-43
PROPULSION SYSTEM COMPONENT ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-44
ELECTRONIC ACCELERATOR AND RETARD PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-54
E2-2
01/02
E02014
ELECTRICAL PROPULSION SYSTEM COMPONENTS

The following information provides a brief description
of system operation and major components of the AC
propulsion system. Refer to the appropriate GE publication for detailed information and theory of operation.
A list of commonly used propulsion system component abbreviations is listed in Table V at the end of
this Section. Figures 2-3 through 2-8 illustrate the
physical location of these components where applicable.
GENERAL SYSTEM DESCRIPTION

The AC drive system consists of the following major
components:
Alternator coupled to a diesel engine
Auxiliary Blower System
Gate Drive Power Converters
Main Rectifier
AC Power Inverters
AC Induction Traction Motors
The Alternator supplies three phase power for the
Auxiliary Blower System, Gate Drive Power Converters and Main Rectifier. The Main Rectifier supplies
DC power to two AC Power Inverters. Each AC
Power Inverter inverts the rectified DC voltage, delivering variable voltage, variable frequency power to
each of the AC Induction Traction Motors.
Refer to the diagram in Figure 2-1 for the following
description.
The two AC Induction Traction Motors, each with its
own Inverter, are connected in parallel across the
rectified output of the Alternator. The Inverters
change the rectified voltage back to AC by turning on
and off (chopping) the applied DC voltage.
The output AC voltage and frequency are controlled
to produce optimum slip and efficiency in the traction
motors. At low speeds, the rectified alternator output
(DC link, or DC bus) voltage is chopped with patterns
called pulse width modulation (PWM) inverter operation. At higher speeds, the DC link voltage is applied
to the motors using square wave inverter operation.
The voltage of the DC link is dependent upon the
Propulsion System Controller (PSC) and engine
RPM during propulsion. The link voltage will vary
between 600 and 1400 volts during propulsion and
600 and 1500 volts during retarding.
E02014 01/02
The alternator field is supplied from a tertiary winding

on the alternator and is controlled by a silicon controlled rectifier (SCR) bridge. A starting boost circuit
initially energizes the alternator from the truck batteries until the flux builds up enough to sustain excitation.
Cooling air for the Alternator only is supplied by an
internal fan assembly mounted on the rear. Cooling
air for the traction system is provided by an AC motor
driven auxiliary blower mounted behind the electrical
cabinet. The auxiliary blower motor is controlled by
an auxiliary inverter which receives 3-phase AC
power from the alternator. This blower provides cooling air to the traction motors, propulsion inverters,
dynamic retarding choppers, and auxiliary inverter.
Blower speed is regulated by the PSC by monitoring
component temperatures to determine cooling
needs.
A resistor grid package is used to dissipate power
from the traction motors (operating as generators)
when in dynamic retarding mode. The total retard
power produced by the traction motors is controlled
by the two motor Inverters. The amount of retard
power dissipated by the grid package is controlled by
a GTO Chopper circuit and stage-controlled contactors.
The PSC, mounted in the main Electrical Control
Cabinet, determines optimum engine operating
speeds based on what the operator requests, propulsion system requirements, and efficient fuel usage.
Interfaces between the PSC and the truck brake system allow the PSC to provide proper retarding, braking, and wheel slide control.
The PSC interfaces with the Truck Control Interface
(TCI), mounted in the Electrical Interface Cabinet
mounted behind the cab at the side of the electrical
control cabinet. System status and control signals
are transmitted and received between these two
components. An RS422 serial link enables the TCI to
access real time data and event information stored in
the PSC for displaying on a Diagnostic Information
Display (DID), located in the cab behind the operator's seat.
E2-3
FIGURE 2-1. PROPULSION SYSTEM DIAGRAM
E2-4
01/02
E02014
SYSTEM COMPONENTS
Auxiliary Blower System
The Auxiliary Blower System, mounted behind the
main electrical cabinet, consists of the blower assembly and control electronics; power inverter/phase
control rectifier, power filter capacitor bank, and
power filter inductor.
The control electronics provide a 3-phase, AC, variable voltage/variable frequency output to the blower
motor. Output frequency (blower motor speed) is
controlled by the PSC.
Propulsion System Controller (PSC)

The PSC (17FL320 Panel) is the main controller for
the AC Drive System. The Panel receives input signals from speed sensors mounted on the alternator
and traction motors, voltage and current feedback
signals from various control devices, and status/command inputs from the Truck Control Interface (TCI).
Using these inputs, the PSC controls the two Inverters, retarding circuits, relays, contactors, and other
external devices to provide:
Propulsion and wheel slip control
Retarding and wheel slide control
Engine speed control
The PSC contains the following internal, removable

printed circuit boards and an external fiber optic
board. Brief descriptions of board functions are as
follows:
*17FB127 Power Supply: Supplies regulated
+15VDC, -15VDC, and +5VDC for internal
panel use and 15VDC external circuits.
17FB147 System CPU Card: Provides serial
communications and control functions; RS232
communications to PTU.RS422 high speed
communications to TCI.Microprocessor controls
for internal panel circuits.
17FB104 Digital I/O Card: Receives digital
inputs and feedback information from various
propulsion and control system components.
Digital outputs drive propulsion system contactors, relays and provide equipment enable commands.
17FB143 System Analog I/O Card: Receives
engine and auxiliary blower speed signals, voltage and current signals for main alternator, link
voltage and current, retard pedal input, retard
lever input.Controls retard effort, engine speed
request, Auxiliary Blower speed, AFSE firing
pulses.
Event detection
**17FB134 Inverter 1, 2 I/O Cards (2 ea.):

Receives motor speed signals, link voltage,
phase voltages, and phase currents for use by
the Inverter 1 & 2 CPU cards. (See note below.)
Initialization of the necessary operating

restrictions, including the shut down of the truck if
a serious system fault (event) is detected. If the
fault is not serious, an indicator lamp alerting the
operator to the problem will illuminate. All event
data is recorded for future review by maintenance
personnel.
**17FB138 Inverter 1, 2 CPU Cards (2 ea.):

Microprocessor control for inverters 1 & 2. Controls GTO phase modules through the Fiber
Optic Assembly. Phase module status is
returned via a separate Fiber Optic Assembly.
(See note below.)
Auxiliary blower speed control.
Log event data

Store statistical data of the history of various
component and system function operations.
Communicate with the TCI to exchange
propulsion system status and control data (event
data, statistical data, etc.) and to receive required
truck systems status data.
Communicate with the TCI to exchange
propulsion PTU data (propulsion real time,
history, diagnostic, and parameter data: software
code etc.)
Drive the operator cab status and warning lamps.
E02014 01/02
17FB172 Inverter 1, 2 CPU and I/O Cards (2

ea.): These cards are used in later production
model trucks equipped with 17FL320E1 or H1
PSC Panel and replace the 17FB134 and
17FB138 cards.
Fiber Optic Assembly: Provides electrical isolation for control and feedback signals for
Phase Modules and Chopper Modules.
NOTES: * The 17FL320H1 PSC panel does not have
a 17FB127 card. **Early production trucks equipped
with 17FL320D1 Panel have 17FB134 and 17FB138
cards installed instead of 17FB172 cards.
E2-5
TRUCK CONTROL INTERFACE PANEL

(TCI)
The Truck Control Interface Panel (TCI) (17FL349 or
17FL373) is the main interface between truck systems and devices and service personnel. This panel
is used in conjunction with the Diagnostic Information
Display (DID) described later.
The TCI panel provides the following functions:
Communicates with the Propulsion System
Controller (PSC) to exchange propulsion control
system status and control data and to provide the
PSC with truck systems status data.
Communicates with the Diagnostic Information
Display (DID) to exchange PSC and/or TCI
diagnostic and parameter data.
Communicates with the Auxiliary Blower System
to exchange diagnostic data.
Communicates with a Portable Test Unit (PTU) to
exchange TCI data.
Communicates with a Modular Mining Dispatch
System to exchange truck status data.
Monitors engine control system, payload
information, ambient and propulsion system
temperature, operator control inputs etc.
Controls the engine start sequence.
Provides signals to activate many of the cab
mounted warning lamps and gauges. Controls
the park brake solenoid.
The 17FL349/17FL373 TCI Panels contain the following internal, removable printed circuit boards:
*17FB127 Power Supply: Supplies regulated

+15VDC, -15VDC, and +5VDC from the filtered
battery supply (B+) input.
17FB144 CPU Card: Provides high speed
RS422 serial communications to PSC and
RS232 serial communication with the PTU.
17FB160 Analog I/O Card: Provides RS232
serial communications with Diagnostic Information Display and an optional Modular Mining
Dispatch System. Provides RS422 serial communication with the Auxiliary Blower System.Receives signals for front wheel speed,
motor cooling and barometric air pressures,
accelerator, retard speed setting, payload,
ambient and hydraulic oil temperature, and
engine cranking voltage. Outputs drive cab
mounted temperature gauges etc.
17FB104 Digital I/O Card: Receives operator
control, engine and body-up signals. Provides
engine start controls, drives cab mounted indicator/warning lamps, etc.
*NOTE: The 17FL373 Panel does not contain the
17FB127 card.
Processes front wheel speed signals for the PSC

and speedometer.
E2-6
01/02
E02014
Diagnostic Information Display
DID PANEL EVENT CODES
The 17FM558 Diagnostic Information Display (DID)

(Figure 2-2) is located in the cab, behind the passenger seat. The display provides a means of communications with the TCI by service personnel.
Information from the PSC Aux Inverter is also routed
through the TCI for display on the DID.
The Tables on the following pages list the possible

event codes which may be displayed on the DID
panel when accessed. Table I (below) describes
restrictions to operation of the propulsion and retarding systems when a fault occurs for a particular code
listed in Tables II, III and IV.
The panel has two display lines, each line 40 characters long. The top line is the "message" line and is
used by the TCI to inform service personnel of the
truck systems and components status.
NOTE: Event codes numbered 000 through 099 are

applicable to the PSC and are listed in Table II.
Codes numbered 100 through 199 are applicable to
Inverter 1, and codes numbered 200 through 299 are
applicable to Inverter 2 and are listed in Table III.
Codes numbered 600 through 699 are applicable to
the TCI and are listed in Table IV.The codes listed in
the Tables are applicable to Release 18 software.
The bottom display line provides information in addition to the top line or relates to the keypad, displaying
possible selection options and display functions. The
keypad, located below the display lines is used by
service personnel to direct the activity of the TCI.
The display provides service and status information
on the various truck systems and the propulsion system by displaying system status information or fault
codes as well as a description of the system status or
a problem on the top display line. Information on the
second display line may change to indicate what
functions are available by pressing the [F1] through
[F5] keys.
In addition, the DID panel can be used by to perform
the self-load test.
TABLE I
RESTRICTION
DEFINITION
No Power
"NO RETARD" (red) light illuminates.
No Propel
NO PROPEL" (red) light illuminates.

No propulsion allowed
Retarding allowed
Link power allowed
Speed Limit
No retarding allowed
No propulsion allowed
No power on the link
PROPEL SYSTEM CAUTION"

(amber) light illuminates.
Propel, retard and DC link power
still allowed.
Speed is limited to 10 MPH
(16 KPH)
INV1 Disable
Prohibits system from enabling

inverter #1 drive signal.
INV2 Disable
Prohibits system from enabling

inverter #2 drive signal.
Engspd/RP
Raises engine speed to account for a

possible stuck RP contactor. Closes
RP1
None
No restrictions. Event is for information purposes only.
FIGURE 2-2. DIAGNOSTIC INFORMATION

DISPLAY
E02014 01/02
E2-7
TABLE II: DID PANEL FAULT CODES

(Codes Received from PSC)
EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
000
NO FAULT
002
GROUND FAULT
No power
A ground fault is detected if leakage current to ground

(truck chassis) exceeds 145 mA for more than 0.05 seconds.
003
FAILED DIODE
No power
Shorted diodes in main rectifier.
004
GFCO OPEN and not in REST
005
DRIVE SYSTEM OVERTEMP
006
E2-8
None
DETECTION
INFORMATION
None
Displayed when all faults have been reset.
GF Cutout Switch is open with the system not in REST.

Temperature exceeds a limit for a sufficient time.
:01
auxiliary phase control
:02
auxiliary inverter
:03
afse
:04
alternator
:05
left stator
:06
left rotor
No Propel
:07
right stator
:08
right rotor
:09
chopper GTO
:10
chopper diode
:11
left GTO module
:12
left diode
:13
right GTO module
:14
right diode
:15
rectifier diode
BOTH INVERTERS COMMUNICATION FAILED
No power
Lost Communication with both inverters.
01/02
E02014

EVENT
NUMBER
008
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
DC LINK OVERVOLTAGE
DC link voltage exceeds limit for a sufficient time.
:01
not in retard
Occurs while not in retard, exceeds propel voltage limit.
:02
in retard
:03
instantaneous
009
No power
ALT FIELD OVERCURRENT

:01
normal
:02
instantaneous
:01
voltage too high
:02
voltage too low
011
Alternator field current exceeds limit.

No power
Incorrect input from retard lever.

None
voltage too high
:02
voltage too low
013
LINKV TEST FAILED
014
ANALOG SENSOR FAULT

RETARD PEDAL BAD

:01
Exceeds current limit over time.

Exceeds current limit with no persistence.
RETARD LEVER BAD
012
Occurs while in retard, exceeds retard voltage limit.

Occurs instantaneously in propel or retard, exceeds link
voltage limit.
Incorrect input from retard pedal.

None

No power
Incorrect link volts

Incorrect input from a sensor.
:01
alt field amps
:02
link amps
:03
load box amps
:04
3 phase alt volts
:05
alt field volts
:10
PSC link volts
:11
inv1 link volts
:12
inv2 link volts
:13
A2D ground
:14
A2D gain
:15
fault current
:16
ATOC
:21
blower 1 amps
:22
blower 2 amps
015
Speed limit
ANALOG SENSOR FAULT (resrtictive)

:02
link amps
E02014 01/02
Speed limit

E2-9

EVENT
NUMBER
016
EVENT
DESCRIPTION
EVENT
RESTRICTION
PSC CPU CARD (FB147)

:01
task_1
:02
task_2
:03
task_3
:04
task_4
:05
task_5
:06
task_6
:07
maintenance task
DETECTION
INFORMATION
Problem has occurred in the system CPU card.
No power
:09
BRAM CRC
CRC on BRAM does not match expected value.
:10
flash CRC
Flash CRC computation did not match expected value.
:11
excess timeouts
On power up, excessive timeouts occurred.
:12
invalid pointers
On power up, the status of data in BBRAM is invalid.
017
DIGITAL I/O CARD FAULT (FB104)
018
ANALOG I/O CARD FAULT (FB143)

:01
analog card no response
:02
analog card timeout
No power
System CPU cannot communicate with digital I/O card.

System CPU cannot communicate with analog I/O card.
No power
Card missing.
Read timeout.
019
RIDING RETARD PEDAL
020
LO SPEED HI TORQUE TIMEOUT
No propel
021
TCI COMM. FAULT
No propel
No serial data received from TCI over period of time.
022
PERSISTENT TCI COMM FAULT
No power
No serial data received from TCI and truck is stopped for

10 seconds.
023
TERTIARY OVERCURRENT
No propel
Current in alternator field tertiary winding exceeds limit

over time.
024
PSC CONFIG FILE INCORRECT
Incorrect PSC configuration file.
:01
no file
No configuration file selected
:02
bad CRC
:03
wrong version
Wrong configuration file version
:04
overspeeds incorrect
Incorrect overspeed values
AUX INVERTER FAULT
Auxiliary Blower System fault.
:01
not ok or no speed feedback
Aux speed feedback indicates no or incorrect blower

speed.
:02
numerous shutdowns
025
E2-10
None
Brake pedal applied while truck speed is >5 mph

Torque limit exceeded
No power
No power
Aux ok goes low twice when speed command is greater

than running speed.
01/02
E02014

EVENT
NUMBER
026
:01
:02
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
CAPACITOR OVERPRESSURE
No power
Excessive filter cap pressure
INV1
No power
INV1 capacitor
INV2
No power
INV2 capacitor
027
PSC PANEL CONNECTOR
No power
A panel connector B, C, or D is not properly connected.
030
GF CONTACTOR
031
BATTERY BOOST CIRCUIT

:01
GFR failed to open
:02
AFSE panels
:03
SCR3 shorted
032
Speed limit
Speed limit
RP CONTACTOR
:01
RP1
:02
RP2
:03
RETARD CIRCUIT
035
ESS INPUT
036
:01
GFR command/ feedback don't agree.
RP command/ feedback don't agree.

Speed limit & engine
speed/RP
RP3
033
GF command/feedback don't agree.

speed/RP
Speed limit
Engine Speed Sensor out of range.
GY19 GRID BLOWER FAILURE
A grid blower has failed.
blower 1 stall
:02
blower 2 stall
:03
blower 1 open
:04
blower 2 open
:05
blower 1 & 2 delta too large
:01
VOLTS 5 POS
037
No power
COMPUTER POWER SUPPLY

+5V Power Supply out of limits.
:02
VOLTS 15 POS
:03
VOLTS 15 NEG
-15V Power Supply out of limits.
040
VOLTS 24 POS
041
VOLTS 24 NEG
-24V Power Supply out of limits.
042
DIRECTION SELECTED IN LOAD BOX MODE
No propel
Selector switch moved to FORWARD or REVERSE during self load.
043
DRIVE SYSTEM BATTERY LOW
Speed limit
Battery volts below limit.
044
DRIVE SYSTEM BATTERY HIGH
None
Battery volts above limit.
045
Speed limit
CHOPPER OPEN CIRCUIT

:01
chopper 1
:02
chopper 2
046
RETARD CIRCUIT SHORT
047
ENGINE STALL
E02014 01/02
Open circuit in a Chopper

Speed limit
Open circuit in Chopper 1

Open circuit in Chopper 2

speed
No power
An engine stall condition has occurred.
E2-11

EVENT
NUMBER
EVENT
DESCRIPTION
048
SHORTED DC LINK
051
TACH LEFT REAR
EVENT
RESTRICTION
No power
DETECTION
INFORMATION
DC link short detected at startup.
Input from M1 sensor out of tolerance.
:01
zero output with truck moving
:02
high output with truck stopped

TACH RIGHT REAR
Input from M2 sensor out of tolerance.
:01
Zero output from sensor with front wheels moving, brake

released.
:02
High output from sensor with all other wheel speeds

zero.
TACH LEFT FRONT
Input from left front wheel sensor out of tolerance.
052
053
INV1 disable
Zero output from sensor with front wheels moving, brake

released.
zero.
INV2 disable
:01
:02

TACH RIGHT FRONT
Input from right front wheel sensor out of tolerance.
:01
Zero output from sensor with rear wheels moving, brake

released.
:02
054
None
Zero output from sensor with rear wheels moving, brake

released.
zero.
None
High output from sensor with all other wheel speeds zero
055
FRONT WHEEL TACHS
None
056
INVERTER SW VERSION
None
061
MOTOR OVERSPEED
None
Truck is over the motor overspeed limit.
063
ENGINE LOAD SIGNAL
None
Engine load out of range.
:01
below minimum
None
:02
above maximum
None
065
TEMP INPUT RANGE CHECK
An analog input is outside the design range of valid values.
:01
aux pc temp sensor
Aux phase controller temp. sensor
:02
aux inv temp sensor
Aux inverter temperature sensor.
:03
afse temp sensor
:04
alternator temp
:05
left stator temp
Temp out of range.
:06
left rotor temp
Temp out of range.
:07
right stator temp
Temp out of range.
:08
right rotor temp
Temp out of range.
E2-12
Speed limit
AFSE temperature sensor.

Alternator temp out of range.
01/02
E02014

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
:09
chopper GTO temp
Temp out of range.
:10
chopper diode temp
Temp out of range.
:11
left GTO module temp
:12
left diode temp
Temp out of range.

Speed limit
Temp out of range.
:13
right GTO module temp
Temp out of range.
:14
right diode temp
Temp out of range.
:15
rectifier diode temp
070
Temp out of range.
LINK CAPACITANCE LEVEL LOW
None
Link capacitance level low, but OK
071
LINK CAPACITANCE LEVEL TOO LOW
Speed Limit
Link capacitance level too low
072
GROUND FAULT CIRCUIT
Speed Limit
Ground fault detection circuit
073
LEM OFFSET TOO HIGH

:01
link amps
None
074
INV1 COMM FAILED
INV1 Disable
075
INV2 COMM FAILED
INV2 Disable
076
FB173 card failure
FB173 CARD
:01
speed FPGA DL
:02
speed FPGA run
:03
ALT FPGA DL
:04
Ucontroller
:05
slow task
:06
med task
:07
fast task
:08
FD task
:09
Alternator 3 phase volts bad
:10
alt FPGA timeout
No power
077
INVERTER FAILED VI TEST
084
CONTROL POWER SWITCH OFF
None
Control Power Switch is turned off while truck is moving.
085
AUX COOLING
None
A fault has occurred in the auxiliary blower operation.
:02
aux rpmfb input
None
Rpm of Aux Blower out of range.
:03
aux rpm feedback
None
Rpm feedback does not match rpm command.
:04
abnormal shutdown
None
Horsepower adjust is at negative limit for 30 seconds.
087
HP LOW
E02014 01/02
No power
A fault occurred during shutdown
E2-13

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
088
HP LIMIT
None
Horsepower limit exceeded while in propulsion.
089
ENGINE SPEED DOES NOT MATCH COMMAND
None
Engine speed feedback does not match commanded

speed.
RPM does not match command
None
Engine speed feedback does not match commanded

speed.
091
INVERTER 1 CUTOUT
None
092
INVERTER 2 CUTOUT
None
094
ILLEGAL LIMP REQUEST
None
:02
A limp mode request is received while truck is moving.
095
BAD BRAM BATTERY
None
BRAM battery voltage low.
096
UNEXPECTED PSC CPU RESET
None
PSC CPU reset without request.
098
DATA STORE
None
PTU data store command.
099
SOFTWARE EVENT
None
Software error
E2-14
01/02
E02014
TABLE III: DID PANEL FAULT CODES

(Codes Received from Inverter 1, 2)
EVENT
NUMBER
100/200
:23
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER CPU CARD (FB138)

pat fail out 100
Pattern had bad A, B, C output 100%
:29
no extvi TIC
Extrapolation interrupt not running
:30
no vector TIC
Vector interrupt not running
:31
no I TIC TIC
I TIC interrupt not running
:32
NMI occurred
Non-maskable interrupt occurred

INV1 (INV2) off
:34
no background TIC
:35
PGA not programmed
PGA could not be programmed
:38
PGA init failed
PGA initialization failed
:39
PGA DP failed
PGA D/P did not initialize
:40
par not found
Parameter not found
:41
multiple par
Parameter multiply defined
:48
no cam TIC
Cam ISR not running
:49
no peak samp TIC
Peak sample ISR not running
101/201
Background not running
INVERTER CPU CARD (NR)
:01
Aup cmd not off
Phase A up command not off
:02
Adn cmd not off
Phase A down command not off
:03
Bup cmd not off
Phase B up command not off
:04
Bdn cmd not off
Phase B down command not off
:05
Cup cmd not off
Phase C up command not off
:06
Cdn cmd not off
Phase C down command not off
:07
Aup cmd not on
:08
Adn cmd not on
Phase A down command not on
:09
Bup cmd not on
Phase B up command not on
:10
Bdn cmd not on
Phase B down command not on
:11
Cup cmd not on
Phase C up command not on
:12
Cdn cmd not on
Phase C down command not on
:13
no chopper TIC1
Chopper 1 interrupt not running
:14
no chopper TIC2
Chopper 2 interrupt not running
:16
inv CPU reset
Inverter CPU was reset
E02014 01/02
INV1 (INV2) off
Phase A up command not on
E2-15

EVENT
NUMBER
102/202
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INV I/O CARD (FB134)
:05
gnd not ok
Logic ground not ok
:08
no IO card
Could not access I/O card
:09
eoc not working
A/D conversion did not work
:10
DB no brake
:11
ptf A signal
DB on too long while not braking

INV1 (INV2) off
Phase A overcurrent signal too long
:12
ptf B signal
Phase B overcurrent signal too long
:13
ptf C signal
Phase C overcurrent signal too long
:14
IC zero not ok
Current IC not zero at start up
:15
IC not ok
C phase current too high
:16
ptl not ok
Protective turn off circuit not ok
:17
cur measure not ok
Phase A and B currents do not match
103/203
:01
INV I/O CARD (NR)

chop 1 cmd not off
Chopper 1 command not off
:02
chop 2 cmd not off
Chopper 2 command not off
:03
chop 1 cmd not on
Chopper 1 command not on
:04
chop 2 cmd not on
Chopper 2 command not on
:05
volt scale A flt
Scale A volts out of range 70%, 100%
:06
volt scale B flt
Scale B volts out of range 70%, 100%
:07
link V scale flt
Link V scale out of range 70%, 100%
:08
current scale A flt
:09
current scale B flt
None
Scale A current out of range 70%, 100%

Scale B current out of range 70%, 100%
:10
input V scale fit
Input V scale out of range 70%, 100%
:11
V test VCO high
High frequency on VCO Vtest channel
:12
V test VCO low
Low frequency on VCO Vtest channel
:13
IA VCO hi
High frequency on IA channel
:14
IB VCO hi
High frequency on IB channel
:15
link V VCO hi
High frequency on VCO link filter V channel
:16
infilV VCO hi
High frequency on VCO in filter V channel
:17
IA too high
IA current too positive
:18
IA too low
IA current too negative
:19
IB too high
IB current too positive
:20
IB too low
IB current too negative
E2-16
01/02
E02014

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
103/203 (cont.)
:21
link V too hi
Link voltage too positive
:22
infilV too hi
Input filter voltage too positive
:23
DB chop VCO hi
High freq. on VCO DB chopper channel
:24
DB chopV too hi
DB chopper voltage too positive
:25
VA VCO hi
High freq. on VCO VA channel
:26
VB VCO hi
:27
VC VCO hi
:28
VA volts too hi
VA voltage too positive
:29
VB volts too hi
VB voltage too positive
:30
volt scale C flt
Scale C volts out of range 70%, 120%
:31
VC volts too hi
VC voltage too positive
104/204
:01
High freq. on VCO VB channel

High freq. on VCO VC channel
FIBER OPTIC CARD

fo ps low
:02
fo card disable
:03
fo card enable
105/205
None
INV1 (INV2) off
Fiber optic power supply monitor

Fiber optic card disabled
Fiber optic card enabled and no dir
POWER SUPPLY CARD
:01
P5V not ok
:02
P15V not ok
:03
N15V not ok
-15 volt not in tolerance
:06
P24V not ok
+24 volt not in tolerance
:07
N24V not ok
-24 volt not in tolerance
106/206
:01
:02
107/207

INV1 (INV2) off
DC WIRING
DC pwr conn open
INV1 (INV2) off
link V phase V mismatch
DC power connection open

Link and phase voltage mismatch
GDPS FAILURE
:01
gate dr ps off
:02
gate dr ps off S
No power to gate drive power supply or it failed with

enable/DC volts
:03
multiple GTO not off S
Multiple GTOs not off with enable/DC volts
109/209
:01
111/211
:01
INV1 (INV2) off
No power to gate drive power supply or it failed
LINK VOLTS SENSOR

linkV sensor flt
INV1 (INV2) off
Link voltage sensor failed
INPUT VOLTS SENSOR

Vfil not ok
E02014 01/02
INV1 (INV2) off
Filter voltage outside limits
E2-17

EVENT
NUMBER
113/213
E2-18
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER, GENERAL
:01
Aup cur hi
Phase A current out too high
:02
Adn cur hi
Phase A current in too high
:03
Bup cur hi
Phase B current out too high
:04
Bdn cur hi
Phase B current in too high
:05
Cup cur hi
Phase C current out too high
:06
Cdn cur hi
Phase B current in too high
:07
Aup cur lo
Phase A current out too low
:08
Adn cur lo
Phase A current in too low
:09
Bup cur lo
Phase B current out too low
:10
Bdn cur lo
Phase B current in too low
:11
Cup cur lo
:12
Cdn cur lo
:13
A zero cur hi
:15
B zero cur hi
Phase B current out not zero
:17
A volt hi Adn
Phase A volt too high while phase A down on
:18
A volt lo Aup
Phase A volt too low while phase A up on
:19
A volt hi Bdn
Phase A volt too high while phase B down on
:20
A volt lo Bup
Phase A volt too low while phase B up on
:21
A volt hi Cdn
Phase A volt too high while phase C down on
:22
A volt lo Cup
Phase A volt too low while phase C up on
:23
B volt hi Adn
Phase B volt too high while phase A down on
:24
B volt lo Aup
Phase B volt too low while phase A up on
:25
B volt hi Bdn
Phase B volt too high while phase B down on
:26
B volt lo Bup
Phase B volt too low while phase B up on
:27
B volt hi Cdn
Phase B volt too high while phase C down on
:28
B volt lo Cup
Phase B volt too low while phase C up on
INV1 (INV2) off
Phase C current out too low

Phase C current in too low
Phase A current out not zero
01/02
E02014

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
113/213 (cont.)
:29
C volt hi Adn
Phase C volt too high while phase A down on
:30
C volt lo Aup
Phase C volt too low while phase A up on
:31
C volt hi Bdn
Phase C volt too high while phase B down on
:32
C volt lo Bup
Phase C volt too low while phase B up on
:33
C volt hi Cdn
Phase C volt too high while phase C down on
:34
C volt lo Cup
Phase C volt too low while phase C up on
:35
Aup fault cur
Phase A fault current when phase A up on
:36
Adn fault cur
Phase A fault current when phase A down on
:37
Bup fault cur
Phase B fault current when phase B up on
:38
Bdn fault cur
Phase B fault current when phase B down on
:39
Cup fault cur
Phase C fault current when phase C up on
:40
Cdn fault cur
:48
A volt hi off
Phase A voltage high with all GTOs off
:49
A volt lo off
Phase A voltage low with all GTOs off
:50
B volt hi off
Phase B voltage high with all GTOs off
:51
B volt lo off
Phase B voltage high with all GTOs off
:52
C volt hi off
Phase C voltage high with all GTOs off
:53
C volt lo off
Phase C voltage high with all GTOs off
:54
phase short pos
Possible phase to DC+ short
:55
phase short neg
Possible phase to DC- short
:60
linkV too hi PTL
Link volts above PTL
:70
Aph neg I low
Phase A negative current low (unbalance)
:71
Bph neg I low
Phase B negative current low (unbalance)
E02014 01/02
INV1 (INV2) off
Phase C fault current when phase C down on
E2-19

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
113/213 (cont.)
:72
Cph neg I low
:73
Aph neg I hi
Phase A negative current high (unbalance)
:74
Bph neg I hi
Phase B negative current high (unbalance)
:75
Cph neg I hi
Phase C negative current high (unbalance)
:76
Aph pos I low
Phase A positive current low (unbalance)
:77
Bph pos I low
Phase B positive current low (unbalance)
:78
Cph pos I low
Phase C positive current low (unbalance)
:79
Aph pos I hi
Phase A positive current high (unbalance)
:80
Bph pos I hi
Phase B positive current high (unbalance)
INV1 (INV2) off
:81
Cph pos I hi
Phase C positive current high (unbalance)
:82
no current w run
No current while running
114/214
E2-20
Phase C negative current low (unbalance)
INVERTER, GENERAL (NR)
:22
IA VCO lo
Low frequency on IA channel
:24
IB VCO lo
Low frequency on IB channel
:26
linkV VCO lo
Low frequency on VCO link filter V channel
:28
infilV VCO lo
Low frequency on VCO in filter V channel
:38
LinkV too lo
Link voltage too negative
:40
infilV too lo
:46
DB chop VCO lo
:48
DB chopV too lo
DB chopper voltage too negative
:50
VA VCO lo
Low frequency on VCO VA channel
:52
VB VCO lo
Low frequency on VCO VB channel
:54
VC VCO lo
Low frequency on VCO VC channel
:56
VA volts too lo
VA voltage too negative
:58
VB volts too lo
VB voltage too negative
:61
VC volts too lo
VC voltage too negative
None
Input filter voltage too positive

Low frequency on VCO DB chopper channel
01/02
E02014

EVENT
NUMBER
115/215
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER SYSTEM
:01
no direction
No direction called for
:02
for dir mismatch
Calling forward, running backward
:03
rev dir mismatch
Calling reverse, running forward
:04
input volt low
Input voltage too low
:05
link volt low
Link filter voltage too low
:06
no hi spd data
:07
V line not ok
Line voltage not ok
:08
I line not ok
Line current not ok
:09
sys TIC fail
System TIC not being updated.
:10
DB GTO jn hot
DB GTO junction too hot
:11
inv GTO jn hot
Inverter GTO junction too hot
:12
VI test incomplete
VI test incomplete
116/216
INV1 (INV2) off
No high speed data from system controller
INVERTER, PHASE A+/A-
:01
alarm A
:02
PTF A
:03
IGBT_SAT_AP
IGBT saturated.
:04
IGBT_SAT_AN
IGBT saturated.
117/217
Phase A GTO did not turn off

INV1 (INV2) off
Overcurrent in phase A
INVERTER, PHASE A+
:01
alarm AP
:02
Aup fb not off
:03
phase A modl pos
:04
hold AP
Phase A positive and negative GTOs on (positive turn on)
:05
Aup fb not on
Phase A feedback not on
:06
Aup GTO not on
Phase A positive GTO did not turn on
:07
IGBT_PS_AP
IGBT protective shutoff
118/218
Phase A pos GTO did not turn off

Phase A up feedback not off
INV1 (INV2) off
Phase A positive module failed
INVERTER, PHASE A+ (NR)
:02
Aup temp short
:03
Aup temp open
:04
Aup temp warm
Phase A up thermistor short

None
Phase A up thermistor open

Phase A up thermistor warm
:05
Aup temp hot
Phase A up thermistor hot
:06
Aup fb not off S
Phase A not off with enable/DC volts
E02014 01/02
E2-21

EVENT
NUMBER
119/219
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER, PHASE A-
:01
alarm AN
:02
Adn fb not off
:03
phase A modl neg
:04
hold AN
Phase A positive and negative GTOs on (negative turn on)
:05
Adn fb not on
Phase A down feedback not on
:06
Adn GTO not on
Phase A negative GTO did not turn on
:07
IGBT_PS_AN
120/220
:02
Phase A negative GTO did not turn off

Phase A down feedback not off
INV1 (INV2) off
Phase A negative module failed
INVERTER, PHASE A- (NR)

Adn temp short
Phase A down thermistor short
:03
Adn temp open
:04
Adn temp warm
Phase A down thermistor warm
:05
Adn temp hot
Phase A down thermistor hot
:06
Adn fb not off S
Phase A down not off with enable/DC volts
121/221
None
Phase A down thermistor open
INVERTER, PHASE A CURR
:01
I sensor ph A
:02
IA zero not ok
:03
IA not ok
:04
I snsr ph A open
Phase A current sensor open
:05
I snsr ph A short
Phase A current sensor short
123/223
INV1 (INV2) off
Current IA not zero at startup

Phase A current too high
INVERTER, PHASE A VOLTS
:01
V sensor phase A
:02
VA not ok
125/225
Phase A current sensor failed
INV1 (INV2) off
Phase A voltage sensor failed

Phase A voltage too high
INVERTER, PHASE B+/B-
:01
alarm B
:02
PTF B
:03
IGBT_SAT_BP
IGBT saturated
:04
IGBT_SAT_BP
IGBT saturated
126/226
INV1 (INV2) off
Phase B GTO did not turn off

Overcurrent on phase B
INVERTER, PHASE B+
:01
alarm BP
:02
Bup fb not off
:03
phase B modl pos
Phase B positive module failed
:04
hold BP
Phase B positive and negative GTOs on (positive turn on)
:05
Bup fb not on
Phase B feedback not on
:06
Bup GTO not on
Phase B positive GTO did not turn on
E2-22
Phase B GTO did not turn off

INV1 (INV2) off
Phase B up feedback not off
01/02
E02014

EVENT
NUMBER
127/227
:02
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER, PHASE B+
Bup temp short
Phase B up thermistor short
:03
Bup temp open
:04
Bup temp warm
Phase B up thermistor warm
:05
Bup temp hot
Phase B up thermistor hot
:06
Bup fb not off S
Phase B up not off with enable/DC volts
128/228
:01
None
Phase B up thermistor open
INVERTER, PHASE Balarm BN
Phase B negative GTO did not turn off
:02
Bdn fb not off
Phase B down feedback not off
:03
phase B modl neg
Phase B negative module failed
:04
hold BN
:05
Bdn fb not on
INV1 (INV2) off
Phase B positive and negative GTOs on (negative turn on)

Phase B down feedback not on
:06
Bdn GTO not on
Phase B negative GTO did not turn on
:07
IGBT_PS_BN
129/229
:02
INVERTER, PHASE B- (NR)

Bdn temp short
Phase B down thermistor short
:03
Bdn temp open
:04
Bdn temp warm
Phase B down thermistor warm
:05
Bdn temp hot
Phase B down thermistor hot
:06
Bdn fb not off S
Phase B down not off with enable/DC volts
130/230
None
Phase B down thermistor open
INVERTER, PHASE B CURR
:01
I sensor ph B
:02
IB zero not ok
:03
IB not ok
Phase B current sensor failed

INV1 (INV2) off
Current IB not zero at startup

Phase B current too high
:04
I snsr ph B open
Phase B current sensor open
:05
I sensr ph B short
Phase B current sensor short
132/232
INVERTER, PHASE B VOLTS
:01
V sensor phase B
:02
VB not ok
134/234
INV1 (INV2) off
Phase B voltage sensor failed

Phase B voltage too high
INVERTER, PHASE C+/C-
:01
alarm C
:02
PTF C
:04
IGBT_SAT_CP
IGBT saturated
:05
IGBT_SAT_CN
IGBT saturated
E02014 01/02
Phase C GTO did not turn off

INV1 (INV2) off
Overcurrent on phase C
E2-23

EVENT
NUMBER
135/235
:01
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
INVERTER, PHASE C+/Calarm CP
Phase C positive GTO did not turn off
:02
Cup fb not off
:03
phase C modl pos
:04
hold CP
Phase C positive and negative GTOs on (positive turn on)
:05
Cup fb not on
Phase C up feedback not on
:06
Cup GTO not on
Phase C positive GTO did not turn on
:07
IGBT_PS_CP
136/236
:02
Phase C up feedback not off

INV1 (INV2) off
Phase C positive module failed
INVERTER, PHASE C+
Cup temp short
Phase C up thermistor short
:03
Cup temp open
:04
Cup temp warm
Phase C up thermistor warm
:05
Cup temp hot
Phase C up thermistor hot
:06
Cup fb not off S
Phase C up not off with enable/DC volts
137/237
:01
None
Phase C up thermistor open
INVERTER, PHASE Calarm CN
Phase C negative GTO did not turn off
:02
Cdn fb not off
:03
phase C modl neg
:04
hold CN
Phase C positive and negative GTOs on (negative turn on)
:05
Cdn fb not on
Phase C down feedback not on
:06
Cdn GTO not on
Phase C negative GTO did not turn on
:07
IGBT_PS_CN
138/238
:02
Phase C down feedback not off

INV1 (INV2) off
Phase C negative module failed
INVERTER, PHASE C- (NR)

Cdn temp short
:03
Cdn temp open
:04
Cdn temp warm
Phase C down thermistor short

Phase C down thermistor open
None
Phase C down thermistor warm
:05
Cdn temp hot
Phase C down thermistor hot
:06
Cdn fb not off S
Phase C down not off with enable/DC volts
141/241
INVERTER, PHASE C VOLTS
:01
V sensor phase C
:02
VC not ok
E2-24
INV1 (INV2) off
Phase C voltage sensor failed

Phase C voltage too high
01/02
E02014

EVENT
NUMBER
143/243
:01
EVENT
DESCRIPTION
tach1 rate hi
tach1 no input
:03
TACH_INTERMIT
:01
145/245
:01
:02
146/246
:01
148/248
DETECTION
INFORMATION
INVERTER, TACH 1 (NR)
:02
144/244
EVENT
RESTRICTION
INV1 (INV2) off
Tach 1 high rate of change

Tach 1 no frequency input
None
tach1 one channel
Tach 1 single channel operation
INVERTER, TACH 2
None
tach2 high rate

tach2 no input
Tach 2 high rate of change

Tach 2 no frequency input
None
tach2 one channel
Tach 2 single channel operation
INVERTER, CHOPPER 1 (NR)
:01
chop1 fb not off
Chopper 1 feedback not off
:02
chop1 fb not on
Chopper 1 feedback not on
:03
chopA temp short
:04
chopA temp open
ChopA thermistor open
:05
chopA temp warm
ChopA thermistor warm
:06
chopA temp hot
ChopA thermistor hot
:07
DB1 fb not off S
Chopper 1 not off with DC volts
150/250
None
ChopA thermistor short
INVERTER, CHOPPER 2 (NR)
:01
chop2 fb not off
Chopper 2 feedback not off
:02
chop2 fb not on
Chopper 2 feedback not on
:03
chopB temp short
:04
chopB temp open
ChopB thermistor open
:05
chopB temp warm
ChopB thermistor warm
:06
chopB temp hot
ChopB thermistor hot
:07
151/251
:01
153/253
DB2 fb not off S
ChopB thermistor short
Chopper 2 not off with DC volts
MISCELLANEOUS
INV1 (INV2) off
tach differential
Too much speed difference.
INVERTER, MOTOR
:01
motor open
:02
motor short
154/254
None
INV1 (INV2) off
Motor connection open

Motor connection short
INVERTER MOTOR FAULTS (NR)
:01
rotor temp hi
:02
stator temp hi
E02014 01/02
None
Motor rotor temperature high

Motor stator temperature high
E2-25
TABLE IV: DID PANEL FAULT CODES

EVENT
NUMBER
155/255
:01
EVENT
DESCRIPTION
INVERTER, SECOND LOAD
EVENT
RESTRICTION
None
second load open
Second load connection open
175/275
INV 1 GENERIC EVENT
None
176/276
INV 1 GENERIC EVENT
INV1 (INV2) off
E2-26
DETECTION
INFORMATION
Inverter shutdown with no event code.
01/02
E02014

(Codes Received from TCI)
EVENT
NUMBER
601
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
TCI FB144 CPU CARD
TCI CPU card problem.
:01
10ms task failed to init
:02
:03
:04
:05
:06
flt manager task
:07
flash CRC

No propel
:09
maint task failed to init
:10
excess timeouts
Upon power-up, excessive bus timeouts occurred.
:11
BBRAM bad
:12
BBRAM CRC
CRC on BBRAM did not match expected value.
602
FB104 DIGITAL I/O CARD FAULT
No propel
Internal TCI self-test detected a digital I/O card problem.
603
FB160 ANALOG I/O CARD FAULT
No propel
Internal TCI self-test detected an analog I/O card problem.
604
:01
605
PSC FAULT
Lost RS422 communication with PSC.
missing message
:02
bad tick
:03
bad CRC

Speed limit
:04
FIFO overflow
:05
bad start bit
:06
bad stop bit
AUX BLOWER COMM. FAULT
Lost RS422 communication with Aux Blower Controller

while Aux Blower in failure mode and DC link not energized.
None
607
POSITIVE 5 VOLTS
Speed limit
+5V power supply out of limits
608
POSITIVE 15 VOLTS
Speed limit
+15V power supply out of limits
609
NEGATIVE 15 VOLTS
Speed limit
-15V power supply out of limits
610
POT REFERENCE
Speed limit
Pot reference (10.8V) out of limits
E02014 01/02
E2-27

EVENT
NUMBER
611
EVENT
DESCRIPTION
EVENT
RESTRICTION
FREQUENCY INPUT
DETECTION
INFORMATION
Front wheel speed input out of range
None
:01
left front wheel speed
:02
right front wheel speed
Right front wheel sensor out of range.
ANALOG INPUT
Signal is outside the design range of valid values.
613
None
Left front wheel sensor out of range.
:01
A2D gnd
:02
A2D gainchk
BATTERY SEPARATE CONTACTOR FAILURE
:01
Battery Separate Failure
:02
crank batt > cntrl batt
:03
cntrl batt > crank batt
614
616
None

Voltage difference greater than 3V
Voltage difference greater than 3V
DIRECTION MISMATCH
617
No propel
Simultaneous FORWARD and REVERSE commands

received.
ENGINE START REQUEST DENIED
Engine start request denied due to the following:
:01
engine warn while cranking
Engine warning occurs after engine crank command

given.
:02
engine kill while cranking
None
Engine kill input occurs while engine crank command is

active.
619
ENGINE WARNING RECEIVED
No propel
Engine controller sends caution signal, rpm above low

idle.
620
ENGINE KILL WHILE VEHICLE MOVING
No propel
Engine shutdown switch activated while truck is moving.
622
PARK BRAKE FAULT
Error in park brake operation has occurred.

No propel
:01
command/response failure
:02
set above maximum speed
Park brake set feedback received when truck is moving.
HYDRAULIC BRAKE FLUID
Hydraulic brake oil temperature has exceeded limit.
623
:01
tank
:02
left front outlet
:03
right front outlet
:04
left rear outlet
:05
right rear outlet
E2-28
Park brake command and feedback don't agree.
None
01/02
E02014

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
624
BODY UP AND PAYLOAD INDICATION
625
DUMP BODY UP WITH SPEED
Speed Limit
None
626
LOAD BRAKE APPLIED WITH SPEED
None
628
CONNECTED BATTERY VOLTS
DETECTION
INFORMATION
Full payload and body up signal received at same time.
Dump body raised while truck is moving.
One of the connected batteries' volts incorrect with engine
speed above low idle.
:01
control battery low
:02
control battery high
:03
crank battery low
:04
crank battery high
Cranking battery voltage above maximum limit.
BAROMETRIC PRESSURE SIGNAL
Barometric pressure signal outside operational limits.
629
None
Control battery voltage below minimum limit

Control battery voltage above maximum limit.
Cranking battery voltage below minimum limit.
None
:01
low
:02
high
Voltage above maximum operational limit.
MOTOR BLOWER PRESSURE
Motor inlet and outlet pressure signal outside operational

limits.
630
:01
no cooling air
:02
low
:03
high voltage
:04
sensor reversed
:02
high
631
Speed Limit
No voltage signal feedback

Voltage feedback below minimum operational limit.
AMBIENT TEMPERATURE
632
Voltage below minimum operational limit.
Ambient temperature signal outside operational limits.

None
TCI CONFIGURATION DATA
No propel
Problem with TCI configuration file.
:01
no file
No propel
No configuration file loaded.
:02
bad CRC
No propel
:03
version incorrect
No propel
633
BBRAM CORRUPTED
634
TRUCK OVERLOADED - RESTRICTIVE
635
TRUCK OVERLOADED - NON-RESTRICTIVE
E02014 01/02
None
Speed limit
None
Wrong version of file loaded.

Battery backed RAM has failed.
The over-payload signal is on, speed is reduced.
The over-payload signal is on, propulsion allowed.
E2-29

EVENT
NUMBER
636
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
AUX INVERTER
None
An Auxiliary Blower Control failure has occurred.
buss volts low
None
Low dc bus detected during powerup.
:02
buss volts high
None
High dc bus detected during powerup.
:03
overcurrent
None
Overcurrent condition detected during operation.
:01
:04
battery loss
None
Loss of blower control battery voltage has occured.
:05
high dc buss when running
None
High dc bus voltage detected during operation.
:06
high dc buss after pc powerup
None
High dc bus voltage detected after phase controller

powerup.
:07
Low dc buss after pc powerup
None
Low dc bus voltage detected after phase controller

powerup.
:08
high dc buss when running
None
High dc bus voltage detected during operation.
:09
overcurrent after pc powerup, current overload
None
Overcurrent condition detected after phase controller

power up.
:10
current overload
None
Sustained current overload exists.
:11
low dc buss overcurrent
None
Overcurrent due to low dc bus voltage.
:12
low dc buss current overload
None
Sustained current overload due to low dc bus voltage.
:13
gate drive trip
None
IGBT protection circuit detected overload.
:14
no input voltage
None
Zero input voltage detected.
638
ENGINE CRANKING TIMEOUT
None
639
ENGINE START REQUEST WHILE RUNNING
None
640
ACCEL PEDAL TOO HIGH
No Propel
Accelerator pedal voltage high
641
ACCEL PEDAL TOO LOW
None
Accelerator pedal voltage low
642
ENGINE STARTED USING OVERRIDE
None
696
UNEXPECTED TCI CPU RESET
None
TCI CPU reset without request.
698
DATA STORE
None
A data snapshot has been manually initiated.
E2-30
01/02
E02014

EVENT
NUMBER
EVENT
DESCRIPTION
EVENT
RESTRICTION
DETECTION
INFORMATION
638
ENGINE CRANKING TIMEOUT
None
639
ENGINE START REQUEST WHILE RUNNING
None
640
ACCEL PEDAL TOO HIGH
No propel
Accelerator pedal voltage high
641
ACCEL PEDAL TOO LOW
None
Accelerator pedal voltage low
642
ENGINE STARTED USING OVERRIDE
None
696
UNEXPECTED TCI CPU RESET
None
TCI CPU reset without request.
698
DATA STORE
None
A data snapshot has been manually initiated.
E02014 01/02
E2-31
PSC SOFTWARE FUNCTIONS
Test State:
The operation of the AC Drive System is regulated by

a software program which resides in the Propulsion
System Control Panel's memory. The software program also contains instructions to test and fault isolate the system.
The purpose of this state is to provide an environment for the verification of system functionality. Test
state will support a variety of activities, including:
This section describes the PSC software program

and its functions without regard to hardware.
1. Waiting for the engine to start (if needed).

2. Automatic testing on initial system startup or following rest state.
3. Application of power to the DC link.
4. Externally initiated testing to clear a fault, set
temporary variables, or for maintenance purposes.
Input Processing
This function reads in all external inputs for use by
the PSC. The Input Processing function performs
any signal conditioning required and computes the
required derived inputs.
NOTE: The Test state may be either powered or

unpowered at a given point in time, depending on
which activities are being performed.
Ready State:
STATE MANAGEMENT
State Machine
As part of the total software package, a particular
group of regulatory software commands is included
called a "state machine". The state machine controls
the various functions of truck operation.
The software implements the state machine by keeping track of which state the truck is in, and which
state the truck is allowed to move into if the operator
requests a different mode of operation. Each software state is defined as follows:
Startup/Shutdown State:
The purpose of this state is to ensure the system is in
a desired known state upon startup or shutdown.
This is an unpowered state.
NOTE: Powered and unpowered refer to the state of
the DC link; 600 volts or more on the DC link equals
"powered". 50 volts or less on the DC link equals
"unpowered".
E2-32
Ready state is the default powered state. The system

will be in this state whenever the engine and control
system are ready to provide power, but none is
requested.
Ready state also is the state where the DC link is discharged in preparation for Shutdown, Rest, or in
reaction to certain event conditions. Therefore,
Ready state should not be considered strictly a powered state (as are Propel and Retard described
below).
Rest State:
Rest is an unpowered state whose purpose is to conserve fuel while the truck idles for an extended period
of time. Rest state also provides an environment
where maintenance personnel can control the engine
without causing power to be applied to the DC link.
Propel State:
The purpose of this state is to provide the power system configuration and overall environment for
engine-powered propulsion. This is strictly a powered
state, i.e., the system will not be allowed to maintain
propel state without sufficient power on the DC link.
01/02
E02014
Retard State:
Transition from Test State to Ready State:
This state provides the power system configuration

and overall environment for retard, where energy
from vehicle movement is dissipated in the retard
grid resistors in an effort to slow the truck. Retard
state is strictly a powered state.
This transition will occur upon completion of any

required testing if all of the following conditions are
true:
Transitions Between States
Transition to Rest State:
Transitions between states under normal operational

conditions (no failures, etc.) are described as follows:
This transition will occur automatically from the Test

or Ready state if a request for Rest state is received
from the TCI and all of the following conditions are
true:
Transition to Startup/Shutdown State (Startup):

The system will transition to the Startup/Shutdown
state for the purpose of "startup" whenever execution
control is initially transferred to the application program (e.g., after application of power, system reset,
etc.).
Transition to Startup/Shutdown State
(Shutdown):
The system will transition to the Startup/Shutdown
state for the purpose of "shutdown" from the Test,
Rest, Ready, or Startup/Shutdown (if previously
entered for the purpose of startup) state if all of the
following conditions are true:
1. The TCI rest request is not active.

2. There is sufficient voltage on the DC link.
1. Any testing in progress is complete.

2. The system temperatures are cool enough to
allow the Rest state (function of GTO Phase
Module, Chopper Module, and Motor temperatures).
3. The AFSE is disconnected and there is essentially no voltage on the DC link.
4. The truck is not moving.
Transition from Ready State to Test State:
This transition will occur if the truck is not moving,
and a request for testing is received.
1. System power is removed or the Control Power

Switch or Key Switch is turned off.
Transition from Ready State to Propel State:
The system will transition from Ready state to Propel

state if all of the following conditions are true:
3. There is essentially no voltage on the DC link.

4. Any testing in progress is complete.
1. The accel pedal is pressed.

NOTE: Testing in progress does not have to be
successful, but for the purpose of ensuring an orderly
shutdown it must be complete before the current
state is exited.
2. A direction has been chosen, i.e., the truck is

either in FORWARD or REVERSE.
3. There is sufficient voltage on the DC link.
4. At least one of the following conditions is true:
a. The retard pedal or lever is not pressed or is
pressed such that an insignificant amount of
retarding effort is requested.
Transition from Startup/Shutdown State to Test

State:
b. Truck speed is such that retard is not

allowed.
This transition will occur automatically once initialization is complete (i.e., functions performed while in
Startup/Shutdown state for the purpose of startup
have been completed).
5. Truck speed is less than the motor overspeed

limit.
E02014 01/02
6. The TCI accel inhibit is not active.
E2-33
Transition from Ready State to Retard State:
Transition from Propel State to Retard State:
The system will transition from Ready state to Retard

state if truck speed is such that retard is allowed and
at least one of the following conditions exists:
The system will transition directly from Propel state to

Retard state if at least one of the following conditions
exists:
1. The retard pedal or lever is pressed such that a

significant amount of retarding effort is
requested.
1. Truck speed is such that retard is allowed, and

the retard pedal or lever is pressed such that a
significant amount of retarding effort is
requested.
2. All of the following conditions are true:

a. Retard speed control is selected.
b. Truck speed exceeds the set retard speed,
or the truck is accelerating such that the
truck speed will soon exceed the set retard
speed if no action is taken.
c. One or both of the following conditions are
true:
1.)The accel pedal is not pressed, or
2.)The truck is configured such that accel
pedal signal does not override retard
speed control.
3. Truck speed is greater than or equal to motor
overspeed limit. Overspeed will not be engaged
such that it prevents the truck from propelling at
40 mph (64 kph).
Transition from Rest State to Test State:
The system will transition from Rest state to Test
state upon release of the TCI rest request.
NOTE: A transition directly from Rest state to Ready
state is not allowed because the system is essentially
off and should be brought back on-line and checked
out before Ready state is entered.
Transition from Propel State to Ready State:
The system will transition from Propel state to Ready
state if all of the following conditions exist:
1. The accel pedal is not pressed.
2. The retard pedal or lever is not pressed or is
3. Truck speed is less than the motor overspeed
limit.
a. Retard speed control is not selected.
b. Truck speed is below the set retard speed,
and acceleration is such that no retard effort
is (currently) required to maintain this condition.
E2-34
2. Truck speed exceeds the motor speed limit.

Overspeed Will not be engaged such that it prevents the truck from propelling at 40 mph (64
kph).
3. All of the following conditions are true:
a. Retard speed control is selected.
b. Truck speed exceeds the set retard speed,
or the truck is accelerating such that the
truck speed will soon exceed the set retard
speed if no action is taken.
c. The truck is configured such that accel pedal
signal does not override retard speed control.
Transition from Retard State to Ready State:
The system will transition from Retard state to Ready
state if all of the following conditions exist:
1. Overspeed is not active.
a. The retard pedal or lever is not pressed or is
b. Truck speed is such that retard is not
allowed.
3. At least one of the following conditions exists:
a. Retard speed control is not selected.
b. Truck speed is low enough such that retard
speed control is not active.
c. The accel pedal is pressed, and the truck is
configured such that the accel pedal overrides retard speed control. This allows the
configuration constant to determine if pressing on the accel pedal kicks the truck out of
retard, even if retard speed control is still
active.
4. The retard torque control logic exit sequence is
complete.
01/02
E02014
DC Link State
De-Powering the Link
Power is provided to the inverters and motors via the

DC link. The DC link has two associated states: powered and unpowered. The following defines the conditions necessary to establish each state as well as
the transitional conditions between the two states:
The PSC software will attempt to de-power the DC

link (i.e., command the system configuration defined
below) if the system is in Test or Ready state, and
any of the following conditions are true:
Powering the Link

The PSC software will attempt to power the DC link
(i.e., command the system configuration defined
below) if all of the following conditions are true:
1. Event restrictions do not prohibit power on the
DC link.
2. The system is in Test state and any initiated
testing is complete.
3. The engine is running.
4. The Gate Drive Power Converters have been
enabled.
5. Neither inverter is requesting that a low voltage
test be run.
In attempting to power the DC link, the PSC software
will establish the necessary system configuration as
follows:
1. Event restrictions prohibit power on the DC link,

2. The system is preparing to transition to Startup/
Shutdown state for the purpose of shutdown
(i.e., all the non-link-related conditions for Startup/Shutdown state have been satisfied),
3. The system is preparing to transition to Rest
state (i.e., all the non-link-related conditions for
Rest state have been satisfied),
4. The engine is being shut off.
To accomplish this, the PSC software will establish
the necessary system configuration as follows:
1. Alternator field reference set to zero,
2. AFSE disabled,
3. GF open and GFR dropped out,
4. Chopper turn on voltage set below approximately 600 volts,
5. Close RP2 or RP3, alternating each time to provide even wear.
1. GF closed and GFR picked up,
Control Functions
2. AFSE enabled,
Engine Control
3. Alternator field reference is commanded such

that the desired DC link voltage or three-phase
voltage is maintained,
4. RP contactors open,
5. Chopper turn-on voltage is set above 600 volts.
This software function generates the engine speed

command. The engine electronic fuel control is
responsible for maintaining that speed.
The desired engine speed is determined according to
the system state:
Propel State:
NOTE: Before the AFSE is allowed to output firing

pulses, the RP contactors will be commanded open
and GF contactor will be verified to be closed. The
AFSE will not output firing pulses if it is disabled, if
GFR is dropped out, or if the alternator reference
signal is 0.
E02014 01/02
The engine speed is commanded such that the

engine supplies only as much horsepower as is
required to achieve the desired torque.
All Other States:
The engine speed is a direct function of the accel
pedal. Additional constraints on the engine speed
command are:
E2-35
1. If the truck is in neutral, the commanded engine

speed at full scale accel pedal will be the
engine's high idle. If the truck is not in neutral,
the maximum commanded engine speed will be
the engine's rated horsepower rpm. This allows
faster hoisting of the truck bed, if desired.
These maximum speeds apply to the MTU
engine.
2. During retard state the engine speed command
will not be increased to support the DC link
when retard is being ramped out at low truck
speeds. However, engine speed may be
increased if needed to support the DC link during normal retard when wheel slides are occurring.
The following constraints are applied to generating
the engine speed command during all operating
states:
The engine speed command will always be
greater or equal to minimum idle signal. The TCI
can request the engine speed command be
increased by setting minimum idle.
The engine speed command will be increased if
more alternator cooling is needed.
ALTERNATOR FIELD CONTROL

The alternator is controlled by controlling the Alternator field reference sent to the AFSE.
The desired alternator output voltage is dependent
on system state. The PSC will command an alternator field reference such that the desired DC link voltage or three-phase voltage is maintained.
Desired Three-Phase Voltage
During all powered states, the three-phase line-toline voltage will not be allowed to drop below 444
volts. This is the minimum voltage needed to supply
the gate drive power converters and the auxiliary
blower inverter.
Desired DC Link Voltage

The desired link voltage is controlled by the alternator during all powered states except retard. The
desired voltage is based on:
1. During propel, the desired DC link voltage will
be adjusted based on motor speed and horsepower commanded to the inverters.
2. During retard, the DC link voltage may rise
above the rectified three-phase voltage. When
this occurs, the DC link voltage is controlled by
the retard torque command, grid resistor command and chopper start. If conditions occur
which prevent the motors from producing power
to support the resistor grids, the alternator may
be required to supply some power. In this case,
the alternator field control will maintain at least
600 volts on the DC link.
3. During all powered states, the DC link voltage
will not be allowed to drop below 600 volts.
4. While the DC link is being powered up, the voltage will be controlled to the levels necessary to
support the inverter self-tests.
Self-load
During self-load, the alternator provides power to the
resistor grids. The rectifying diodes will be forward
biased, and DC link voltage will be controlled by the
alternator. The alternator field control will be based
on the following:
1. The DC link voltage will not be allowed to drop
below 600 volts.
2. One mode of self-load will require the alternator
output to be controlled to maintain a set desired
horsepower dissipation in the resistor grids.
3. Another mode of self-load will require the alternator output to be controlled to maintain a set
desired link voltage between 600 volts and
1500 volts.
During all powered states except retard, the DC link

voltage will represent the rectified three-phase voltage. In this case, as long as the DC link voltage is
above 600 volts, the three-phase voltage will be adequate.
During retard, the DC link voltage is not necessarily
related to the three-phase voltage since the motors
will be powering the DC link and reverse biasing the
rectification diodes. In this case, the control ensures
that the minimum three-phase voltage is maintained.
E2-36
01/02
E02014
Propel Torque Control
Retard Torque Control
This software function commands the appropriate

motor torque to the inverters during propel. The
torque command is primarily a function of the accel
pedal position and is limited by the physical constraints of the system.
The retard system converts braking torque from the

wheel motors to energy dissipated in the resistor
grid. The requested retard torque is based on the following three sources:
Each wheel torque is computed independently

because the wheels may be operating at different
speeds. Each torque command is adjusted to
account for the following constraints:
Speed Override
The propulsion system will attempt to limit truck
speed to the design envelope of the wheel
motors. As such, the torque command will be
modulated as the truck speed approaches the
motor overspeed limit so that this limit is not
exceeded if possible. Note, however, that steady
state operation is kept as close to the overspeed
limit as possible without exceeding it.
Motor Torque Limits
The torque command will be constrained to the
operating envelope of the inverters and the
traction motors. The maximum torque that can be
commanded is dependent on motor speed and
on DC link voltage.
Gear Stress
The torque commanded will not exceed that
which will produce excess gear stress.
Horsepower Available
The horsepower available will be estimated from
the engine speed. Parasitic loads are taken into
account. The torque will be limited such that the
engine does not overload.
Jerk Limit
The torque command will be slew-rate limited to
prevent jerking motion.
Wheel Spin
In the event that the inverters detect a wheel spin
condition and reduce torque in the slipping
wheel, the motor torque in the other wheel may
be increased within the above constraints such
that as much of the total desired torque as
possible is maintained.
E02014 01/02
Retard Foot Pedal or Lever

The maximum short time retard torque (at any
speed, hence the constant torque level) will be
scaled (linearly) by the retard foot pedal input
(RPINHI) to produce the foot pedal retard torque
call.
Overspeed
While overspeed is active, the full available retard
torque will be requested.
Retard Speed Control
While RSC is active, the RSC retard torque call
will be adjusted to control truck speed to the RSC
set point. Retard speed control will not request
any retard torque if RSC is not active.
The maximum torque call from the above three
sources will be selected as the retard torque call.
Retard Torque Limits are as follows:
1. The retard torque call will be limited to the maximum torque level based on speed.
2. The retard torque call will be limited to the maximum torque level available within the thermal
constraints of the motors.
3. The retard torque call will be limited as needed
to prevent overvoltage on the DC link.
4. While in retard, the minimum retard torque call
will provide enough power to support at least
one grid with 600 volts on the DC link. Retard
will be dropped if the torque call falls below this
value.
5. At low speed, the available retard torque will be
ramped to zero.
Wheel Slide Control

The inverters prevent wheel slide by limiting torque to
maintain wheel speeds above preset limits. These
preset limits are a function of truck speed and the
allowable creep; additional compensation will be
applied to provide for differences between wheel
speeds during turns.
E2-37
Resistor Grid Control
EVENT PROCESSING
The first resistor grid (RG1) will always be engaged

when retard is active since the grid blower motors are
wired across it.
The PSC contains very powerful troubleshooting

software. The PSC software constantly monitors the
AC drive System for any abnormalities (events).
The second and third fixed resistor grids (controlled

by RP2 and RP3) will be engaged as needed to dissipate the energy produced in retard state. Limitations
are:
Automatic self-tests are performed periodically on

various parts of the system to ensure its integrity.
Additionally, there are some elaborate tests which
may be run by an electrician with the use of DID
screens. Predictive analysis is used in some areas to
report potential problems before they occur.
1. The use of RP2 and RP3 will be alternated to

provide even wear on the contactors.
2. The grids will be engaged to prevent drawing
more power than the motors can produce. At
high motor speeds the maximum motor torque
does not produce enough power to support
three grids across the DC link (at the given voltage). Therefore, at high speeds, only two resistor grids will be engaged.
Note: The 17KG526A1 Electrical Cabinet does not
have RP3 installed.
The troubleshooting system is composed of two

parts:
1. The PSC for detection, event logging, data storage and fault light indications.
2. The TCI (or a PTU) for retrieval of stored event
information, real time vehicle status, troubleshooting, etc.
Chopper Voltage Control

Chopper turn-on voltage will be set to give the motors
as much of the retard envelope as possible (i.e.,
keep the voltage as close to the maximum value as
possible) and to keep the DC link voltage at or below
the maximum link voltage value.
Event Detection
This software function is responsible for verifying the
integrity of the PSC hardware and the systems to
which the PSC interfaces by detecting an "event"
(abnormal condition).
The events fall into three detection categories:
AUXILIARY BLOWER CONTROL
Power On Tests
The Auxiliary Blower Control regulates the temperatures of the AFSE, auxiliary blower system, rectifier
diodes, phase modules, chopper modules, and traction motors by controlling the speed of the auxiliary
blower. Additionally, this software function checks for
faults in the auxiliary blower.
Three power-on tests are executed once every time

power is applied to the PSC. They are as follows:
This software function is performed using the following process:

1. The commanded auxiliary blower speed will be
calculated to control all system temperatures.
The control priorities will be:
a. Keep all temperatures below allowable maximums.
b. Keep the GTO temperatures as constant as
possible.
2. If the aux blower system status (AUXOK) indicates the aux blower system is not okay, a reset
pulse will be sent. Additional reset pulses will be
sent at periodic intervals if the aux blower system does not respond.
E2-38
1. CPU Card Checks - Upon powerup, the PSC

will confirm the integrity of its CPU card hardware before transferring execution control to
the application program residing in its FLASH
memory.
2. Battery-backed RAM (BBRAM) Test/Adjustable
Parameter Initialization - A battery backed RAM
(BBRAM) check will be performed to check for
BBRAM data integrity. If the check fails, all TCI/
PTU-adjustable parameters will be initialized to
their default values.
3. Inverter Powerup Tests - The purpose of these
tests is to verify that each inverter sub-system is
functional:
a. Enabling Inverter Powerup Tests - The powerup tests for a given inverter will be enabled
if all of the following conditions are true:
1.) The system is in Test state for the purpose
of powerup.
01/02
E02014
2.) The associated gate drive power converter has been enabled.
3.) The engine is running.
4.) Battery voltage is at least 25 VDC.
5.) The inverter is requesting that the low
voltage and/or high voltage powerup tests
be performed.
6.) The inverter has not been physically cut
out of the system.
7.) Active event restrictions do not preclude
powering the DC link or running the
inverter.
b. Low Voltage Test - A given inverter will automatically perform its low voltage test if
needed once inverter powerup testing is
enabled per the above requirements. The
PSC will declare the test failed and log an
event if the test does not successfully complete within an expected time period.
c. High Voltage Test - If the low voltage testing
defined above is successful for a given
inverter, the inverter will automatically perform its high voltage test if needed once
there is sufficient power on the DC link. The
PSC will declare the test failed and log an
event if the test does not successfully complete within an expected time after the DC
link is sufficiently powered.
4. DC Link Capacitance Test - Test will run once
every 24 hours when conditions allow, normally
after a VI-test during normal powerup
sequence. This test can also be run from the
DID panel to aid in troubleshooting. During test
execution, engine speed is set to 1500 rpm and
the link is charged to 1200VDC. The engine is
then returned to idle while the link is allowed to
discharge to 100 volts.Total link capacitance is
then calculated using the time it took to discharge. If capacitance is getting low, but still
OK, event 70 logs. If capacitance is below the
minimum allowable level, event 71 logs and the
truck is restricted to 10 MPH. If test is not able
to complete after numerous attempts, event 72
logs, indicating a problem in the truck's ground
detection circuit, and truck speed is limited to 10
MPH.
Initiated Tests
These tests are performed when requested by maintenance personnel; the truck must be in test mode for
these tests to run:
1. Maintenance Tests - The purpose of these tests
is to facilitate verification of system installation
and wiring (particularly the "digital" interfaces relays, contactors, etc.).
2. Self-load Test - Self-load testing is a means by
which the truck diesel engine can be checked
for rated horsepower output.
Periodic Tests
These automatic tests are run continuously during
the operation of the truck to verify certain equipment.
EVENT RESTRICTIONS
The PSC software will not override an event restriction as long as Limp Home mode is not active. Transitions to restricted states will not be allowed. If the
system is in a state which becomes restricted, it will
transition down to the highest unrestricted state. The
order from lowest to highest state is Startup/Shutdown, Rest, Test, Ready, Retard, Propel. Transitions
to the Test state or lower states in reaction to event
restrictions will not be allowed until the truck is not
moving.
NOTE. Limp Home mode is a state which is entered
when the truck has suffered a failure and is not able
to continue normal operation but is still capable of
"limping" (getting either back to the maintenance
area or at least out of the way of other trucks).
Event Restrictions associated with a given event are
listed in Table I, page E2-5.
EVENT LOGGING AND STORAGE

This software function is responsible for the recording of event information. There are two basic levels
of event storage: event history buffer and data packs.
The event history buffer provides a minimum set of
information for a large number of events, while data
packs provide extensive information for a limited
number of events.
The following requirements apply to both data packs
and the event history buffer:
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1. Fault information is maintained until overwritten, it is not cleared out following a reset. This
allows the user to examine data associated
with events that have been reset, as long as
there have not been so many new events as to
necessitate reuse of the storage space.
2. If a given event is active (logged and not reset),
logging of duplicate events (duplicate is defined
as having the same event and sub-id numbers)
will not be allowed. If the event is reset and subsequently reoccurs, it may be logged again.
Likewise, if an event reoccurs with a different
sub-id from the original occurrence, the event
may be logged again.
Event History Buffer
Event history buffer is defined as a collection of event
history records.
A buffer contains 300 entries filled with event numbers occurring in chronological order. Also included
in this buffer will be all the input and output values,
time the event occurred, reset time, state information,
etc., for each event. This buffer is filled continuously
and overwritten (if necessary).
Limits (accept-limit) are placed on the amount of
space which a given event code may consume. This
prevents a frequently occurring event from using the
memory space at the expense of a less frequent
event. This data may be cleared (after downloading
for troubleshooting) at each maintenance interval.
Data Packs
A data pack is defined as an extended collection of
information relevant to a given event.
NOTE: The concepts of lockout, soft reset, and
accept limit do not apply to data packs.
Thirty (30) data packs are stored with each containing 100 frames of real time snapshot data. Snapshot
data is defined as a collection of key data parameter
values for a single point in time). The purpose of
each data pack is to show a little "movie" of what
happened before and after a fault.
The time interval between snapshots is default to 50
ms, but each data pack may be programmed via the
DID (or PTU) from 10 ms to 1 sec. (In multiples of 10
ms). The "TIME 0:00 frame #" at which the fault is
logged is default to frame #60, but each data pack is
programmable from 1 to 100.
E2-40
In the above default cases, data is stored for 3 seconds (2.95 second actual) before the fault and 2 seconds after the fault.
A data pack status structure is assigned to each data
pack plus any programmable settings. This status
structure is used by the TCI (or PTU) to check for
available data (event number, id, and status, should
be set to zero if data pack is not frozen), as well as
for control of the data packs.
If a data pack is unfrozen (not holding any particular
fault data), it is continually updated each 100 frames,
organized in a circular queue, with new real time
snapshot data. When a fault occurs, the frame number at which the event occurred is used as a reference to mark the end of the data pack, and data is
collected until the data pack is full. Only when the
data pack is full will the event number, id and status
be updated in the status structure.
All logic control variables are saved in battery backed
RAM, in case a fault occurs and battery power is
cycled before the data pack is filled with data (the
software allows for proper recovery and then continues to fill the data pack). Maintenance personnel, by
way of the DID (or PTU), can assign the data pack to
hold only certain event numbers (for the case where
it is desired to collect data on a particular fault).
However, in the default case, faults will be stored as
they come until all data packs are frozen (holding
fault data). When all data packs are frozen, the data
pack with the fault that was RESET first (either automatically or by the DID/PTU), if any, will be unfrozen
and will start storing new data in case a new fault
occurs.
To Record and Save a Data Pack to a Floppy Disk
PSC:
1. With the PTU serial cable attached to the PSC
port, type c:\ACNMENU and press {enter}.
2. Select "PTU TCI and PSC" and press {enter}
3. Type your name and press {enter}.
4. Type your password and press {enter}.
5. Cursor to "Special Operation" and press {enter}.
6. Cursor to "Event Data Menu" and press {enter}.
7. Cursor to "View Data Packs" and press {enter}.
8. Type FLTR number to be recorded and press
{enter}.
9. Watch the lower right of the screen as 100 frames
are recorded. Press the F2 key.
01/02
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10. Cursor to "Record Screen" and press {enter}.
Event Reset
11. Assign a file name for the data pack.
There are two basic types of event resets: soft and

hard. The difference between the soft and hard reset
is a soft reset only affects events that have not been
locked out and a hard reset affects events regardless
of lockout status.
12. Press {escape} until back to the DOS "C:>"

prompt.
13. Insert a blank disk in drive A.
14. Type the following command: copy c:\geohvac\ptuaccur\f2data\filename
Note: Insert the name assigned to the file in step 11
in place of "filename" in the command in step 14.
15. Press {enter} to copy the file to the disk.
Events will be reset:

On powerup - a soft reset will be issued against
all events at powerup.
By DID commands - the TCI can issue both hard
and soft resets.
By PTU commands - the PTU can issue both
hard and soft resets.
TCI:
1. With the PTU serial cable attached to the TCI
port, type c:\ACNMENU and press {enter}.
2. Select "PTU TCI and PSC" and press {enter}
3. Type your name and press {enter}.
4. Type your password and press {enter}.
5. Cursor to "Special Operation" and press {enter}.
6. Cursor to "Event Data Menu" and press {enter}.
7. Cursor to "View Data Packs" and press {enter}.
8. Type PK number to be recorded and press
{enter}.
9. Watch the lower right of the screen as 100
frames are recorded. Press the F2 key.
10. Cursor to "Record Screen" and press {enter}.
11. Assign a file name for the data pack.
12. Press {escape} until back to the DOS "C:>"
prompt.
13. Insert a blank disk in drive A.
14. Type the following command: copy c:\geohvac\ptuaccur\f2data\filename
Note: Insert the name assigned to the file in step 11
in place of "filename" in the command in step 14.
15. Press {enter} to copy the file to the disk.
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E2-41
SERIAL DATA COMMUNICATIONS
Inverter Communications Processing
The PSC System CPU Card uses serial data busses

to communicate with the TCI, the PTU, and the two
Inverter CPU Cards.
This software function performs the processing necessary for the System CPU Card to communicate
with both Inverter CPU Cards. The communications
is through a high-speed serial link that is operated in
a polled fashion with the System CPU Card initiating
communications to an Inverter CPU Card.
PSC - TCI Communications processing

This software function performs the processing necessary for the PSC (System CPU Card) to communicate with the TCI through an RS-422 serial link. The
communication is comprised of periodic data and
non-periodic data.
Periodic data is a predefined set of data which is
used for transferring real time control information
from the PSC to the TCI and from the TCI to the PSC
at a fixed rate.
The non-periodic messages are used to transfer all
background data. Background data consists of DID
Commands, Remote Monitor Data, and Download
Code.
Packets containing periodic data will be asynchronously (not initiated) transmitted from the PSC to the
TCI and from the TCI to the PSC every 200 ms. The
TCI initiates the transfer of non-periodic data.
The TCI and the PSC are interfaced using the General Electric Asynchronous Communications Protocol
(ACP). ACP provides two general types of messages, acknowledged and unacknowledged. The
unacknowledged messages are used to transmit the
periodic data.
Every message transmitted across the serial link

may contain two separate sections of information:
periodic data and acknowledged data. The periodic
data format is fixed and is used for transferring control information from the System CPU Card to the
Inverter CPU Card and vise-versa. The acknowledged data format is used to transfer all background
data. When large amounts of background data are to
be transferred via the acknowledged data format, the
originating CPU will break the data down into smaller
pieces and transmit each piece individually. All
acknowledged data flows are initiated from the System CPU with the Inverter CPU providing a
response.
The System CPU Card has one high-speed channel
available for communications to the Inverter CPU
Cards. This channel transfers periodic data across
the serial link every 5 ms. This means the periodic
data to each Inverter CPU is updated every 10 ms.
Each inverter responds to the data when the ID code
in the periodic data matches the ID code of the specific Inverter CPU Card: the ID code is hardwired in
the card's backplane wiring.
The acknowledged messages are used to transmit

the background data.
PSC - PTU Communications Processing

This software function performs the processing necessary for the PSC (System CPU Card) to communicate through an RS-232 serial link to the Portable
Test Unit (PTU).
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OUTPUT PROCESSING
Limp Home Mode
This software function processes all external outputs

from the PSC. Refer to the G.E. publication, "System
Description" for a listing of the PSC outputs.
The purpose of Limp Home mode is to address the

situation where the truck has suffered a failure and is
not able to continue normal operation but is still
capable of "limping" (getting either back to the maintenance area or at least out of the way of other
trucks). The intent is that limp mode will be used by
maintenance personnel operating the truck at low
speeds with the truck unloaded. Maximum truck
speed will be limited to a reduced value while in limp
home mode.
ABNORMAL CONDITIONS/OVERRIDING
FUNCTIONS
Software functions given up to this point assumed for
the most part that the truck is operating under more
or less normal circumstances. The following paragraphs define system operation under abnormal or
exceptional circumstances. In the event of conflict
between these functions and those given for normal
operation, the functions in this section will take precedence.
If the TCI requests limp home mode, the state

machine will ignore the restrictions associated with
any fault for which limp home mode is possible.
Entering/Exiting Limp Home Mode

Fast Start
A fast start software function is provided to address
the case where the PSC is reset unexpectedly
(power supply glitch, etc.) while the system is running. Its purpose will be to regain control of the truck
as quickly as possible.
The PSC will enter limp home mode if all of the following conditions are true:
2. The TCI is requesting limp home mode.
3. The PSC is in Ready or test state and there is
no initiated testing in progress.
4. At least one inverter is functional.
Engine Shutdown/Engine Not Running

The engine must be running to enable the gate
drives and to maintain power on the DC link. Typically, the PSC will be given advanced warning that
the engine is about to be shut off. However, if the
engine stalls or stops because of a mechanical malfunction, the system will most likely have no advance
warning. The system reaction to an engine not running condition will be the same as to an event carrying a "no power" restriction except that no event will
be recorded, and no external reset to clear the condition will be required (the no power restriction will be
automatically lifted as soon as the engine starts running). If the system is given warning of an impending
engine shutdown, the existing torque commands will
be command to zero over a "long" ramp time (2 to 10
seconds). If no warning is given and the engine stops
running, the existing torque commands will be command to zero over a "short" ramp time (0.1 to 0.5
second).
5. There are no events active for which limp home

mode is not possible.
6. If there are any events active for which an
inverter must be turned off or cut out before limp
home mode is allowed, those actions have
been taken (Inverter is turned off or cut out as
required).
NOTE: Two Inverter Cut Out Switches (I1CO and
I2CO), located in the switch panel on the side of the
Electrical Cabinet near the cab, can be used to cut
out an Inverter. In some cases, certain DC link bus
bars/cables within the Inverter also may need to be
removed. The DID will prompt maintenance
personnel if any of the above actions need to be
accomplished.
The PSC will exit limp home mode if any of the following conditions occur:
1. The TCI stops requesting limp home mode.
2. An event occurs for which limp home mode is
not possible.
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PROPULSION SYSTEM COMPONENT

ABBREVIATIONS
The following Tables list component abbreviations
used in schematics and system description information. Refer to Figures 2-3 through 2-8 for the location
on the truck of components listed in the "Ref. No."
column.
The GE part number for major components is shown

in parentheses. A short description of the component's primary function is also listed.
TABLE V: PROPULSION SYSTEM COMPONENTS DESCRIPTION

REF.
NO.
AFSE
FUNCTION
Alternator Field Static Exciter Panel

(17FM466)
Regulates current in the alternator field based on firing

pulses from the PSC.
Alternator Field Voltage Divider

Panel (17FM363)
Attenuates high voltage output from the AFSE to an

acceptable level for use by the Analog I/O card in the
PSC.
ALT
Alternator (5GTA34)
Main alternator, propulsion and control system.
ANALOG I/O CARD
System analog input/output card

(17FB143)
Provides signal conditioning for analog signals to and

from the TCI and PSC.
AUX BLOWER
MOTOR
Auxiliary Blower Motor (5GDY84)
A 3-phase, AC induction motor mounted in the blower

assembly behind the electrical cabinet. Used to drive two
blowers for cooling the traction motors and control cabinet components.
AFVLT
36
COMPONENT
21
AXCAP
11
Auxiliary Power Filter Capacitor

Bank
Used with the AXIND to filter the regulated DC voltage

from the Auxiliary Phase Control Rectifier into a smooth
DC supply suitable for use by the Auxiliary Power
Inverter.
AXFU1, 2
33
Auxiliary Power Rectifier Input

Fuses 1 and 2
Provide overload protection for the Auxiliary Power

Inverter/Phase Control Rectifier.
AXIND
30
Auxiliary Power Filter Inductor
Used with the AXCAP to filter the regulated DC voltage

from the Auxiliary Phase Control Rectifier into a smooth
DC supply suitable for use by the Auxiliary Power
Inverter
Auxiliary Phase Control Rectifier

and Power Inverter Module
The Auxiliary Phase Control Rectifier converts the 3phase, AC input voltage from the Alternator to regulated
DC voltage and supplies the regulated voltage through a
filter to the Auxiliary Power Inverter. The Auxiliary Power
Inverter inverts the regulated, filtered, DC voltage into a
variable voltage, variable frequency, 3-phase output to
power the Auxiliary Blower Motor.
AXINV
29
ASYN
35
Alternator Synchronization
Transformer
Monitors frequency of the tertiary winding and provides a

sample of the frequency to the PSC, which uses the input
to synchronize the firing pulses sent to the Alternator
Field Static Exciter Panel (AFSE).
A3PV
Alternator 3-phase Voltage Measuring Module (17FM458)
Attenuates high voltage from two phases of the Alternator to a level acceptable to the Analog I/O card in the
PSC.
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01/02
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REF.
NO.
BATFU
19
BATTSW
COMPONENT
FUNCTION
System Fuse
Provides overload protection for control equipment and

the System Batteries.
Battery Disconnect Switch

(System Batteries)
Connects and disconnects the 12 VDC and 24 VDC circuit batteries (located at right front corner of truck).
BDI
68
Battery Blocking Diode
Works in conjunction with BFC and BLFP to maintain

battery voltage to CPU.
BFC
67
Battery Line Filter Capacitor
Additional capacitance for BLFP to prevent nuisance

CPU resets.
BLFP
10
Battery Line Filter Panel

(17FM311)
Reduces voltage ripples in System Battery power supplied to the PSC.
BM1, 2
63
Grid Blower Motors 1 and 2

(5GY19)
DC motors driving blowers to provide cooling air for the

retarding grids.
BM1I
65
Current Sensing Module
Monitors current flowing through grid blower motor #1
BM2I
66
Current Sensing Module
Monitors current flowing through grid blower motor #2
CCLR1, 2
20
Capacitor Charge Resistor Panels

1 and 2
Connected across the DC link to provide a voltage attenuated sample of the DC link voltage to the Capacitor
Charge Indicating lights.
CCL1, 2
61
Capacitor Charge Indicating Lights Illuminated when 50 volts or more is present on the DC
link (the DC bus connecting the Alternator output, Chop1 and 2
CIF11, 12, 13, 14,

15, 16
40
Inverter 1 Filter Capacitors
Stores the Inverter 1 DC bus voltage to provide instantaneous power when the PM1 GTO Phase Modules first
turn on.
CIF, 21, 22, 23, 24,

25, 26
41
Inverter 2 Filter Capacitors
Stores the Inverter 2 DC bus voltage to provide instantaneous power when the PM2 GTO Phase Modules first
turn on.
CLSW
59
Cabinet Light Switch
Controls electrical cabinet interior lights.
CMAF
27
Alternator Field Current Sensing

Module
Detects amount of current flowing through the Alternator

field winding.
CMT
28
Alternator Tertiary Current Sensing Detects amount of current flowing through the Alternator
tertiary winding.
Module
CM1, 2
5, 6
Chopper GTO Phase Module 1 and Controls the DC voltage applied to the grids during
retarding.
2 (17FM630)
CM1A, 1B
45
Current Sensing Modules, Phase

1A and 1B
Detects amount of current flow through the A and B

phases of Traction Motor 1.
CM2A, 2B
44
Current Sensing Modules, Phase

2A and 2B
Detects amount of current flow through the A and B

phases of Traction Motor 2.
CPR
53
Control Power Relay (17LV66)
Picks up when the Key Switch and Control Power Switch

are closed.
CPRD
Dual Diode Module
Allows two separate voltages to control the CPR coil.
CPRS
Control Power Relay Suppression

Module
Suppresses voltage spike when CPR coil is de-energized.
Control Power Switch
Energizes CPR coil.
per Module/Resistor Grid circuits and traction Inverters).
CPS
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56
E2-45

REF.
NO.
COMPONENT
FUNCTION
Detects amount of current flow through the Alternator ter-
CT
34
CTR
Battery Boost Current Transformer tiary winding. Signal turns off the AFSE battery circuit
when the tertiary winding voltage level is able to excite

the Alternator field.
CT Voltage Limiting Resistor
Provides a resistive load for the CT.
DC Bus
The DC bus connects the Alternator output, Chopper

Module/Resistor Grid circuits, and Traction inverters.
DID
Diagnostic Information Display

(17FM558)
Provides maintenance personnel with the ability to monitor the operational status of certain truck systems and
perform system diagnostic test.
DIGITAL I/O CARD
Digital Input/Output Card

(17FB104)
Receives contactor, relay and switch feedback signals

and provides drive signals to relays, contactors, indicator
lamps etc. (Located in PSC and TCI.)
DC link
38
DIT1A, 1B, 1C
43
DI/DT Transformers
Reduce current overshoots, or spikes in phase A, B, and

C power for Traction Motor 1.
DIT2A, 2B, 2C
42
DI/DT Transformers
Reduce current overshoots, or spikes in phase A, B, and

C power for Traction Motor 2.
FDP
24
Fault Detection Panel (17FM384)
Provides an output signal when a diode fails in the Main

Rectifier.
FDT
23
Fault Detection Transformer

(17ET33)
Monitors Alternator Field current for FDP operation.
FIBER OPTIC
ASSEMBLY
31
Fiber Optic Assembly
Provides voltage and electrical noise isolation for control

and feedback signals between the PSC and Phase/
Chopper Modules.
FP
39
Filter Panel (17FM460)
Filters electrical noise on 3 phases of Alternator output.
GDFU1, 2
Gate Driver Power Source Fuse 1

and 2
Provide overload protection for the Gate Drive Power

Supply.
GDPC1
17
Gate Drive Power Converter 1

(17FM670)
Converts 19 to 95 VDC from the Gate Drive Power Supply to 25 kHz, 100 VRMS, square wave power to drive
Inverter 1 GTO Phase and Chopper Modules.
GDPC2
16
Gate Drive Power Converter 2

(17FM670)
Converts 19 to 95 VDC from the Gate Drive Power Supply to 25 kHz, 100 VRMS, square wave power to drive
Inverter 2 GTO Phase and Chopper Modules.
GDPS
18
Gate Drive Power Supply

(17FM645)
Provides a 19 to 95 VDC output, at approximately 3kW,

from one of two input power sources; either the main
Alternator or the System Batteries.
GF
49
Alternator Field Contactor

(17CM53)
Connects the AFSE to the Alternator field.
GFCO
62
Generator Field Contactor Cutout

Switch
Disables Alternator output.
GFIP
22
Ground Fault Current Panel

(17FM363)
Reduces Alternator field voltage input to provide a low

voltage signal for use by the PSC. Used to provide
ground fault warning.
GFM
Gate Firing Module (17FM415)
Receives pulses from the Analog I/O card in the PSC,

amplifies the pulses, and then splits the pulses to drive
two SCR circuits in the AFSE.
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01/02
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REF.
NO.
COMPONENT
FUNCTION
GFR
52
Alternator Field Relay (17LV66)
Picks up with GF contactor and applies B+ to the AFSE

(battery boost) during initial acceleration phase.
GFRS
50
Alternator Field Relay Coil Suppression Module
Suppresses voltage spikes when GF coil is de-energized.
GRR
26
Ground Resistor Panel
Detects power circuit grounds.
INV1 TMC CARD
Inverter 1 Central Processing Unit

Card and Input/Output Card
(17FB172)
Generates Phase Module turn-on/turn-off commands for

the Inverter 1.
Monitors voltages and currents from various areas for
Inverter 1. Monitors Traction Motor 1 speed.
INV2 TMC CARD
Inverter 2 Central Processing Unit

Card and Input/Output Card
(17FB172)
Generates Phase Module turn-on/turn-off commands for

the Inverter 2.
Monitors voltages and currents from various areas for
Inverter 2. Monitors Traction Motor 2 speed.
I1CO
57
Inverter 1 Cut Out Switch
Cuts out inverter 1 when in the "cutout" position. Located

on switch/LED panel, left front corner of electrical cabinet.
I2CO
58
Inverter 2 Cut Out Switch
Cuts out inverter 2 when in the "cutout" position. Located

on switch/LED panel, left front corner of electrical cabinet.
Key Switch
Connects battery voltage to CPR and control circuits

when closed. (Located on instrument panel.)
KEYSW
LDBXI
48
Load Box Current Sensing Module Monitors current during load box test.
LED's indicate status of the following:
CPR: Illuminated when CPR is energized.
SYS RUN: Illuminated when the PSC power-up
sequence has completed successfully and control logic
is executing.
NAFLT: When illuminated, indicates a fault has occurred
that prevents propulsion or retarding.
TEST: Illuminated when system is in the Test state.
REST: Illuminated when system is in Rest state and there
is essentially no voltage on the DC link.
LEDP
60
Light Emitting Diode Panel
LINKI
Link Current Sensing Module
Detects amount of current flow through the DC link.
LINKV
Link Voltage Measuring Module

(17FM458)
Attenuates the high voltage from the DC link to a level

acceptable to the electronics on the Analog I/O card in
the PSC.
L1, 2, 3
Cabinet Lights
Provide interior cabinet illumination.
M1, 2
Motorized Wheels (5GDY85)
E02014 01/02
Each Motorized Wheel consists of a Traction Motor and a

Transmission Assembly. The 3-phase asynchronous
Traction Motors convert electrical energy into mechanical
energy. This mechanical energy is transmitted to the
wheel hub through a double reduction gear train (Transmission).
E2-47

REF.
NO.
COMPONENT
FUNCTION
PSC
32
Propulsion System Controller

(17FL320)
The PSC is the main controller for the AC drive system.

All propulsion and retarding functions are controlled by
the PSC based on internally stored software instructions.
PM1A+, 1B+, 1C+
13
GTO Phase Modules (17FM628)
Provide positive driving voltages (PWM or square wave,

depending on truck speed) for each of the three windings
of Traction Motor 1.
PM1A-, 1B-, 1C-
12
Provide negative driving voltages (PWM or square wave,

PM2A+, 2B+, 2C+
15
Provide positive driving voltages (PWM or square wave,

PM2A-, 2B-, 2C-
14
Provide negative driving voltages (PWM or square wave,

RD
Rectifier Diode Panel (17FM528)
Converts Alternator 3-phase, AC voltage to DC voltage to

power the two Inverters.
64
Retard Grid Resistors
Dissipate power from the DC link during retarding, load

box testing, and Inverter Filter Capacitor discharge operations.
RP1, 2, 3
47
Retard Contactors 1, 2 and 3

(17CM55)
RP1S, 2S, 3S
55
Suppression Modules
Suppresses voltage spikes in coil circuit when RP contactors are de-energized.
RSN1, 2
Snubber Resistors
Provide a current path for the associated Chopper Module filter capacitors.
RS1A, 1B, 1C, 2A,

2B, 2C
Snubber Resistors
Provide a current path for the associated Phase Module

filter capacitors.
RG1A, 1B, 1C, 2A,

2B, 2C, 3A, 3B, 3C,
4A, 4B, 4C, 5A, 5B,
5C
When closed, connects Grid Resistors to the DC link during retarding, load box testing, and Inverter Filter discharge operations.
Note: Some trucks do not have RP3 installed.
R1
51
Battery Boost Resistor
Limits surge current in the Alternator field circuit when

GFR contacts first close.
AUX SNUB
25
Snubber
Suppresses voltage spikes in Aux Blower Motor circuit.
SPS
37
Power Supply (17FH36)
A DC to DC converter which provides regulated 24

VDC outputs from the unfiltered battery supply.
PS
37a
Power Supply (17FH41)
A DC to DC converter which provides regulated 24

VDC outputs from the unfiltered battery supply.
Note: This power supply replaces SPS above, and also
replaces the 17F127 power supply cards in the
17FL320H1 PSC and 17FL 373A1 TCI panels in later
model trucks.
SS1, 2
Traction Motor Speed Sensors
Each speed sensor provides two output speed signals,

proportional to the Traction Motor's rotor shaft speed.
SYS CPU Card
System Central Processing Unit

Card (17FB147)
Provides control of propulsion and dynamic retarding

functions, battery backed RAM, real-time clock, downloadable code storage, and an RS422 serial link.
E2-48
01/02
E02014

REF.
NO.
TCI
COMPONENT
FUNCTION
Truck Control Interface

(17FL349 or 17FL373)
Provides the main interface between the various truck

systems, controls, and equipment and is used in conjunction with the DID by maintenance personnel.
TH1
54
Alternator Field Thyrite (Varistor)
Discharges the Alternator field when the AFSE is first

turned off.
VAM1
46
Voltage Attenuation Module

(17FM702)
Attenuates the three high voltage outputs applied to each

phase winding of Traction Motor 1 to a level acceptable
for use by the Analog I/O card in the PSC.
VAM2
46
Voltage Attenuation Module

(17FM702)
Attenuates the three high voltage outputs applied to each

phase winding of Traction Motor 2 to a level acceptable
for use by the Analog I/O card in the PSC.
E02014 01/02
E2-49
FIGURE 2-3. ELECTRICAL CABINET, FRONT VIEW
E2-50
01/02
E02014
FIGURE 2-4. ELECTRICAL CABINET, TOP VIEW
E02014 01/02
E2-51
FIGURE 2-5. ELECTRICAL CABINET, REAR & FLOOR VIEW
E2-52
01/02
E02014
FIGURE 2-6. CONTACTOR BOX

(Right Side, Electrical Cabinet)
FIGURE 2-7. INFORMATION DISPLAY PANEL

(Left Front Corner of Electrical Cabinet)
FIGURE 2-8. RETARDING GRIDS
E02014 01/02
E2-53
ELECTRONIC ACCELERATOR AND

RETARD PEDALS
The accelerator pedal provides a signal to the Truck
Control Interface (TCI) when the operator requests
power. The retard pedal provides a signal to the Propulsion System Controller (PSC) when the operator
requests retarding. The pedal signals are processed
by the analog card in the respective panel for use by
the system controllers to provide the desired mode of
operation.
As the operator depresses the pedal, the internal
potentiometer's wiper is rotated by a lever. The output voltage signal increases in proportion to the
angle of depression of the pedal.
Repair and initial adjustment procedures are discussed in the following. Refer to "AC Drive System
Checkout Procedure" for final calibration of the pedal
potentiometer after installation in the truck.
FIGURE 2-9. TYPICAL ELECTRONIC PEDAL

1. Cable Clamp
4. Potentiometer
2. Electrical Harness
5. Adjustment Screw
3. Grommet
6. Cover
Removal
NOTE: Repair procedures for the retard and
accelerator pedal are identical. The retard pedal is
mounted on the brake pedal. Refer to Section "J" for
instructions for removing and installing the electronic
pedal on brake actuator.
Note routing and clamp location of wire harness.
Proper wire routing is critical to prevent damage
during operation after reinstallation.
1. Disconnect pedal wire harness from truck harness connector.
2. Remove mounting capscrews, lockwashers and
nuts and remove pedal assembly.
Installation
1. Install pedal assembly using hardware
removed in step 2, "Removal". Connect potentiometer to wiring harness.
2. Calibrate pedal potentiometer per instructions
in "AC Drive System Checkout Procedure - Setting Pedal Percentages".
Disassembly
1. Remove screws on cable clamps (1, Figure 29) and potentiometer cover (6).
Assembly
1. Position new potentiometer with the flat side
toward the potentiometer cover and install on
shaft as follows:
a. Align cutouts in shaft with the potentiometer
drive tangs.
b. Press potentiometer onto shaft until it bottoms against the housing.
2. Install screws (5) and lockwashers but do not
tighten.
3. Rotate potentiometer counterclockwise until
mounting slots contact the mounting screws
and tighten screws (5) to 15 in. lbs. (1.70 N.m)
torque.
4. Install grommet (3) and potentiometer cover.
Tighten screws to 15 in. lbs. (1.70 N.m) torque.
5. Install cable clamps and tighten screws to 40 in.
lbs. (4.21 N.m) torque.
6. Inspect assembly and verify proper wiring clearance during operation of pedal throughout the
range of travel.
2. Remove potentiometer mounting screws (5)

and grommet (3). Remove potentiometer (4).
E2-54
01/02
E02014
SECTION E3
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
INDEX
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-3
AC DRIVE SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-3
TRUCK SHUTDOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-3
NORMAL TRUCK SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-4
SHUTDOWN AFTER SYSTEM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-5
SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-6
Battery and Control Checks of System WITH Battery Power OFF. . . . . . . . . . . . . . . . . . . . . . E3-6
Battery and Control Circuit Checks of System With Battery Power ON . . . . . . . . . . . . . . . . . . E3-9
Checks with Key Switch OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-10
CPU Battery Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-12
MEMORY BACKUP BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-12
TCI PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-13
PSC PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-13
INVERTER PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-14
TCI CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-14
Modular Mining Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-15
TCI Input Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-16
TCI Digital Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-18
TCI Digital Input Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-20
PSC Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-22
PSC Digital Input Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-26
Miscellaneous Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-27
A3PV Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-27
LINKV Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-27
E03015 1/02
AC Drive System Electrical Checkout Procedure

(Release 18 Software)
E3-1
Thermistor Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-27

17FM384 Panel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-27
Pedal Percentages and Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-28
Meter Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-28
Reprogram With Serial Numbers and Pedal Percentages . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-30
LOAD TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-32
Preload Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-32
ADDITIONAL TRUCK CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-34
On-Board Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-36
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-36
Initiate Loadbox Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-39
Manual Offset HP Output Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-41
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-43
PVM Optimum Load Curve Handshaking Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-43
MISCELLANEOUS COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-44
Troubleshooting Phase Modules and Chopper Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-44
Phase Module Removal and Snubber Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . E3-44
Snubber Resistor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-45
Phase Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-45
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . E3-46
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . E3-49
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-50
IGBT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-51
E3-2

1/02 E03015
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE

AC DRIVE SYSTEM MAINTENANCE
DANGEROUS VOLTAGE LEVELS ARE PRESENT

WHEN THE ENGINE 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

NEVER open any electrical cabinet covers or

touch the Retarding Grid elements until all
shutdown procedures have been completed.
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.
Power cables must be cleated in wood or

other non-ferrous materials. Do not repair
cable cleats by encircling the power cables
with metal clamps or hardware. Always
inspect power cable insulation prior to servicing the cables and prior to returning the truck
to service. Discard cables with broken insulation.
If weld repairs are required, 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.
Power cables and wiring harnesses should be
protected from weld spatter and heat.
Prior to welding, disconnect Engine Control

System (ECS) harnesses and ground wire
(MTU engine). If equipped with DDEC or
Komatsu engine, disconnect ECM harnesses.
GE cards should be pulled forward far enough
to disconnect card from backplane connector.
Some power cable panels throughout the

truck are made of aluminum or stainless steel.
They must be repaired with the same material
or the power cables may be damaged.
TRUCK SHUTDOWN PROCEDURES

After the truck is parked in position for the repairs, the
truck must be shut down properly to ensure the safety
of those working in the areas of the deck, electrical
cabinet, traction motors, and retarding grids. The following procedures will ensure the electrical system is
properly discharged before repairs are started.
IN THE EVENT OF A PROPULSION SYSTEM

MALFUNCTION, a qualified technician should
system does not have dangerous voltage levels present before repairs are started.
E03015 1/02
If a problem occurs in the AC drive system preventing NORMAL shutdown procedures, ADDITIONAL
PRECAUTIONS ARE NECESSARY to ensure dangerous drive system voltages are not present when
tests or repairs are performed.

E3-3
NORMAL TRUCK SHUTDOWN

PROCEDURE
1. Reduce the engine speed to idle. Place the selector switch in NEUTRAL and apply the parking
brake and brake lock switches. Be certain the
Parking Brake and the Service Brake Applied
indicator lamps in the overhead display panel are
illuminated.
2. Place the drive system in the REST mode by
turning the Rest switch on the instrument panel
ON. Be certain the REST warning lamp on the
overhead display is illuminated.
3. Shut down the engine using the keyswitch. If, for
some reason the engine does not shut down, use
the shutdown switch on the center console.
4. After approximately 90 seconds, verify the steering accumulators have bled down by attempting
to steer.
5. Verify the LINK VOLTAGE lights on the electrical
cabinet Information Display Panel (6, Figure 3-1)
and the DID panel in the cab are OFF. If they
remain on longer than 5 minutes after shutdown, the propulsion system must be
inspected to investigate the cause.
6. To ensure the link will not be energized during
test and repair procedures, turn the GF Cutout
Switch (8, Figure 3-1) to the CUTOUT position by
pulling the switch handle out before moving the
switch.
FIGURE 3-1. INFORMATION DISPLAY PANEL
AN ADDITIONAL 10 TO 15 MINUTES IS REQUIRED

FOR THE AUXILIARY BLOWER MOTOR CIRCUITS
TO DE-ENERGIZE. Do not attempt to perform Auxiliary Blower repairs until it has been verified the
system is de-energized by verifying the Blower
Module Link LEDs (6, Figure 3-2) on top of the
AXCAP are NOT illuminated.
1. Control Power Switch

2. Inverter 1 Cutout Sw.
3. Inverter 2 Cutout Sw.
4. Cabinet Interior light
Sw.
5. Status LED Panel

6. Link Voltage Lights
7. Chart Recorder Connector
8. GF Cutout Switch
If there is any question the system has potential

hazardous voltage present, return to the operator
cab and perform the normal shutdown procedure.
Normal operation of the drive system at shutdown
should allow high voltages to be dissipated over
the time periods noted.
IN THE EVENT OF A SYSTEM FAILURE, performing
the SHUTDOWN AFTER SYSTEM FAILURE procedure will insure no hazardous voltages are present
in the drive system.
E3-4

1/02 E03015
SHUTDOWN AFTER SYSTEM FAILURE

1. Before shutting down the engine, verify the status
of the drive system warning lights on the overhead display. Use lamp check to verify proper
lamp function.
NOTE: The Link Voltage lights on the control cabinet
Information Display Panel (6, Figure 3-1) are not lamp
checked.
2. If any of the red drive system warning lights
are on, DO NOT attempt to open any cabinets,
disconnect any cables, or reach inside the
retarder grid cabinet EVEN AFTER SHUTTING
DOWN THE ENGINE.
3. If all red drive system warning lights are off, apply
the parking brake, shut down the engine and
chock the wheels.
IF THE RED LIGHTS (6, FIGURE 3-2) ON THE

BLOWER CAPACITOR PANEL (AXCAP) (4) ARE
ILLUMINATED AFTER FOLLOWING THE ABOVE
PROCEDURE, A FAULT HAS OCCURRED. (THE
NORMAL DE-ENERGIZATION TIME IS 10 TO 15
MINUTES.)
Reinstall the control cabinet panel.

Do not perform maintenance on the Blower
Capacitor Panel, blower motor, or blower
power cables.
Notify the Komatsu factory representative or

Distributor immediately.
4. After the engine has been off for at least five (5)
minutes, inspect the Link Voltage lights in the
Information Display Panel (6, Figure 3-1) on the
main control cabinet and back wall of the operator
cab (next to the DID panel). If all lights are off, the
retard grids, wheel motors, alternator, and power
cables connecting these devices are safe to work
on.
5. The blower motors, control cabinet and power
cables connecting these devices may still be
unsafe. To establish these devices are safe, wait
approximately 15 minutes, open the top control
cabinet cover and inspect the red lights (6, Figure
3-2) on the Auxiliary Capacitor Panel (AXCAP)
(4). If these lights are off, the blower system,
blower power cables and remainder of the control
cabinet is safe to work on. The normal de-energization time is 10 to 15 minutes.
IF THE LINK VOLTAGE RED LIGHTS IN THE CONTROL CABINET INFORMATION DISPLAY PANEL,
AND/OR THE BACK WALL OF THE OPERATOR
CAB CONTINUE TO BE ILLUMINATED AFTER FOLLOWING THE ABOVE PROCEDURE, A FAULT HAS
OCCURRED.
Leave all cabinet doors in place, do not touch

the retard grid elements,
Do not disconnect any power cables or use

them as hand or footholds.
Notify the Komatsu factory representative or

Distributor immediately.
E03015 1/02
FIGURE 3-2. BLOWER CONTROL DEVICES

1. Snubber Panel
2. Auxiliary Power Filter Inductor (AXIND)
3. Auxiliary Phase Control Rectifier and Power
Inverter Module (AXINV)
4. Auxiliary Power Filter Capacitor Bank (AXCAP)
5. Information Display Panel
6. Blower Control System Warning LEDs
7. Propulsion System Controller (PSC)
8. Control Cabinet (RH Side, Top View)

E3-5
SYSTEM CHECKOUT
Test equipment needed to fully test A/C system:
Battery and Control Checks of System WITH

Battery Power OFF
One PTU (Portable Test Unit; lap top computer)

(The test could be more efficiently conducted
with two PTU units).
One Digital Multi-Meter

Several jumper wires
One analog VOM
BE CERTAIN LINK VOLTAGE IS DRAINED DOWN

before servicing propulsion system or performing
tests.
1. Preparation
The Portable Test Unit (PTU) is used to test, download

and record system parameters on the TCI and PSC
modules. The PTU is plugged into the DB9 plug at the
rear of the console, closest to the operator seat for
monitoring the PSC module. The PTU is plugged into
the DB9 plug closest to the passenger seat for monitoring the TCI Module.
The TCI and PSC are programmed through the

DB9 port connectors in the operator cab.
The Inverter cards are programmed through the

DB9 port connectors located to the right of the
17FL320 (PSC) panel.
If only one PTU is available, in some cases it will be
necessary to switch from the PSC port to the TCI port
or vice versa to complete the test when necessary to
monitor both during a test procedure. After the serial
cable has been switched, exit to the Main Menu and
the software will automatically switch to the menu for
the connected panel.
Several different numbering methods or symbols are
used in the following procedures to denote the operation to be performed...
1., 2., a., b. etc.: Test preparation and instruction steps
are preceded by a number or a letter.
Procedures requiring visual checks, voltage
measurements etc. are preceded by this symbol.
PTU keyboard entry steps are preceded by this
symbol.
{escape}: When a keyboard key must be pressed, the
key label is enclosed in braces.
a. Turn all three battery disconnects to the OFF

position.
b. Disconnect and insulate circuit wires 21SS
and 21SR from engine starter if equipped with
MTU engine. If equipped with MTU/DDC
16V4000 or Komatsu engine, remove 21B
from starter solenoids.
c. Remove 50 amp fuse (BATFU) from inside the
control cabinet. (Grid side, lower corner.)
d. Disconnect the four CN connectors on the
PSC panel and the three connectors on the
TCI panel. Open both panels and slide cards
(except 17FB127 cards) out far enough to disconnect from backplane.
e. Turn OFF all circuit breakers behind operator
seat in cab and RB1, RB2, RB3, RB4, and
RB5 in the Electrical Interface Cabinet.
f. Be certain key switch is OFF, 5 minute delay
timer is OFF, and the Rest Switch is in the
REST position.
g. Turn all lights and switches off.
Battery Circuit Voltage Check:
2. Measure voltage to ground at each of the following circuits; 11, 11B1, 712 @ TB32, 11ST
@TB28.
All voltages should be zero.
Resistance Checks, Low Voltage Circuits:
3. Measure resistance from ground to the circuits
listed in Table I. STOP and troubleshoot any
direct short (0 ohms) to ground.
PTU screen display information is

shown in this type font and preceded by this symbol.
Note: The following test procedures are applicable to
Release 18 software. Procedures required for later
software versions may vary. Contact the Komatsu
distributor or factory representative for current software
version available.
E3-6

1/02 E03015
TABLE I. CIRCUIT RESISTANCE CHECKS

(All readings - from circuit to ground)
LOCATION
APPROX.
VALUE
NOTES
11B1
* Measure at the 12VDC insulator in the Electrical Interface Cabinet
11
*Measure at the 24VDC insulator in the Electrical Interface Cabinet.

All devices listed for 11A circuit reading must be OFF.
15V
TB21
71GE
TB22
120
71TCI
TB23
120
439
TB25
10V
TB28
11SL
TB28
11ST
TB28
15PV
TB29
11S
TB30
Ground level engine shutdown switch open
CIRCUIT
17FL349 Panel Only (Not applicable on 17FL373 Panel.)
Engine service lights turned OFF.
11A
TB30
The following must be turned OFF:

Brake cabinet service light, operator cab light, passenger seat compartment service light, hazard lights, headlights, ground level engine
shutdown switch, engine governor heater switch (MTU 396 only - in
Electrical Interface Cabinet), left and right side engine service lights.
11T
TB30
>36
Engine governor heater switch in Electrical Interface Cabinet open.

(MTU 396 engine only)
11FR
TB30
11HTR
TB30
712
TB32
The Electrical Interface Cabinet service lights must be switched OFF.
71
TB32
11L
CB30
12M
>10
*Measure at AID Module terminal B-13 under passenger seat in cab.
12F
>200
*Measure at AID Module terminal B-12 under passenger seat in cab.
E03015 1/02
Measure at circuit breaker CB30 in cab.

E3-7
Resistance Checks, Propulsion System Circuits:

4. Additional Preparation
NOTE: Be certain preparations described in step 1.
have been completed.
a. Verify the PSC (17FL320) panel 104 pin connectors are removed.
b. Verify the TCI panel connectors are removed.
c. Place the two Inverter Switches in the Information Display Panel, on the side of the control
cabinet in the CUTOUT position (down).
d. Place the GF Cutout Switch, located in the
Information Display Panel on the side of the
control cabinet, in the CUTOUT position
(down).
Chopper Modules (CM1, CM2):

9. With the VOM set on the Rx10,000 scale, measure the following at each Chopper Module in the
electrical cabinet (left side when facing cabinet).
GR(-) wire to ground - approximately 2 megohms or greater.
GR(+) wire to ground - approximately 2
megohms or greater.
Gate Driver Power Supply (GDPS):
Note: Verify 50 amp fuse (BATFU) is removed.
10. With the VOM set on the Rx10,000 scale, measure the following at the Gate Drive Power Supply, located in the electrical cabinet, below the
Chopper Modules (left side when facing cabinet).
e. Verify the Rest switch on the instrument panel

is in the REST state.
Terminal AI-1 (circuit #GDAI1) to ground - 2

megohms or greater.
f. Disconnect the CCLR1 connector and the

CCLR2 connector located in the electrical
cabinet, to the left of the AFSE.
Terminal AI-2 (circuit #GDAI2) to ground - 2

megohms or greater.
g. Disconnect the RTN62 wire on TB4-D to

remove the VAMS ground circuit.
h. Remove the wires on the GB1 ground block,
behind the AFSE. Make sure the lug on these
wires are not touching one another after the
wires are removed.
DC Link Checks:
Terminal AI-3 (circuit #T305) to ground - 2

megohms or greater.
Terminal 1B+ (circuit #BATPO1) to ground approximately 1.0K ohms or greater.
Terminal 1B+ to terminal 1B- (circuit
#RTNO1) - approximately 1.0K ohms on the
Rx100 scale.
Terminal 1B- to ground - read 0 ohms.
NOTE: Use an analog meter (VOM) to measure

resistance in the following steps:
5. Place VOM positive lead on the DC plus link bus
(top bus bar) and the VOM negative lead on a
cabinet ground.
Resistance should be 2 megohms or greater.
6. Place VOM positive lead on the DC negative bus
(bus underneath the positive link) and the VOM
negative lead on a cabinet ground.
Resistance should be 2 megohms or greater.
7. Place VOM positive lead on the DC plus link and
the VOM negative lead on the DC negative link.
VOM must be on the Rx1 scale otherwise the link
capacitors will start charging and an accurate
reading will not be possible.
Resistance should be infinity ().
8. VOM positive lead on the DC negative bus and
the VOM negative lead on the DC positive bus.
On the Rx1 scale the resistance should be
approximately 5.5 ohms.
E3-8

1/02 E03015
AFSE P1 adjustment:
11. Connect an ohmmeter from the wiper of Pot P1
(cathode of ZD1) to Terminal E (GND) on the Battery Boost Module.
If necessary, adjust P1 to obtain an ohmmeter
reading of 6000 ohms.
12. Restore the following circuits:
a. Reconnect ground wires at GB1 ground block.
b. Reconnect wire RTN62 on TB4-D.
c. Reconnect the CCLR1 and CCLR2 connectors.
GRR wiring:
13. Remove the circuit #DCP20 wire on the DCPBUS
located to the right of the Main Rectifier Panel
(RD). Connect the VOM positive lead to this wire
and the negative lead to the negative link bus.
Make sure the ground block wires are connected.
Resistance should be 10K ohms.
14. Reconnect DCP20.
15. Measure between the GRRC wire on GFIP Terminal A to ground.
Resistance should be 500 ohms.
Battery and Control Circuit Checks of System With

Battery Power ON
CHECK TO BE CERTAIN LINK VOLTAGE IS

DRAINED OFF before performing tests.
1. Preparation for Power Supply Voltage Checks:
a. Remove the 50 amp system fuse (BATFU)
located on the bottom left wall in the left compartment of the control cabinet.
b. If equipped with MTU 396 engine, disconnect
circuits 21SS and 21SR and insulate wire terminals at the engine starter. If equipped with
Komatsu or MTU/DDC 16V4000 engine, disconnect circuit 21B wires at the starter solenoids and insulate.
c. PSC panel (17FL320) - plug in all cards. Verify
the CNA, CNB, CNC, and CND connectors
are connected.
d. TCI panel (located in the Electrical Interface
Cabinet) - plug in all cards. Verify the CNP
round connector is installed. Verify the CNA
and CNB connectors are installed
16. Restore all circuits, harness connectors etc.

Remove meters.
e. Verify circuit breakers and battery disconnect

switches are closed.
17. Close battery disconnect switches. Close all open

circuit breakers.
f. Verify key switch and 5 minute idle delay timer

are off.
A3PV Panel (17FM458A2):

2. Measure the following resistances at the terminals on the Alternator 3-phase Voltage Measuring
Module in the electrical cabinet (left side when
facing cabinet):
Terminal G to ground - Approximately 900
ohms
Terminal E to ground - Approximately 150
ohms
Terminal E (negative lead) to Terminal G (positive lead) - Approximately 6K ohms.
E03015 1/02

E3-9
Power Supply Check (PS):
Sensor Power Supply (SPS):
Note: The following procedure is applicable to

17KG498E1 Control Cabinets. For earlier model
trucks, refer to Sensor Power Supply (SPS) Check.
Note: The following is applicable to 17KG498D1 and

prior Control Cabinets. For later model trucks, refer to
Power Supply Check (PS).
3. Remove the CN1 connector on the Power Supply

and check the harness side connector pins to
ground using an ohmmeter. Refer to the table
below for resistance value at each pin.
5. Measure the following resistances at the Sensor

Power Supply located in the center of the electrical cabinet, above the terminal boards:
V (+) P24VDC19 to ground: >100 ohms
VR (+) RTN58 to ground: 0 ohms
S (+) P24VDC14 to ground: >100 ohms
TABLE II.
Pin
Ohms
47
Circuit
RS (+) RTN57 to ground: 0 ohms
Pin
Ohms
Circuit
+5
32
return
47
+5
33
return
RS (-) RTN61 to ground: 0 ohms
47
+5
34
return
V (-) N24VDC19 to ground: >100 ohms
47
+5
35
return
VR (-) RTN60 to ground: 0 ohms
47
+5
36
return
47
+5
37
return
IN (-) RTN59 to ground: 0 ohms
38
515
-15
47
+5
39
515
-15
S (-) N24VDC14 to ground: >100 ohms
IN (+) BP24V03 to ground: >100 ohms

6. Preparation continued.
11
47
+5
42
return
a. Verify key switch is OFF, batteries are connected and the battery disconnect switches
closed.
12
return
43
b. Verify all circuit breakers are closed.
13
return
44
return
14
return
45
return
c. Ground level shutdown/prop lock out switch

must be closed (Run position).
15
return
46
1.3K
16
return
47
17
return
48
1.3K
18
49
19
return
50
20
return
51
21
return
52
11S (TB30)
22
53
11L (CB30)
23
600
+15
54
return
11A (TB30)
24
600
+15
55
return
25
56
543
-24
26
600
+15
57
47
+5
40
515
-15
10
47
+5
41
515
-15
+24
+24
27
58
543
-24
28
210
+15
59
29
210
+15
60
30
return
61
31
return
62
4. After resistance checks are complete, reconnect

CN1 connector.
E3-10
Checks with Key Switch OFF

7. With key switch OFF, verify 25.0 volts to ground
minimum at the location shown in parenthesis on
the following circuits:
11 (Front wall, Electrical Interface Cabinet)
11SL (TB28)
NOTE: The voltage should be 25.0 volts minimum. If
voltage is significantly low, check battery circuits. If
voltage is slightly low, install a battery charger.
8. Check circuit 11B1 voltage to ground.
Read approximately 12V DC.
9. Using a digital multimeter, check polarity at the
BATFU fuse holder.
With the leads on BATP (positive lead) and
RTN (negative lead) meter should indicate
BATP is positive.

1/02 E03015
Verify voltage at BATP is equal to voltage

measured at circuit 11, step 7.
If truck is equipped with Komatsu or MTU/DDC

16V4000 engine, measure the following:
10. Turn the Key Switch ON.
+15 volts at the 15VL wire on TB32.
11. Check Circuit 712 to ground.
Approximately 14.8 volts at the 15SIM wire on

TB32.
Voltage should equal the Circuit 11 value in

step 7.
12. Turn the Key Switch OFF. Open the battery disconnect switches.
13. Reinstall the 50 amp fuse (BATFU).
7. Measure voltage between circuit 72E (TB24) (+)

and circuit 0 (TB24-H) (-) in the Electrical Interface Cabinet.
Voltage should be 5.0 volts.
8. If truck is equipped with Komatsu engine, install a
jumper from 22F0 @ TB32 to ground.
Voltage should change to 7.0 volts.
Checks with Key Switch ON:

1. Close the battery disconnect switches. Turn key
switch ON.
9. Remove jumper to 22F0.

10. Verify the display on the DID panel is lit.
2. Turn ON the Control Power Switch (CPS) in the

Information Display Panel on the side of the control cabinet.
Sensor Power Supply (SPS):
3. If truck is equipped with the 17KG489E1 Control

Cabinet with Power Supply PS installed, verify all
five green lights in the power supply located on
the shelf behind the center cabinet door are lit.
NOTE: Check only if experiencing problems with the

Fiber Optic Card, the LEMs, or the Capacitor Monitor
Panel. (Applicable to trucks equipped with 17KG498D2
Control Cabinet only.)
4. Measure voltage between the circuits listed

below and cabinet ground:
11. Measure and verify the specified voltages below:
At A3PV (17FM458 panel, left side of control

cabinet), measure +15VDC at terminal G (circuit P15VDC04).
At A3PV, measure -15VDC at terminal E (circuit N15VDC04).
5. Check voltage on the following circuits in the
Electrical Interface Cabinet. Voltage at each
should equal the circuit 11 voltage measured at
step 7, Checks With Key Switch OFF:
Circuit 71 on TB32
CIrcuit 71GE on TB22
Circuit 71TCI on TB23 if equipped with the
17FL349 TCI panel.
6. Measure and verify the specified voltage to
ground at the following locations in the Electrical
Interface cabinet:
Input Voltage
Voltage should be between +20 and +32 volts
with voltmeter positive (+) lead on IN+
(SP24V03) and negative lead (-) on IN-
(RTN59).
Positive Output Voltage
Voltage should be between +22.8 and +25.2
volts with voltmeter positive (+) lead on V+
(P24VDC19) and negative lead on VR+
(RTN58).
Negative Output Voltage
Voltage should be between -22.8 and -25.2
volts with voltmeter positive (+) lead on V-
(N24VDC19) and negative lead on VR-
(RTN60).
+15 volts at the 15PV wire on TB29. (From

TCI, supply to operator control pedals)
+15 volts at the 15V wire on TB21. (From TCI,
power to cab gauges)
Approximately 11 volts at the 10V wire on
TB28.
E03015 1/02

E3-11
CPU Battery Checks

12. Turn OFF the Control Power Switch (CPS) for this
test.
13. Connect a VOM across the screws securing the
green plate on the edge of the 17FB147 card in
the PSC panel. Connect the positive lead to the
top screw (2, Figure 3-3) and the negative lead to
the bottom screw (4).
Verify approximately 3.5 volts.
14. Connect a VOM across the screws securing the
green plate on the edge of the 17FB144 card in
the TCI panel. Connect the positive lead to the top
screw and the negative lead to the bottom screw
Verify approximately 3.5 volts.
Note: If battery voltage is low in step 13 or 14, refer to
Memory Backup Battery Replacement instructions on
the following page.
MEMORY BACKUP BATTERY

REPLACEMENT
The replaceable memory backup battery on the
17FB144 or 17FB147 card will require replacement if
voltage is low when performing CPU Battery Checks
test or if during truck operation an event code appears
on the DID display as follows:
FIGURE 3-3. BATTERY LOCATION

(PSC Panel Shown)
1. FB147 CPU Card
2. Positive (+) Screw
3. Battery Assy.
4. Negative (-) Screw

5. FL320 Panel Enclosure
17FB147: Event Number 095 (BBRAM Battery Low)

17FB144: Event Number 633 (BBRAM Battery Failure)
To replace the battery on either card:
1. With control power OFF, remove the appropriate
card and locate the green plate with the battery,
near the card edge. (See Figure 3-3.)
2. Have a replacement battery (Komatsu Part Number GE0455) available for immediate installation.
To prevent data loss, the new battery must be installed
within 5 minutes of removal of the old battery.
3. Remove the 2 screws (2 & 4, Figure 3-3) retaining the battery assembly (3) to the mounting
bocks. (Note arrow direction (polarity) on green
plate before removal.)
4. Remove old battery and install new battery positioned for proper polarity. Reinstall screws.
5. Reinstall card in appropriate panel slot.
E3-12

1/02 E03015
TCI PROGRAMMING
PSC PROGRAMMING
BE SURE TO VERIFY LINK VOLTAGE IS DISCHARGED BEFORE PERFORMING THE FOLLOWING PROCEDURES.
1. Disconnect Circuits 21SS and 21SR, and insulate

from engine starter if equipped with MTU 396
engine. If MTU/DDC 16V4000 or Komatsu engine
is installed, disconnect and insulate 21B circuits
at starter solenoids. Apply park brake and brake
lock.
1. Disconnect Circuits 21SS and 21SR and insulate

is installed, disconnect and insulate circuit 21B at
the starter solenoids. Apply park brake and brake
lock.
a. Connect the serial communication cable from

the PTU to the TCI port located behind the
center console in the cab on the passenger
side.
a. Connect the serial communication cable from

the PTU to the PSC port located behind the
center console in the cab on the operators
side.
b. Be certain the Rest Switch in the cab is in the

REST position.
b. Be certain the Rest Switch in the cab is in the

REST position.
2. Turn the key switch ON.
2. Turn the Key Switch ON.
To program the 17FB144 CPU card:
c:\>ACNMENU {enter}
c:\>ACNMENU {enter}
Highlight PROGRAM TCI PANEL {enter}
Highlight PROGRAM PSC PANEL {enter}
Highlight SELECT TCI SETUP {enter}
Highlight SELECT PSC SETUP
Cursor to the appropriate configuration file for

the truck being programmed from the list of configuration files {enter}
Cursor to the appropriate configuration file for

the truck being programmed from the list of configuration files {enter}
Highlight- PROGRAM TCI PANEL {enter}
Highlight PROGRAM PSC PANEL
Highlight- PROGRAM TCI {enter}
Highlight PROGRAM PSC
3. Cycle keyswitch or CPS when requested on

screen.

screen.
4. Verify the Object Code and Configuration file

shown on the screen for downloading is correct.
4. verify the Object Code and Configuration file

shown on the screen for downloading is correct.
E03015 1/02

E3-13
INVERTER PROGRAMMING
TCI CHECKOUT
BE SURE TO VERIFY LINK VOLTAGE IS DISCHARGED AND ENGINE IS NOT RUNNING

BEFORE PERFORMING THE FOLLOWING PROCEDURES.
1. Open the right door on the Electrical Control Cabinet and connect the serial communication cable
from the PTU to one of the two ports located to
the right of the PSC Panel. (RS11 is used for the
inverter card in slot No. 09, RS12 is used for the
inverter card in slot No. 11.)
To program the Inverters:
c:\>ACNMENU {enter}
Highlight PROGRAM INVERTERS {enter}
Highlight either DOWNLOAD TMC - FB172 (2735) or DOWNLOAD IMC - FB138, depending
on which cards are installed in slots No. 09 and
11. {enter}.
1. Disconnect Circuits 21SS and 21SR, and insulate

is installed, disconnect and insulate 21B circuits
at starter solenoids. Apply park brake and brake
lock.
Log on to the TCI panel:
2. Connect the serial communication cable from the
PTU to the TCI port located behind the center
console in the cab on the passenger seat side.
Turn control power ON.
c:\>ACNMENU {enter}
Highlight- PTU TCI & PSC {enter}
Type technicians (your) name {enter}

screen.
Type your password {enter}
3. Verify the file shown on the screen for downloading is correct.
Set the Date and Time in the TCI panel:

Cursor to Special Tasks {enter}
Cursor to Set Date & Time {enter}
Cursor to Day of Month
Type day of month {enter}
Cursor to month {enter}
Arrow to desired month {enter}
Cursor to year - type year {enter}
Cursor to hour - type hour {enter}
Cursor to minute - type minute {enter}
Move cursor to (reset clock) {enter}
Cursor to exit {enter}
E3-14

1/02 E03015
Modular Mining Communication Port
Log on to the PSC panel:

3. Connect the serial communication cable from
another PTU to the PSC port, behind the center
console in the cab on the driver side.
c:\>ACNMENU {enter}
Highlight - PTU TCI & PSC {enter}
In the version 18 software, the PTU baud rate has been

increased from 9600 to 38400, however the Modular
Mining port remains at 9600 baud. Therefore, before
testing the Modular Mining port, the PTU baud rate
must be changed back to 9600. Follow the instructions
below to reset:
Type your name {enter}
1. Using DOS, select the c:\geohvac\ptuaccur

directory.
2. Select the following file to edit: ptu.cfg
View/Set the Date and Time in the PSC panel:
3. At approximately line 94 the following should be

displayed:
Cursor to Special Tasks {enter}
27 0 38400 8 1 n/* comm port 1, 9600

baud, 8 data, 1 stop, no parity */
Cursor to View/Set Time {enter}
4. Change the 38400 value to 9600 and save the

file.
Cursor to Day of Month

Type day of month {enter}
Arrow to desired month {enter}
Cursor to year - type year {enter}
Cursor to hour - type hour {enter}
Cursor to minute - type minute {enter}
Move cursor to (reset clock) {enter}
1. Connect the serial communication cable from a

PTU to the port near the DID panel in the cab
behind passenger seat.
c:\>ACNMENU {enter}
Highlight - PTU TCI & PSC {enter}
Cursor to exit {enter}
Check Comm Status:
Cursor to Normal Operation {enter}
On the TCI PTU:

Move the cursor to Normal Operation {enter}
Cursor to TCI Real Time Data {enter}
Verify PTU display indicates:
Cursor to TCI Real Time Data {enter} (see

notes below)
Verify the PTU is communicating on this screen
by observing a blinking cursor on the screen.
{escape} {escape}
COMMLINK=OK
{escape} {escape}
On the PSC PTU:
Move the cursor to Normal Operation {enter}
Cursor to PSC Real Time Data {enter}
Verify PTU display indicates:
Check MMI Port:
Notes: Only 4 command numbers are supported

through this port.
When the PTU starts, it sends out 3 or 4 commands
that the TCI will not respond correctly to. At the top TCI
screen, press the space key a number of times when
the screen indicates a mismatch until reaching the Real
Time Data screen.
COMMLINK=OK
{escape} {escape}
E03015 1/02

E3-15
TCI Input Checks

On the TCI PTU:
Move cursor to Normal Operation {enter}
Cursor to TCI Real Time Data {enter
1. Verify analog values and functions highlighted on the PTU are similar to the examples below:
Note: Actual values shown in illustrations will vary from those displayed on truck being serviced:
2. Press {enter} to display TCI SERIAL LINK DATA screen shown below:
E3-16

1/02 E03015
3. Press {enter} to display TCI ANALOG INPUT CHANNELS screen below:
E03015 1/02

E3-17
TCI Digital Output Tests
Before performing step 18 (Table III), verify circuits

21SS and 21SR (MTU 396 engine) are removed
from the starters or 21 B (MTU/DDC 16V4000 or
Komatsu engine) are removed from starter solenoids and the parking brake is applied.
Note: The lamp test switch on the Overhead Display

will not activate the G.E. propulsion system lamps
when the PTU is in the Manual Digital Output Test
mode.
1. Apply the park brake switch and place the Rest
switch in the OFF position.
5. For Table III, step 18, change PTU from Engine

Stopped Tasks screen to Real Time Data screen:
2. On the TCI COMMUNICATION MENU, place cursor on Engine Stopped Tasks and press {enter}.
{escape} {escape}
3. Place cursor on Manual Test Screen. Press

{enter}.
cursor to Normal Operation {enter}
4. For Table III steps 1 through 17, turn on each discrete output by highlighting it then pressing
{enter}. After the output is verified, press {enter}
to turn it off. Refer to Figure 3-4 for lamp location
and color.
cursor to TCI Real Time Data screen {enter}

a. Place selector switch in NEUTRAL and apply
park brake.
b. Turn key switch to START position.
TABLE III. TCI DIGITAL OUTPUT TESTS

STEP
DO NAME
DESCRIPTION
LOCATION
(Fig. 3-3)
RESTLT
Rest Light
B6
PSCNOTRDY
Propel System Not Ready Light
C6
REDUCELT
Reduced Propulsion Level Light
D6
LINKONLT
Link ON light, DID Panel (Behind Operator's Seat)
TEMPWARNLT
Propulsion System Temperature Warning Light
C5
NORETARDLT
No Retard, No Propel Light
A5
NOPROPELLT
No Propel Light
A6
PSCWARNLT
PSC Warning Light
B5
RTRDCONTLT
Reduced Retarding Light
E6
10
HYDBHOTLT
Hydraulic Brake Fluid Hot Light
D5
11
PKBRKON
Verify park brake switch is applied:

Measure Circuit 52CS @ TB26 to ground:
Press {enter} to turn PKBRKON on:
12
RETARDLT
Retard Light (on overhead display)
13
RETARDXLT
Retard light (on top of cab and rear of truck)
14
BATSEPC
Battery Separate Relay

Measure Circuit 21BSR @ TB28 to ground
With BATSEPC highlighted, press {enter}: Verify 0.0 VDC
15
SPEED1
not used
16
SPEED2
not used
17
REVERSELT
Activates backup horn and backup lights
Verify 0.0 volts

Verify approx. 24 volts
A3
D3
B4
Refer to TCI Digital Output Test procedure step 5. before performing the following test:
18
E3-18
ENGCRANK
Engine Crank Signal

1/02 E03015
Trucks without prelube system:

Measure 24V DC to ground on Circuit 21A
(TB25) and also 21B (TB31) to ground.
Trucks with prelube system:
Measure 24V DC to ground on Circuit 21A @
TB25 and also 21PT @ TB28 to ground, after
the prelube system has reached proper oil
pressure. (Note: Engine oil level must be correct.)
Verify digital input ENGSTRTREQ and digital
outputs ENGCRANK, ENGCRNK2, and BATSEPC are highlighted when 21A (& 21PT)
and 21B are 24V DC.
6. Return key switch to ON position.
7. Move selector switch to FORWARD.
FIGURE 3-4. STATUS/WARNING LIGHTS
8. Turn key switch to START.

Circuit 21A should remain 0V DC.
9. Release key switch.
10. Place selector switch in NEUTRAL.
11. Place park brake switch in the OFF position.
12. Turn key switch to START position.
Row-Col.
Indicator Description
Color
A1*
Spare
B1*
Low Steering Pressure
Red
C1
Low Accumulator Precharge
Red
D1
Spare
E1
Low Brake Pressure
Red
A2*
Low Hydraulic Tank Level
Red
13. Release the key switch.
B2*
Autolube Low Pressure
Amber
14. Apply parking brake.
C2*
Circuit Breaker Tripped
Amber
D2*
Hydraulic Oil Filter Restricted
Amber
E2*
Low Fuel
Amber
A3*
Park Brake Applied
Amber
B3*
Service Brake Applied
Amber
Circuit 21A should remain 0VDC.
AUX ERROR CODE Check:

1. With the PTU still on the TCI Real Time Data
screen, check the AUX_ERROR_CODE at the
upper right of the screen:
Value should be blank or (001)
Note: A Value of (-01) may indicate the TCI is not
communicating with the aux inverter.
E03015 1/02
C3*
Body Up
Amber
D3*
Dynamic Retarding Applied
Amber
Red
E3
STOP ENGINE
A4*
Spare
B4*
Manual Back-Up Lights
Amber
C4*
5 Minute Shutdown Timer
Amber
D4*
Amber
E4*
CHECK ENGINE
Amber
A5
No Propel/Retard
Red
B5
Propulsion System Caution
Amber
C5
Propulsion System Temp. Caution
Amber
D5
High Brake/Hydraulic Oil Temp.
Red
E5*
STOP ENGINE (Komatsu engine only)
Red
A6
No Propel
Red
B6
Propulsion System at Rest
Amber
C6
Propulsion System Not Ready
Amber
D6
Propel System at Reduced Level
Amber
E6
Retard System at Reduced Level
Amber

E3-19
TCI Digital Input Tests

1. Verify park brake switch is on. Turn REST switch
OFF (down).
2. On the TCI COMMUNICATION MENU, select
Engine Stopped Tasks and press {enter}.
cursor to Manual Test Screen
3. Activate each truck function listed in Table IV for
Table checkout steps 1 through 16.
5. Turn OFF circuit breakers on RB2 (if installed).

Verify the Circuit Breaker Tripped lamp on the
overhead display illuminates.
6. Check steps 17 and 18 in Table IV.
7. Remove jumpers and turn circuit breakers on
RB2 ON.
8. Press {escape}.
Verify the inputs are highlighted on the PTU

screen when activated.
When performing step 1 in Table IV, and if
truck is equipped with warning/caution light
dimmer, adjust the dimmer control and verify
intensity of lamps indicated by * in Figure 3-4
can be varied. (Remaining lamps will remain
at full intensity regardless of dimmer control
position.)
DID Display:
1. Observe the DID display.
The cursor to the right of the event code
should appear to spin.
NOTE: In some steps it may be necessary to jumper a

circuit to activate the function. Refer to Table IV on the
following page for instructions.
4. Turn OFF and ON all circuit breakers on relay
boards RB1, RB2 (if installed), RB3, RB4, and
RB5 in the Electrical Interface Cabinet.
Verify the Circuit Breaker Tripped lamp on the
overhead display illuminates when each circuit breaker is turned off, except as noted
below.
Notes:
To check CB19 on relay board RB3, selector switch
must be in REVERSE position.
CB20 will not activate Circuit Breaker Tripped lamp
when turned off.
To check CB13 & CB15 on relay board RB1, the
running lights must be on.
E3-20

1/02 E03015
TABLE IV. TCI DIGITAL INPUT TESTS

STEP
DO NAME
DESCRIPTION
LAMPTEST
Lamp Test Switch (Overhead Display - all lamps except last two rows should illuminate)
Note: When version 18 software is installed, the following will occur when the Lamp Test Switch is
activated:
Back-up horn sounds and back-up lights turn on.
Retard lights at rear of truck and on top of cab turn on.
ENGCAUTION
Check Engine Caution Lamp (Jumper circuit 419M @ TB30 to ground to illuminate overhead lamp)
(Note: If equipped with Komatsu engine, ENGCAUTION will not be highlighted on PTU but overhead
display lamp should illuminate.)
ENGWARN
Stop Engine Warning Lamp (Jumper circuit 509 @ TB30 to ground to illuminate overhead lamp)
If equipped with Komatsu engine, jumper 528A @ TB32 to ground to illuminate 2nd indicator lamp.)
RESET
Clear/delete/dump body up override pushbutton switch on console
RESTSW
Rest Switch (Place in REST position to activate) Note: Some trucks are equipped with a release button on the Rest Switch that must be pressed before moving the switch to the REST position. Verify the
internal lamp on the Rest Switch lights when in REST position.
REVREQ
Selector Switch in REVERSE position
FORREQ
Selector Switch in FORWARD position
ENGKILL
Engine Shutdown Switch (Depress switch on console) Verify circuit 439 (TB25) changes from 0 to
24VDC.
DATASTORE
Data Store Switch (on front of console - push to activate)
10
BODYDWN
Body Up Switch (Activated when body is down) Circuit 63L (TB12) to ground voltage should be
approximately 24 volts with body down, 0 volts when body is raised. Verify lamp is Overhead Display
is OFF when body is down.
11
PRKBRKSW
Park Brake Switch (Highlighted with switch ON)
12
PRKBRKFDBK
Park Brake Feedback Signal (Highlighted - Jumper circuit 73S on Park Brake Pressure switch, on
brake manifold in brake cabinet to ground to remove highlight.)
13
ENGSTRTREQ
Engine Start Request (Refer to Digital Input for check procedure)
14
RSC
Retard Speed Control Switch (on console - pull up to highlight)
15
OVERPAYLD
Truck Overloaded (Jumper circuit 72IP@TB29 to circuit 712 @ TB32)
16
CONTROLON
Control Power ON (Do not check)
Refer to procedure step 3. before performing the following checks (RB2 circuit breakers must be OFF, if RB2 is installed):
17
MIDPAYLD
Truck at 70% Payload (Jumper 73MS @TB25 to ground.)
18
FULLPAYLD
Truck Fully Loaded (Jumper 73LS @TB25 to ground.)
E03015 1/02

E3-21
6. Type the following on the PTU keyboard:

c:\>ACNMENU {enter}
PSC Checkout Procedure

PSC Digital Output Tests:
1. Turn OFF the Control Power Switch.
2. Place the Rest Switch In the cab in the OFF position. Turn Park Brake switch ON.
3. Disconnect the round connector at the top of
each Phase Module and Chopper Module.
PTU to the PSC port, behind the center console
on the drivers side.
5. Turn ON the Control Power Switch.
Highlight PTU TCI and PSC {enter}

7. Verify the values and functions highlighted on the
PTU are similar to the PSC Serial Link Data
screen in Figure 3-5 below:
FIGURE 3-5. PSC REAL TIME DATA SCREEN

8. Press {enter}. Verify PTU screen values are similar to Figure 3-6.
FIGURE 3-6. PSC SERIAL LINK DATA SCREEN
E3-22

1/02 E03015
9. Press {enter}. Verify the values on the PTU are similar Figure 3-7 below:
FIGURE 3-7. PSC ANALOG INPUT CHANNELS SCREEN

10.
Press {enter}. Verify the values on the PTU are similar to Figure 3-8 below:
FIGURE 3-8. PSC TEMPERATURES SCREEN
E03015 1/02

E3-23
Cursor to Engine Stopped tasks {enter}

Cursor to Manual Test Mode {enter}
11. Highlight the devices listed in steps 1 through 11
in Table V below on the digital output section on
this screen and then press {enter}. Press {enter}
again to turn off
12. For step 14 (GD1E) in Table V below, use an AC
voltmeter set on 750V AC scale to check for 90 to
100 volts AC between the pins on each round
connector removed in step 3 (cable side) to
Inverter 1, (top row).
13. Use the AC voltmeter to check for 90 to 100 volts

AC between the pins on the round connector on
the top of Chopper Module One (CM1 G-X)
removed in step 3.
Press {escape} {escape}
14. Turn OFF the Control Power Switch
15. Reconnect the round connectors to Inverter 1.
16. Reconnect the round connector to Chopper Module 1.
TABLE V. PSC DIGITAL OUTPUT TEST

STEP
DO NAME
DESCRIPTION
DEVICE CHECKOUT
GF
GF Contactor
Verify the GF contactor picks up and GFFB is highlighted on the PTU

(NOTE: The GF Cutout Switch must be in the NORMAL (up) position
to check).
GFR
GFR Contactor
Verify the GFR relay picks up.
RP1
RP1 Contactor
Verify RP1 picks up and RP1FB is highlighted.
RP2
RP2 Contactor
Verify RP2 picks up and RP2FB is highlighted.
RP3
RP3 Contactor (If installed)
If installed, verify RP3 picks up and RP3FB is highlighted.
CPRL
Control Power Relay
With CPRL highlighted turn off CPS and verify that control power is not
lost. Turn CPS back on.
AFSE
Alternator Field Static Exciter
With AFSE highlighted verify 24 volts to ground on the +25 terminal

on the AFSE terminal board.
SYSRUN
Control System OK LED
Verify the second LED from the top (labelled Control System OK),
located on Information Display Panel on the side of the control cabinet
is ON
TEST
Test Mode LED
Verify the fourth LED from the top (labelled Test Mode), located on the
Information Display Panel on the side of the control cabinet is ON.
10
REST
Rest Mode LED
Verify the fifth LED from the top (labelled Rest Mode), located on the
Information Display Panel on the side of the control cabinet is ON.
11
SYSFLT
System Fault LED
Verify the third LED from the top (labelled System Fault), located on
the side of the control cabinet is on.
Early Production Trucks: For steps 12 & 13, jumper a 20K ohm resistor across circuits 72FD (TB23) to 712 (TB32) and a 20K ohm resistor
across circuits 79RD (TB23) to 712 (TB32). Remove resistors after steps 12 and 13 are completed.
12
FORT
Forward Travel Direction
Verify circuit 72FD changes from 24VDC to 0VDC when FORT is activated
13
REVT
Reverse Travel Direction
Verify circuit 79RD changes from 24VDC to 0VDC when REVT is activated
14
GD1E
Gate Drive Power, Inverter 1

Enable Signal
Refer to steps 12 through 19 in digital output test procedure.
15
GD2E
Gate Drive Power, Inverter 2

Enable Signal
Refer to steps 20 through 28 in digital output test procedure.
16
CMCTL
Chopper Module Control
Do not check.
17
AUXRESET
AUX Inverter Reset
AUXRSET should be highlighted.
E3-24

1/02 E03015
17. Turn ON the Control Power Switch
25. Turn ON the Control Power Switch
Cursor to Engine Stopped Tasks {enter}
Highlight GD1E on the digital output section and

press {enter}.
Highlight GD2E on the digital output section and

press {enter}.
When performing the following procedures, never

look directly into the fiber optic light. Eye damage
could result.
When performing the following procedures, never

look directly into the fiber optic light. Eye damage
could result.
18. Carefully remove the grey plug on the top of each

Phase Module for Inverter 1.
26. Carefully remove the grey plug on the top of each

Phase Module for Inverter 2.
Without looking directly into the plug on each

Phase Module, verify that a red light is
present.
Without looking directly into the plug on each

Phase Module, verify that a red light is
present.
19. Carefully remove the grey plug on the top of

Chopper Module 1.
27. Carefully remove the grey plug on the top of

Chopper Module 2.
Without looking directly into the plug on Chopper Module One, verify that a red light is
present.
Without looking directly into the plug on Chopper Module 2, verify that a red light is present.
20. For step 15 (GD2E) in the PSC Digital Output Test

Table, use an AC voltmeter to check for 90 to 100
volts AC between the pins on each round connector removed in step 3 (cable side) to Inverter 2
(bottom row).
28. Reconnect plug on each Phase Module 2 for

inverter 2 and Chopper Module 2.
21. Use an AC voltmeter to check for 90 to 100 volts

AC between the pins on the round connector on
the top of Chopper Module 2 (CM2 G-X) removed
in step 3.
Press {escape} {escape}
22. Turn OFF the Control Power Switch
23. Reconnect the round connectors to Inverter 2.
24. Reconnect the round connector for Chopper Module 2.
E03015 1/02

E3-25
4. Turn ON the key switch.
PSC Digital Input Checks

The following tests are made on the Manual Test
Screen as selected during PSC Digital Output Test
procedure.
1. With the key switch and the Control Power Switch
ON:
Verify the digital inputs in steps 1 through 5 in
Table VI below are highlighted.
2. Check digital inputs in Table steps 6 through 8
using the instructions in the Device Checkout column.
5. Turn OFF the Control Power Switch.

KEYSW will stay highlighted, CPSFB will no
longer be highlighted.
6. Turn ON the Control Power Switch.
Press {enter} to turn off CPRL.
{escape} {escape}
7. Turn OFF Control Power Switch.
Highlight CPRL on the digital output section of

the PTU screen and then press {enter}.
3. Turn OFF the key switch in the cab.
KEYSW and CPSFB will no longer be highlighted
TABLE VI. PSC DIGITAL INPUT TEST
STEP
DI NAME
DESCRIPTION
DEVICE CHECKOUT
KEYSW
Key Switch
CPSFB
Control Power Switch Feedback
CNFB
Panel Connectors Status
CNIFB
CNI and CNENG Connector

Status
CNXFB
Auxiliary Blower Connector

Status
INV1CO
Inverter 1 Cutout Switch Status
Will be highlighted with Inverter #1 switch on the side of the control cabinet in
the CUTOUT position (down).
INV2CO
Inverter 2 Cutout Switch Status
Will be highlighted with Inverter #2 switch on the side of the control cabinet in
the CUTOUT position (down).
BRKON
Service Brake Apply Status
Will be highlighted with wire 44R (TB26) jumpered to 712 (TB22) (Wires do not
have to be removed.)
E3-26
With the Key Switch and Control Power Switch ON, digital inputs should be
highlighted.

1/02 E03015
Verify panel output is 0.12 volts (battery volts

divided by 200)
Miscellaneous Checks
A3PV Panel
1. Remove the wires from panel terminals A and C.
2. With the Control Power Switch ON, measure voltage between terminals D and F:
Verify 0.0 30 Millivolts.
3. Connect a jumper wire from the BATFU fuse
located on the bottom left wall in the left compartment to terminal A on A3PV.
6. With the PTU connected to the PSC, enter the

following:
c:\>ACNMENU {enter}
Highlight PTU TCI & PSC {enter}
4. Connect a jumper wire from a cabinet ground to

terminal C on A3PV.
5. Measured voltage between terminals D and F.
Verify panel output is 0.12 volts (battery volts

divided by 200)
6. Connect a serial communication cable from the
PTU to the PSC.
Verify LINKV is equal to battery volts

7. Remove the jumper wires. Reconnect the wires
to terminals A and C.
7. On the PSC PTU, enter the following:

Thermistor Checks
c:\>ACNMENU {enter}
1. With the PTU connected to the PSC:


Cursor to PSC Real Time Data Screen {enter}
Verify A3PV is approximately 1.17 X battery
volts

Verify AUXPCT is showing ambient temperature
Verify AUXIT is showing ambient temperature
Verify AFSET is showing ambient temperature
8. Remove the jumper wires.

9. Reconnect the wires to terminals A and C.
17FM384 Panel Check

1. With the PTU connected to the PSC;
Cursor to Normal Operation {enter}.
LINKV Panel
1. Remove the wires from panel terminals A and C.
2. With the Control Power Switch ON, measure voltage between terminals D and F:
Verify 0.0 30 Millivolts.
3. Connect a jumper wire from the BATFU fuse
located on the bottom left wall in the left compartment to terminal A on LINKV.

2. Carefully remove the FAILDIOD wire from terminal D on the 17FM384 panel.
Verify FDIODE is highlighted on PTU screen
3. Reconnect wire to terminal D.
4. Connect a jumper wire from a cabinet ground to

terminal C on LINKV.
5. Measure voltage between terminals D and F.
E03015 1/02

E3-27
Pedal Percentages and Meter Calibration

The following procedures are used to calibrate the
retarder and accelerator pedals, retarder lever, and the
hydraulic brake temperature and propel system temperature gauges and the speedometer for the software.
If any of the above components require replacement
during truck servicing or troubleshooting procedures,
the new or rebuilt component must be recalibrated
using the applicable procedure before the truck is
returned to service.
PTU to the PSC port, behind the center console
on the drivers side.
2. Turn keyswitch and Control power Switch ON.
Meter Calibration Procedure

PTU to the TCI port, behind the center console,
on the passenger side.
2. Turn ON the Key Switch and the Control Power
Switch.
3. On the PTU, enter the following:
c:\>ACNMENU {enter}
4. Turn park brake switch ON and turn Rest switch
OFF.
3. Enter the following on the PTU:

c:\>ACNMENU {enter}
C: Hydraulic Brake Fluid Temperature Meter:
Cursor to Temporary Meter Calibration. {enter}
Cursor to the box to the right of Type a Test

Hydraulic brake Fluid Temperature {enter}
Cursor to View/Set PSC Analog Outputs

{enter}
Type in: 120 {enter}

5. Hydraulic Brake Fluid Temperature meter should
move to a position near the line separating green
and red.
A: Retard Pedal:
Move the cursor under the (K - Z) column on
channel 1 (CH1) {enter}
Cursor to Parameter name rpinhi_ail5 {enter}
Record the parameter value with the retard
pedal fully released. (typical value; 1.53
volts).
Record the parameter value with the retard
pedal fully depressed. (typical value; 9.50
volts).
Move the cursor to the Increment\Decrement

boxes and press {enter} to position the meter
pointer on the line between the green and red
sections.
6. When at the desired meter position, record the
value shown in the Gauge Scale box.
D: Propulsion System Temperature Meter:

Cursor to the box to the right of Type a Test
Propulsion System Temperature {enter}
Type in: 60 {enter}
B: Retard Lever:
Cursor down to channel 2 (CH2) and position
the cursor under the (K - Z) column {enter}
Cursor to parameter name retlever_ail4 {enter}
Record the parameter value with the lever up
(typical value; 0.0 volts).
Record the parameter value with the lever
down (typical value; 8.75 volts).
E3-28
7. Propulsion System Temperature meter should

move to a position near the line separating green
and yellow.
Move the cursor to the Increment\Decrement
boxes and press {enter} to position the meter
pointer between the green and yellow sections.
8. When at the desired meter position, record the
value that is in the Gauge Scale box.

1/02 E03015
10. Record the following information from the screen:
E: Truck Speed:
F: Accelerator pedal:
Arrow to mph box {enter}

Type in: 25 {enter}
Adjust speedometer internal adjustment pot
to obtain 25 mph (or 40 km/h).
Type in: 40
Verify speedometer in cab reads 40 mph (or
64 km/h).
9. Press {escape} to return to Engine Stopped Menu
screen.
Cursor to Exit {enter}
On the TCI Communication Menu, cursor to
Normal Operation {enter}
With TCI Real Time Data screen displayed,
press {enter} to go to TCI Serial Link Data
screen
Press {enter} to go to TCI Analog Input Channels screen
E03015 1/02
Record the accel pedal voltage with pedal

released (typical value; 1.61)
Record the accel pedal voltage with pedal
fully depressed (typical value; 8.53)
G: Retard Speed Pot Setting:
11. Pull the retard speed control button UP.
Record value of RSC POT with knob fully
counterclockwise (typical value; 10.75)
Record value of RSC POT with knob fully
clockwise (typical value; 0.01)
H: Pot Reference:
Record value of POTREF (typical value;
10.86)
12. Press {escape} to return to TCI Normal Operation
Menu.
Cursor to Exit {enter}
On TCI Communication Menu, cursor to Exit
{enter} {enter} to return to Main Menu.

E3-29
Reprogram With Serial Numbers and Pedal

Percentages
On the Main Menu, highlight AC TRUCK
SETUP (CFG) {enter}
Cursor to Mine Configuration {enter}
Note: If the calculated value for Retard Lever Travel

Off Request is less than 3%, use 3% as the input
value.
Cursor to: 0) Select a truck config, currently

using file: {enter}
Cursor to desired configuration file {enter}
Cursor to: 3) View GE Product Service Data
{enter}
Type meter scale values, and stat quarter start

month.
Cursor to Truck Identification Number and type
assigned mine truck number {enter}
Cursor to Leave GE Product Service screen

{enter}.
Cursor to Leave Truck Specifics Screen {enter}
Cursor to: 4) Change/View Truck Specifics

{enter}
Cursor to S) Save a truck configuration, filename: {enter}
Type accelerator pedal, retard pedal and retard

lever percentages (see instructions and example in Figure 3-5), for the OFF and fully applied
positions.
Type the configuration filename {enter}

Cursor to Q) Quit {enter}
Type Y
FIGURE 3-9. PEDAL PERCENTAGE CALCULATIONS
E3-30

1/02 E03015
K: Check Pedal Percentages
I: Program TCI
(PTU connected to TCI port)
1. 1. Place the REST switch in the OFF position and
turn keyswitch ON.
From the Main Menu, highlight DOWNLOAD
TCI PANEL {enter}
Highlight SELECT TCI SETUP {enter}
Cursor to configuration desired {enter}
Highlight DOWNLOAD TCI PANEL {enter}
Highlight DOWNLOAD TCI {enter}
screen.
shown on the screen for downloading are correct.
J: Program PSC
On the PSC PTU - cursor to Normal Operation

{enter}
1. With the accelerator pedal released, verify the following is displayed:
ACCEL_SEL = 0.00
2. With the accelerator pedal fully applied, verify the
following is displayed:
ACCEL_SEL = 1.00
3. With the retard pedal released and retard lever
up, verify the following is displayed:
RETRD_SEL = 0.00
4. With the retard pedal fully applied, verify the following is displayed:
RETRD_SEL = 1.00
5. With the retard lever fully down, verify the following is displayed:
RETRD_SEL = 1.00
(PTU connected to PSC port)
6. With Retard Speed Control knob pulled up and

the knob turned fully counterclockwise, verify the
following is displayed:
1. Turn keyswitch ON.

From the Main Menu, highlight DOWNLOAD
PSC PANEL {enter}
Highlight SELECT PSC SETUP {enter}
Cursor to configuration desired {enter}
RSCMPH = 5
7. With Retard Speed Control knob pulled up and
the knob turned fully clockwise, verify the following is displayed:
RSCMPH = 37 (see note below)
Note: In step 7, truck configurations 07E and 13E will
indicate 31 (instead of 37) for 38.1 gear ratio.
Highlight DOWNLOAD PSC PANEL {enter}

Highlight DOWNLOAD PSC {enter}
screen.
shown on the screen for downloading are correct.
E03015 1/02

E3-31
LOAD TESTING
1. Reconnect wires 21SR and 21SS (MTU 396
engine) to the starter or 21B (MTU/DDC 16V4000
or Komatsu engine) to the starter solenoids.
1. Connect a voltmeter across resistor R1 located in

the Contactor Box on the Electrical Cabinet.
a. Connect the positive lead to BAT
b. Connect the negative lead to F101.
2. Place both Inverter Cutout Switches on the side

of the control cabinet to the CUTOUT position
(down).
2. Close the cabinet door.
3. Place the Rest Switch in the REST position.
4. Connect one serial communication cable from the

PTU to the PSC port.
4. Make sure the wheels are chocked, and the park

brake switch is ON.
5. Remove the locking bar from the right side of the
auxiliary blower behind the inspection cover.
6. Install locks on the three front doors of the electrical cabinet. Also secure the 3 top covers.
3. Turn Key Switch and Control Power Switch ON.
C:\>ACNMENU {enter}
Preload Checks
Alternator Speed Sensor Check:

1. Connect an AC voltmeter to circuits 74X (TB22)
and 74Z (TB22).
2. Place the GF Cutout Switch in the CUTOUT position (down).
3. With Rest Switch in the REST position, start the
engine and operate at low idle.
5. Verify the analog values and the functions highlighted on the PTU are similar to Figure 3-10.
6. Connect a second serial communication cable
from the PTU to the TCI port.
C:\>ACNMENU {enter}
Verify approximately 4 VAC on the meter.
Verify tach (in cab) reads approximately 700

RPM.
4. Shut down the engine. Remove voltmeter.

7. Verify the analog values and the functions highlighted on the PTU are similar to Figure 3-11.
Battery Boost Check:
8. Start the engine.

9. Place the GF Cutout Switch in the NORMAL position (up).
THE BATTERY BOOST CHECK MUST BE PERFORMED EXACTLY AS DESCRIBED BELOW. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY.
The contactors in the cabinet with the R1

resistor may be energized with the engine running.
DANGEROUS
VOLTAGES
ARE
PRESENT INSIDE THE CABINET.
Engine must be OFF during setup preparation.
Rest switch in the cab must be in REST.

GF cutout switch must be in the CUTOUT
10. While observing the voltmeter installed in step 1,

place the Rest Switch in the OFF position.
The voltmeter will momentarily show about 18
volts and then drop to zero
11. Place the Rest Switch in the ON position.
12. Place the GF Cutout Switch in the CUTOUT position.
13. Shut down the engine.
14. Verify ALL lights indicating link voltage are OFF.
15. Remove the voltmeter and lock the cabinet door.
position, (down).
ALL Link Voltage lights must be OFF.
E3-32

1/02 E03015
FIGURE 3-11. TCI REAL TIME DATA SCREEN
E03015 1/02

E3-33
ADDITIONAL TRUCK CHECKS

Be certain Rest Switch is ON.
Place Inverter Cutout switches in the CUTOUT
(down) position.
6. On the PSC Real Time data screen:

Verify BRKON is highlighted when the wheel
brake lock is applied.
7. Turn brake lock switch OFF.
8. In the brake cabinet, short Circuit 33 on the brake
pressure switch to ground.
Brake System Pressure Switch Checks:

1. Start engine and allow engine to warm up for
approximately 10 minutes.
2. Verify the following:
All indicator lights on overhead are OFF
except System Rest, Propel System Not
Ready and Park Brake.
3. Individually check (other than the differential
pressure switch in rear axle housing) the service
brake system switches on the truck. (This can be
done by shorting the circuit to ground, momentarily. The circuits are active while being shorted.)
a. Front to rear brake differential Circuit 33Z, in
the front of operator cab. (There is a 5-second
delay timer in this circuit.)
b. Front differential brake Circuit 33Z in the brake
cabinet. (There is a 5-second delay timer on
this circuit.)
4. Put brake lock switch ON.
a. Short Circuit 33T to ground (brake lock degradation pressure switch located in brake cabinet). (There is a 5-second delay timer on this
circuit.)
b. Note that when the brake lock is applied, the
service brake lights on the truck are active and
the service brake light indicator on the overhead display illuminates.
5. Connect the PTU to the PSC communication
port.
c:\>ACNMENU {enter}
Enter your name {enter}
Enter your password {enter}
The low brake pressure light on the overhead

display and the low brake pressure buzzer
should be active.
9. On the left frame rail, short Circuit 33F at the
steering pressure switch on the bleeddown manifold to ground.
The low brake pressure, low steering pressure lights in the overhead should come on
and the low brake pressure buzzer should be
active.
Hoist & Steering Circuit Switch Checks:
10. On the inner side of the fuel tank, short Circuit 39
on hoist circuit hydraulic filters bypass indicator
switch, to ground.
The Hydraulic Oil Filter light in overhead turns
on.
11. At the steering circuit hydraulic filter, short circuit
39 on filter bypass indicator switch to ground.
The Hydraulic Oil Filter light in overhead turns
on.
12. On the fuel tank, short Circuit 38 at low fuel level
switch to ground.
The Low Fuel light indicator in the overhead
should light.
13. Short Circuit 51A at nitrogen precharge pressure
switches on top of steering accumulators to
ground.
The Low Accumulator Precharge indicator
light is activated. This light stays on even
when the short is removed.
14. Use engine shutdown switch on selector switch
console to shut down engine. Do not turn Key
Switch OFF.
The Accumulator Precharge light should
remain on and brakes and steering pressure
remain charged.
15. Turn key switch OFF.
Verify steering pressure bleeds down.
E3-34

1/02 E03015
Final Checks:
Aux Blower Rotation Check

If the blower has been replaced or cables removed and
reinstalled, verify correct blower rotation to insure correct hookup.
Note: On some trucks the Auxiliary Blower System is
replaced by the Alt external fans.
1. Remove the inspection cover from the Aux
Blower on the driver side of the truck.
2. Verify Inverter Cutout Switches are in the CUTOUT position (down).
3. Start the engine.
4. Move the GF Cutout Switch to the NORMAL position.
5. Move the Rest Switch to the OFF position.
6. Check the rotation of the Aux Blower.
Make sure it is rotating counterclockwise as
viewed from the driver side of the truck.
Verify the Link Voltage lights are ON.
Verify that the exhaust holes on the control
cabinet are free of debris and air is flowing
out of them.
1. Connect the PTU to the PSC communication

port.
2. Start the engine. Select PSC Real Time Data
screen on the PTU:
c:\>ACNMENU {enter}
Enter your name {enter}
Enter your password {enter}
3. Place the GF cutout switch in the normal position
(up).
4. Place the REST switch in the OFF position.
5. Compare the values displayed with the values
shown on the sample screen in Figure 3-12.
6. Verify AUXFB is about 1700 rpm and exhaust air
is flowing from the rear exhaust ports of the control cabinet.
7. With the engine running, move the GF cutout
switch to the normal position and turn the Rest
Switch OFF:
Verify both inverter link voltages (I1V & I2V)
are approximately 700 volts.
7. Move the Rest Switch to the REST position. Note

the Link Energized lights turn off.
8. Place the Rest Switch in the ON position.
8. Shut down the engine.
9. Press {escape} {escape}.
9. Replace the Aux Blower cover.
10. Shut down engine and remove equipment.
E03015 1/02

E3-35
On-Board Load Testing
Inspect and verify the front and side electrical cabinet doors are closed and locked before performing
the following tests.
Preparation
2. Connect a VOM from circuit 72E @ TB24-G (+) to

circuit 0 @ TB24-H (-). This is the 10 volt load
hand-shaking signal from the engine. (Value
should be 5.0 volts with just control power on.)
Refer to PVM Test at the end of this section for
additional information.
3. Turn brake lock ON.
4. On the PSC PTU:
1. Jumper fan clutch control circuit to lock fan in full

on condition.
a. If truck is equipped with DDEC engine, jumper
circuit 541M @ TB24 to ground.
b. If truck is equipped with Komatsu engine,
jumper circuit 22FO @ TB32 to ground.
Note: Load testing can be performed through the DID
panel or by using the PTU. The procedures below
assume the PTU will be used.

5. With the engine running, place the Rest Switch in
the OFF position.
6. Verify the values and the functions highlighted on
the PTU are similar to the screens shown in Figures 3-13 through 3-15.
Note: Press {enter} to move to the next screen.
FIGURE 3-13. PSC REAL TIME DATA SCREEN SAMPLE
E3-36

1/02 E03015
FIGURE 3-14. PSC SERIAL LINK DATA SCREEN
FIGURE 3-15. PSC ANALOG INPUT CHANNELS
E03015 1/02

E3-37
7. Place the Rest Switch in the REST position.

8. On the TCI PTU:
Cursor to TCI Real Time data {enter}
9. With the engine running, place the Rest Switch in

the OFF position.
Verify the analog values and the functions
highlighted on the PTU are similar to the
screen shown in Figure 3-16.
FIGURE 3-16. TCI REAL TIME DATA SCREEN
E3-38

1/02 E03015
Initiate Loadbox Test

1. To initiate the loadbox test, on the PSC PTU:
Cursor to SELF LOAD ENGINE TEST {enter}
NOTE: If the HP ADJ value is (-)400 it is an indication

that the zero to ten volt engine command is not getting
to the PSC (Circuit 72E and 0).
Refer to PVM Optimum Load Curve Handshaking
Troubleshooting Test for additional troubleshooting
information.
Cursor to ENTER LDBX {enter}

2. CCU should momentarily display at the bottom
of the screen. (This is a self-test indication).
3. Put the Selector Switch in NEUTRAL and
depress the accelerator pedal. RPM must be
above 1300 RPM to pick up RP1.
4. Compare the values on the Loadbox Screen to
the values shown in Figure 3-17.
FIGURE 3-17. SELF LOAD TEST; RP1 PICKED UP
E03015 1/02

E3-39
9. Compare the values on the loadbox screen with

the values shown in the sample screen in Figure
3-19.
In the following step, air exhausted from grid vents
can be very hot.
5. Without touching them, check for air flow from the

grid blowers as follows:
a. Increase engine RPM until two RP contactors
pickup.
10. Record the Loadbox Screen on the PTU as follows:

a. While viewing the loadbox screen during full
load:
Press the {F2} key
Cursor to record and press {enter}
Type a filename and press {enter}
Hot air should be felt from one front section of

the grid.
b. Reduce RPM to idle and then increase RPM
to pickup two RP contactors.
Hot air should be flowing from the other front
section of the grid.
6. Warm-up engine with two RP contactors picked
up until the engine coolant temperature stabilizes.
7. Compare values displayed on the Loadbox Test
Screen with the sample screen in Figure 3-18.
8. Fully depress the accelerator pedal to pickup all
three RP contactors.
11. Note the ENGLOAD value On the screen:

If the value is 5 volts during load testing, loading is satisfactory.
If the value is below 5 volts, the electrical system needs to remove horsepower loading.
(This is an indication of a weak engine.)
If the value is above 5 volts, the electrical system needs to load the engine more.(This is an
indication of a strong engine.)
Note: Some trucks have RP1 & RP2 only
FIGURE 3-18. SELF LOAD TEST SCREEN; RP1 RP2/RP3 PICKED UP
E3-40

1/02 E03015
FIGURE 3-19. SELF LOAD TEST SCREEN; RP1 RP2 & RP3 PICKED UP
12. The load box screen should be recorded and values compared to values calculated to account for
parasitic losses at the elevation of the test site
and ambient temperature during testing as follows:
Trucks with DDEC engine:
a. The output horsepower should be 2700 HP
5% @ 1900 +10, -15 rpm.
b. The requested rpm from GE must be 1910
rpm.
c. Refer to Figure 3-20 for parasitic losses curve.
Read the parasitic losses from the graph
based on ambient temperature and altitude.
Add the value on the graph to the delivered
HP to GE and compare that to the -5%
value at the rpm rated tolerance. (i.e. 2612
HP plus value from graph = corrected HP)
Trucks with Komatsu SSDA16V160 engine:
a. The output horsepower should be 2700 HP
5% @ 1900 +10, -15 rpm.
b. The requested rpm from GE must be 1900
rpm.
c. Refer to Figure 3-21 for parasitic losses curve.
Read the parasitic losses from the graph
based on ambient temperature and altitude.
Manual Offset HP Output Adjustment

If necessary to troubleshoot HP problems, use the following procedure:
13. With loadbox initiated, cursor to HP Offset
{enter}
Cursor to => 0 HP
Input a + or - offset but not greater than +300
{enter}
14. Perform load test again.
Return offset to 0.0 {enter}
cursor to HP Offset {enter}
cursor to LDBXINIT {enter}
15. Exit the loadbox test mode and allow engine to
cool down:
Cursor to LDBX INIT on the Loadbox Screen
and press {enter}.
16. Note engine temperature and pressure gauges for
normal values.
17. Place Rest Switch in the ON position.
18. Turn key switch OFF. Allow steering accumulators
to bleed down.
19. Record all data to create a truck record for future
comparison.
Add the value on the graph to the delivered

HP to GE and compare that to the -5%
value at the rpm rated tolerance. (i.e. 2612
HP plus value from graph = corrected HP)
E03015 1/02

E3-41
FIGURE 3-20. TOTAL PARASITIC LOSS AT FULL POWER

DDEC 4000, 2700 GHP, ECS 8 Blade, 78 dia. 5.3 PW @836 RPM
FIGURE 3-21. TOTAL PARASITIC LOSS AT FULL POWER

Komatsu SSDA16V160, 27000 GHP, ECS 8 Blade, 78 dia. 5.3 PW @ 798 RPM
E3-42

1/02 E03015
TROUBLESHOOTING
PVM Optimum Load Curve Handshaking
Troubleshooting
Note: a value of below 0.5VDC or above 9.5VDC (on
circuit 72E) indicates a failure.
Trucks equipped with DDEC engine:
1. 1. With the engine shut down, keyswitch ON and
control power ON, measure voltage between 72E
(+) and 0 (-) lead. Voltage should be 5.0VDC.
a. If the voltage is low or 0VDC, check voltage of
circuit 15VL @ TB32. (This supply is from the
GE drive system power supply card through
the GE/Auxiliary Control harness.)
b. Then check voltage of circuit 15SIM @ TB32.
Voltage should be approximately 14.5 VDC.
c. If voltage is 0VDC or considerably lower than
14.5 volts, check the 20 ohm resistor on DB1.
2. 2. With the engine running and under load, with
keyswitch and control power switch ON, check
the voltage at 72E(+) to 0 (-).
Voltage should be 5.0 volts
a. If the voltage in step 2 is lower or higher than
5.0 volts, check using the DDR to see the percent of load the engine is given to the PVM
module.
b. Multiply the percentage value in the previous
step by 10. This should equal the 72E to 0
voltage reading. (i.e. 50% X 10 = 5.0 VDC)
Note: The DDR is updated every second and is not a
true real (electronic) time value. The GE system
updates every 20msec. A more accurate method of
measuring the updated value is to attach an
oscilloscope to the circuit 908M terminal point to
ground and measure the time the signal is positive
divided by the total time of the signal wave form and
multiply it by a factor of 10. This should equal the 72E
to 0 circuit voltage. This is a 50HZ signal.
Examples:
10ms/20ms = .50 X 10 = 5.0VDC
15ms/20ms = .75 X 10 = 7.5VDC
5ms/20ms = .25 X 10 = 2.5VDC
c. Verify circuit 0 is connected to ground.
d. If the signal 908M is correct and the supply
voltage (15SIM) to the PVM is correct, but output is incorrect, replace the PVM module.
E03015 1/02
Trucks equipped with Komatsu engine:

1. With the engine shut down, keyswitch ON and
control power ON, measure voltage between 72E
(+) and 0 (-) lead.
a. Jumper circuit 22FO to ground and verify voltage on 72E to 0 changes to 7.0VDC.
b. If the voltage is 0VDC, verify the connections
to the PVM are correct and circuit 439 and
11SL connected to CN P382 positions 5 and
40 are 24VDC.
2. With the engine running and under load, with keyswitch and control power switch ON, check the
voltage at 72E(+) to 0 (-).
Voltage should be 5.0 volts
a. Check the PVM diagnostic connector P381.
b. Verify the voltage between position A to B is 8
to 11VDC. (A reading of 0VDC indicates the
1939 transmission line failed. Check 1939 wiring.)
c. Verify the voltage between position C to B is 8
to 11VDC. (A reading of 0VDC indicates the
PVM has failed only if the voltage from position A to B is correct and the filtering circuit is
correct.) Check filtering circuit resistors and
capacitors connected to P383 positions 12
and 20 and P382 position 33 mounted on
diode board DB1.
3. If both step 1 and 2 are 0VDC, then circuit 439 or
11SL or both are incorrect.
Trucks with Either Engine:

If necessary, a variable voltage can be substituted for
the 72E/0 circuit voltage to determine if the problem is
caused by the engine or the GE drive system.
This voltage can be varied above and below 5VDC to
see if the GE drive system follows this signal, dropping
load when the signal is below 5VDC and increasing
load if the signal is above 5VDC.
If the GE drive system follows the signal and with
5VDC the system can produce full power, but cannot
function normally, troubleshoot engine boost or fuel
injection system.

E3-43
MISCELLANEOUS COMPONENT REPAIR
BE CERTAIN TO ALLOW ADEQUATE TIME

FOR LINK VOLTAGE TO DRAIN DOWN before
opening the electrical cabinet to perform the
following checks or repairs. Verify the Blower
Control Panel (AXCAP) LEDs (4, Figure 3-22
are OFF.
If any of the above warning lights remain ON,

a system failure may have occurred. Refer to
Truck Shutdown Instructions Shutdown After
System Failure for procedures to follow
before attempting repairs.
Troubleshooting Phase Modules and Chopper
Modules
1. To troubleshoot a phase module or chopper module, access the PSC Manual Test screen on the
PTU while connected to PSC panel, engine
stopped, and NOT in rest mode.
2. Move cursor to the appropriate GD1E or GD2E
signal in the digital output area and turn it ON.
(GD1E turns on all Inverter 1 phase modules and
chopper module 1. GD2E turns on all Inverter 2
phase modules and chopper module 2.)
3. Disconnect the GRAY fiber optic cable on the
phase module or chopper module being checked.
In the following step, DO NOT look directly at the

red light. Eye damage could occur.
4. There should be red light visible out of the GRAY
receptacle on the gate drive module.
5. If there IS red light, the phase module or chopper
module is OK.
6. If red light IS NOT visible, disconnect the round
power supply harness from the gate drive module.
7. Check the AC voltage in the two pins in the harness; There should be 100 VAC square wave on
the harness. The actual reading on the VOM will
depend on the meter and how it is designed to
measure AC voltage. Most meters read less than
100 volts. Normally, there will either be proper
voltage on the harness or NO voltage at all on the
harness.
E3-44
8. If there is NO voltage, troubleshoot the Gate

Drive Power Converter (GDPC) or the harness.
9. If there IS voltage, reconnect the harness and
disconnect the GTO Gate lead on the G terminal.
10. If there IS red light visible with the gate lead disconnected, the GTO is shorted and the entire
phase module or chopper module must be
replaced.
11. If there IS NOT red light visible with the gate lead
disconnected, the GATE DRIVE MODULE is
faulty and should be replaced. All the gate drive
sections for phase modules and chopper modules
are alike and interchangeable. The Red-covered
and White-covered gate drive modules are interchangeable where mounted by the 6 capscrews
to the cooling tubes of the phase module or chopper module.
Phase Module Removal and Snubber Resistor

Replacement
To Remove the Phase Modules:
1. Open the battery disconnects to disconnect the
truck batteries.
2. Short out the DC link by installing jumpers from
(+) to (-) next to the AFSE and then to ground.
3. Remove the front cabinet supports between the
doors.
4. Disconnect the fiber optic cables and the plug at
the top of each Phase Module. Tuck the removed
cables under the blue loom to protect the cables
when the modules are pulled out.
5. With a 15/16 inch socket, remove the four
mounting nuts on each Phase Module.
6. Cut the tyrap by the capacitor on top of each
Phase Module.
7. Partially pull out each Phase Module. Using a
7/16 inch socket, remove the snubber wire
behind the top capacitor.
8. Remove each Phase Module which weighs 65
pounds (29.5 Kg). Mark each Module so that it
will be put back in the same location that it was
removed from.

1/02 E03015
To Remove the Snubber Resistors:

1. Disconnect the upper and lower L brackets to
the DC link with a 3/4 inch socket. Remove only
the outer four L brackets on the snubbers and
leave the brackets on the center two snubbers.
8. When the outer snubber assemblies are installed,

reinstall the L brackets.
9. Following a similar procedure as explained
above, replace the resistors on the center top and
bottom snubber resistor assemblies.
Note: The brackets on the two center snubbers must

remain in place to prevent the DC link from falling.
2. Remove the cables to the DIT located on the L
brackets.
3. Remove the snubber mounting bolts with a 3/4
inch socket.
4. Remove the snubber assembly. The threaded rod
pulls out with the snubber assembly. To remove
the top left snubber assembly, loosen the bolts on
the bracket securing the left side of the link and
then push the link up to get the snubber assembly
out.
Phase Module Installation

1. Return each Phase Module to its original location.
2. Apply two full twists on the snubber cables prior
to connecting it to the phase modules. Put a tyrap
at each twist.
3. Secure each snubber cable to the capacitor box
on top of each phase module with a tyrap.
4. Tighten the four 5/8-11 Phase Module mounting
bolts to 111-124 ft. lbs. (150 - 168 N.m) torque.
5. Remove the four screws holding the resistor to

the base. (These screws have been installed and
retained with Loctite, and will require extra force
to remove.)
5. Reconnect the fiber optic cables and the plug at

the top of each Phase Module.
6. Remove the rubber grommet along with the resistor cables.
7. Remove the ground jumpers from the DC link.
7. Remove the resistor from the base and remove

and discard the gaskets.
6. Replace the front cabinet supports between the

doors.
8. Close battery disconnect switches to reconnect
the truck batteries.
Snubber Resistor Installation

1. To pull the new resistor cables through the hole in
the base, spray the cables with ether or alcohol
near the new grommet so that it slides easier in
place. Do not RTV the new grommet.
2. Using RTV 6708, seal the corners of the resistor
where it contacts the snubber base to prevent air
leakage at the seams.
3. Install a flat washer over each mounting hole
between the base and the gasket.
4. Install new inner and outer gaskets. Using RTV
6708, seal the seam between the outer gasket
and the two inner gaskets.
5. Apply Loctite to the four mounting screws for the
snubber resistors and install the resistors on the
base.
6. Install the snubber assembly in the truck, making
sure the resistor wires are on top.
7. Install the four mounting bolts for each snubber
resistor assembly. Tighten to 65 ft. lbs. (88 N.m)
torque.
E03015 1/02

E3-45
AUXILLIARY BLOWER CONTROL SYSTEM

TROUBLESHOOTING
Subcode 03:
Description: An overcurrent condition was detected
during operation.
1. Check Capacitor Bank and Controller connections.
The Auxiliary Capacitor Panel remains charged for

at least 15 minutes after engine shutdown. Be certain LEDs D1 and D2 (4, Figure 3-22) are OFF
before working on Auxiliary Blower Control circuits. Short CP+ to CP-.
2. Verify the inductor connections match-up (+ and ) from the Auxiliary Inverter and to the Auxiliary
Capacitor bank (PH+ to IV+ and PH- to IV-).
The following are recommended checks to be made to

the Auxiliary Blower Control System components and
circuits based on the detection of Event Code 636 and
the subcodes listed. Refer to Figure 3-22 for component and terminal locations.
4. If problem still exists, disconnect AM101, AM201

and AM301 wires connecting the Auxiliary
Inverter to the blower motor.
Subcode 00:
No fault condition - initial state upon applying power.
Subcode 01:
Description: A low DC bus voltage was detected during power up sequence.
1. Check the 3-phase input connections and input
fuses F1 and F2.
3. If a problem was found and corrected in step 1 or
2, restart and check again.
4. If no problem was found in above steps, replace
the Controller.
Subcode 02:
5. Using an ohmmeter, check for shorts between

blower motor cables and between blower motor
cables and chassis ground.
AM101, AM201 and AM301 wires and between
IV+ and IV-.
the Controller.
Subcode 05:
Description: A high DC bus voltage was detected during operation.
2. Check DC Sense connection (connector J13 to
IV+ (red wire) and IV- (black wire)).
3. Attempt to restart and check operation.
4. If problem still exists, replace controller.
Description: A high DC bus voltage was detected during power up sequence.

2, restart and check again.
the Controller.
E3-46

2, restart and check operation again.
Subcode 06:
Description: A high DC bus voltage was detected after
the phase controller power up sequence.

1/02 E03015
Subcode 07:
Subcode 08:
Description: A low DC bus voltage was detected after

the phase controller power up sequence.
Description: A high DC bus voltage was detected during operation.
1. Check the 3-phase input connections and fuses

F1 and F2.
2. If no problem was found in step 1, use an ohmmeter to check for short circuits between AM101,
AM201, and AM301 wires and between IV+ and
IV-.

3. If no problem was found in step 1 or 2, replace

the controller.
FIGURE 3-22. AUXILIARY BLOWER CONTROL COMPONENTS

1. Auxiliary Inductor (AXIND)
2. Snubber (AUX SNUB)
3. Auxiliary Inverter (Controller AXINV)
4. Blower Control System Warning LED's
5. Auxiliary Power Filter Capacitor Bank (AXCAP)
E03015 1/02
6. Capacitor Fuses
7. Propulsion System Controller (PSC)
8. Cover
9. Input Fuses (F1 & F2)
10. 3- Pin Connector

E3-47
Subcode 09:
Subcode 12:
Description: An overcurrent condition was detected

after the phase controller power up sequence.
Description: A sustained overload exists due to low

DC bus voltage.

F1 and F2.
2. Verify the inductor connections match-up

(+ and -) from the Auxiliary Inverter and to the
Auxiliary Capacitor bank (PH+ to IV+ and PH- to
IV-).

2, restart and check operation again.
4. If problem still exists, replace the controller.
4. If problem still exists, disconnect AM101, AM201

and AM301 wires connecting the Auxiliary
Inverter to the blower motor.
IV+ and IV-.
the Controller.
3. After performing checks in step 1 and 2, attempt

to restart.
Subcode 13:
Description: IGBT protection circuit detected an overcurrent condition.
1. Disconnect AM101, AM201 and AM301 wires
connecting the Auxiliary Inverter to the blower
motor.
IV+ and IV-.
Subcode 10:
Description: A sustained current overload exists that
is below component safe operating range.
1. Verify the inductor connections match-up
(+ and -) from the Auxiliary Inverter and to the
Auxiliary Capacitor bank (PH+ to IV+ and PH- to
IV-).
2. Check the blower fan for blockage or damage.
3. If no problem was found in step 1 or 2, the blower
motor may be damaged.

the Controller.
Subcode 14:
Description: Zero input voltage detected.
F1 and F2.
2. If no problems were found in step 1, replace the
controller.
Subcode 11:
Description: An overcurrent condition exists due to a
low DC bus voltage.
F1 and F2.
3. After performing checks in step 1 and 2, attempt
to restart.
4. If problem still exists, replace the controller.
E3-48

1/02 E03015
AUXILLIARY INVERTER (CONTROLLER)

TROUBLESHOOTING
7. Whenever it is determined that an Aux Inverter

input SCR has failed, both AC Input fuses must
be replaced and the old ones discarded.
8. Check pin and wire continuity between Aux controller CNX connector (7, Figure 3-25) and appropriate PSC & TCI connectors.

before working on Auxiliary Blower Control circuits.
The following items should be checked if an auxiliary
Inverter failure is suspected.
1. Observe the two LEDs on top of the Auxiliary
Power Filter Capacitor Bank (AXCAP); Both
LEDs should be ON (lit) when the Aux. Inverter is
running and OFF after the circuit has discharged.
2. Check for loose wires and check resistance
between the terminals on the Aux Snubber panel.
Measurements from 1 to AF1, 2 to AF2, & 3 to
AF3 should all be 0 ohms. Measurements from 1
to either AF2 or AF3 and similarly from 2 & 3
should be 2 ohms.
3. Check continuity from PH+ to INV+ and from PHto INV-. These circuits connect the Aux Phase
Control, Aux Inductor, Aux Capacitors, & Aux
Inverter. The resistance should be 0 ohms for
these two measurements to verify continuity
through the Aux Inductor.
9. Disconnect the blower motor cables from AM101,

201, & 301 (4) and megger the Aux Blower motor
and its wiring. Be sure to reconnect properly to
assure proper rotation direction.
10. Check the Gate Drive Power Supply AC input
fuses GDFU1 & 2 and replace if necessary.
11. Disconnect the main rectifier Filter Panel wires
T103, T203, & T303 at the rectifier bus bars.
Using an analog VOM on the ohms scale, measure between T103 & T203, between T203 &
T303, and between T303 & T103. A capacitance
deflection should show on each measurement.
12. Disconnect the main rectifier from the circuits and
perform a standard diode check with a VOM and
back-bias each diode with a 1000 volt megger.
13. After all checks are made, and repairs completed
if required, reconnect all wiring to their proper terminals and reinstall fuses.
4. Check the fuses on the Aux Capacitor panel.

(The fuses must be removed from the circuit to
check.)
5. Check for loose connections on all wires associated with the Aux Inverter circuits.
6. Check Aux Inverter Phase Control SCRs (see
Table below). Measure between AC input terminals 1, 2, & 3 and DC output terminals PH+ & PHA reading of less than 100 ohms indicates a
shorted SCR. Good SCRs will measure more
than 100K ohms. Replace at least the connected
pair of SCRs if one is shorted (preferably replace
all 6 SCRs).
Measurement Points
AC Input 1
AC Input 2
AC Input 3
Term 1
PH+
Term 2
PH+
Term 3
PH+
Term 1
PH-
Term 2
PH-
Term 3
PH-
E03015 1/02

E3-49
AUXILLIARY SNUBBER PANEL

TROUBLESHOOTING

1. After verifying capacitor charge warning LEDs (6,

Figure 3-25) are not lit, disconnect external wiring
from snubber panel terminals (3, Figure 3-23) to
isolate the panel from other system components
before making measurements.
2. Using an ohmmeter and capacitance meter, verify Snubber Panel components by measuring
resistance values between points shown in Table
below. Refer to Figure 3-23 and 3-24 for test point
locations.
Measuring Point
FIGURE 3-23. AUXILIARY SNUBBER PANEL

1. Capacitor
2. Choke
3. Terminals
Specified Value
C2-4
23.75
26.25
C1-4
23.75
26.25
C3-4
23.75
26.25
C2-2
C1-2
R1-1
C3-2
C1-4
C1-2
0.10 F
0.17 F
C2-4
C2-2
0.10 F
0.17 F
C3-4
C3-2
0.10 F
0.17 F
3. After all measurements have been made and

repairs completed if needed, reconnect wiring
removed in step 1.
FIGURE 3-24. AUXILIARY SNUBBER
E3-50

1/02 E03015
IGBT TROUBLESHOOTING
7. After all circuits have been tested, reconnect all

cables to their proper terminals. Reconnect J1,
J2, J3, J4, J7 and J8.
8. Reinstall cover (2) and attach harness connector
at CNX receptacle.

1. After verifying capacitor charge warning LEDs (6,
Figure 3-25) are not lit, remove cable attached at
CNX connector (7).
2. Remove 6 screws retaining cover (2). Remove
cover.
3. Disconnect cables at AM101, AM201, and
AM301 connection studs (4) and isolate from
other circuits.
4. Disconnect wires at IV+ and IV- terminals (5).
5. Remove connectors J1, J2, J3, J4, J7 and J8.
Refer to Figure 3-25 for pin numbers when viewing face of harness end of connector.
6. Using an ohmmeter and the specifications in the
Table below, measure by probing the pins in the
harness connectors. All circuit test points listed in
the Table should show continuity.
Note: All #3 pins in connectors should show an open
circuit to all other test points.All IGBTs should be free
of cracks or leaks.
Connector
J1
J2
J3
J4
J7
J8
E03015 1/02
From Pin
To
Measurement
IV+
Continuity
AM101
Continuity
AM101
Continuity
IV-
Continuity
IV+
Continuity
AM201
Continuity
AM201
Continuity
IV-
Continuity
IV+
Continuity
AM301
Continuity
AM301
Continuity
IV-
Continuity
FIGURE 3-25. IGBT CHECK TEST POINTS

1. Auxiliary Inverter (Controller)
2. Cover
3. 3-Pin Connectors
4. AM101, AM201, AM301 Connection Studs
5. IV+, IV- Terminals
6. Blower Control System Warning LED's
7. CNX Connector

E3-51
NOTES
E3-52

1/02 E03015
SECTION G
REAR AXLE, SPINDLES AND WHEELS
INDEX
TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-1
FRONT WHEEL HUB AND SPINDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-1
REAR AXLE HOUSING MOUNTING ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-1
REAR AXLE HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-1
G01017
Index
G1-1
NOTES
G1-2
Index
G01017
SECTION G2
TIRES AND RIMS
INDEX
TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-3

FRONT TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
REAR TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-6
RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-8
Tire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-8
Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-9
G02015 08/01
Tires and Rims
G2-1
NOTES
G2-2
Tires and Rims
08/01 G02015
TIRES AND RIMS

The truck tires should be inspected and tire pressure
checked with an accurate pressure gauge before
each working shift. Tire pressure will vary according
to manufacturer and local working conditions. Consult the tire manufacturer for recommended tire pressure.
Insure valve caps are securely applied to valve
stems. The caps protect valves from dirt build up and
damage. DO NOT bleed air from tires which are hot
due to operation; under such circumstances, it is normal for pressure to increase in the tire due to expansion.
A bent or damaged rim which does not support the
bead properly may cause abnormal strain on the tire
resulting in tire damage. If a tire becomes deeply cut,
it should be removed and repaired. Neglected cuts
cause many tire problems; water, sand, dirt and other
foreign materials work into the tire through a cut,
eventually causing tread or ply separation.
Tires should be stored indoors if possible. If stored
outdoors, cover tires with tarpaulin to keep out dirt,
water and other foreign materials. Long exposure to
the sun will cause ozone cracks. Storage should be
in a cool, dry, dark, draft free location. Tires should
be stored vertically. If they must be laid on their sides
for a short period, avoid distortion by stacking no
more than three tires on top of one another. Avoid
contact with oil, grease and other petroleum products.
When inflating tires always use a safety cage.

Never inflate a tire until the lockring is securely in
place. Do not stand in front of or over the lockring during inflation procedures. Never overinflate a tire. Refer to tire manufacturers
recommendations.
Always keep personnel away from a wheel and
tire assembly when it is being removed or
installed.
The tire and rim weigh approximately 14,285 lbs.
(6,480 kg). Be certain tire handling equipment is
capable of lifting and maneuvering the load.
Due to the size and weight of the tire and rim assemblies, special handling equipment such as a modified
fork lift (tire handler) as shown in Figure 2-1 is
desirable. Consult local tire vendors for sources of
equipment designed especially to remove, repair,
and install large off-highway truck tires.
Before storing used tires, clean thoroughly and

inspect for damage. Repair as necessary. When a
truck is placed in storage, it should be blocked to
remove the weight from the tires. If a stored truck
cannot be blocked, check air pressure and inspect
tires twice a month for proper inflation pressure.
DO NOT weld or apply heat on the rim assembly

with the tire mounted on the rim. Remaining
gases inside the tire may ignite causing explosion of tire and rim.
DO NOT go near a tire if a brake or wheel motor
has experienced a fire until the tire has cooled.
FIGURE 2-1. TYPICAL TIRE HANDLER
G02015 08/01
Tires and Rims
G2-3
FIGURE 2-2. FRONT WHEEL HUB AND RIM ASSEMBLY

1. Wheel Hub
2. Stud
3. Tire Inflation Hose
4. Swivel Connector
5. Rim
6. Bead Seat Band
7. Side Flange
8. Lock Ring
9. O-Ring
10. Clamp Bracket
11. Flanged Nut
FRONT TIRES AND RIMS

Removal
1. Apply parking brake and block rear wheels to
prevent movement of truck.
2. Following normal shutdown procedures, place
rest switch in the ON position, shut down the
engine and verify the link voltage lights are OFF.
Allow at least 90 seconds for the accumulators
to bleed down. Turn the steering wheel to be
sure no pressure remains. As a safety precaution, bleed down brake accumulators.
3. Place jack under spindle or under frame at the
front cross tube.
4. Raise front end of truck until tire clears ground
and block up securely under frame.
5. Inspect hydraulic brake lines for damage or
leaking fittings.
G2-4
6. Grip tire and wheel assembly with tire handler.

Remove nuts (11) securing wheel assembly.
7. Care should be taken not to damage the inflation hose during tire removal. Move wheel
assembly away from wheel hub and into clean
work area.
Do not attempt to disassemble wheel assembly

until all air pressure is bled off.
Always keep personnel away from a wheel
assembly when it is being removed or installed.
Tires and Rims
08/01 G02015
Installation
REAR TIRES AND RIMS
NOTE: Remove all dirt and rust from mating parts

before installing wheel assembly.
Removal
1. Grip wheel assembly with the tire handler and

align tire inflation hose and wheel hub (1, Figure 2-2). Position rim onto wheel hub studs.
2. Lubricate all stud threads and nut seating
flanges with lithium base grease. Install and
tighten nuts in the following sequence:
a. Install six nuts at the 12 o'clock and six nuts
at the 6 o'clock positions. Tighten each nut to
1715 100 ft. lbs. (2326 136 N.m) torque.
b. Install three nuts directly below the 3 o'clock
and three nuts directly above the 9 o'clock
positions. Tighten the nuts to 1715 100 ft.
lbs. (2326 136 N.m) torque.
c. Install three nuts directly above the 3 o'clock
and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 1715 100
ft. lbs. (2326 136 N.m) torque.
d. Install the remaining nuts and torque in a
clockwise direction to 1715 100 ft. lbs.
(2326 136 N.m) torque.
1. Park truck on level ground and block front

wheels. Position a jack under rear suspension
mounting plates as shown in Figure 2-3.
2. Raise rear axle housing of truck until tires clear
ground. Securely block up rear axle housing
near the wheel motor mounting flange.
3. If rear, inner tire is to be removed, remove inner
tire inflation hose at clamp on outer wheel and
disconnect from inner extension (7, Figure 2-5).
4. Grip outer wheel and tire with tire handler arms
as shown in Figure 2-4. Remove flanged nuts
(10, Figure 2-5) from adaptor ring (9) securing
outer rim to wheel motor hub.
5. Pull straight out on outer wheel assembly and
remove.
6. If inner wheel removal is necessary, disconnect
inner tire inflation extension (7) and remove.
7. Position tire handler to grip inner wheel.
Remove flanged nuts (6).
e. Re-torque all nuts in a clockwise direction to

the required 1715 100 ft. lbs. (2326 136
N.m) torque.
3. Remove blocking etc. and lower jack.
4. Operate truck for one load and retighten wheel
nuts to the specified torque.
FIGURE 2-4. REAR TIRE REMOVAL

1. Tire Handler
2. Outer Rear Tire
3. Inner Rear Tire
FIGURE 2-3. REAR AXLE JACK LOCATION
G02015 08/01
Tires and Rims
G2-5
FIGURE 2-5. REAR WHEEL ASSEMBLY

1. Wheel Motor
Mounting Flange
2. Inner Wheel Rim
3. Disc Brake Assembly
8. Clamps
9. Adapter Ring
10. Flanged Nut
11. Flanged Nut
4. Extension
5. Wheel Hub
6. Flanged Nut
7. Inner Extension
12. Wheel Motor

Transmission
13. Extension
14. Bracket
15. Outer Wheel Rim
2. Grip inner wheel assembly with tire handler and

install onto wheel hub (5, Figure 2-5). Use care
to align tire inflation extension line (4) for mating
with inner extension (7).
8. Pull straight out to remove from wheel hub.
NOTE: If the wheel motor is to be removed from the

truck for service, install approximately 8 flanged nuts
with appropriate spacers in place of the outer wheel
adaptor ring and nuts removed in Step 4. This will
provide additional support for the wheel motor
transmission (12) during removal and transportation.
3. Lubricate all stud threads and nut seating

flanges with lithium base grease. Install and
tighten nuts in the following sequence:
a. Install six nuts at the 12 o'clock and six nuts
at the 6 o'clock positions. Tighten each nut to
1715 100 ft. lbs. (2326 136 N.m) torque.
b. Install three nuts directly below the 3 o'clock
and three nuts directly above the 9 o'clock
Installation
c. Install three nuts directly above the 3 o'clock

and three nuts directly below the 9 o'clock
Always keep personnel away from a wheel
assembly when it is being removed and installed.
d. Install the remaining nuts and torque in a

clockwise direction to 1715 100 ft. lbs.
(2326 136 N.m) torque.
e. Re-torque all nuts in a clockwise direction to
the required 1715 100 ft. lbs. (2326 136
N.m) torque.
NOTE: Clean all mating surfaces and check stud

threads before installing wheel assemblies.
1. If either wheel motor has been removed, bleed
the disc brakes before installing the rear tires.
Refer to Section J, Wet Disc Brake Assembly Wet Disc Brake Bleeding Procedure.
G2-6
4. If the adaptor ring (9) requires installation,

install adaptor onto wheel hub/wheel motor.
Lubricate the studs and nut flanges with lithium
base grease.
Tires and Rims
08/01 G02015
5. Using the procedures in Step 3, install flanged

nuts (10) in the sequence described and tighten
to the same torque value as the inner wheel.
6. Grip outer wheel assembly with tire handler and
position onto wheel motor hub.
8. Secure inner and outer dual tire inflation lines to

bracket (14) on outer rim.
9. Remove blocks from under truck and lower
truck to the ground. Operate truck for one load
and retighten outer wheel nuts (11) and adapter
flange nuts (10) to 1715 100 ft. lbs. (2326
136 N.m) torque.
NOTE: Position outer dual wheel to align tire valve

bracket with inner wheel inflation line.
7. Using the procedures in Step 3, install flanged
nuts (11) in the sequence described and tighten
to the same torque value as the inner wheel.
Recheck torque after each load for first day and

then intermittently thereafter until all nuts hold
torque.
NOTE: Inner flanged nuts (6) and studs should be
visually inspected for breakage or missing nuts
during scheduled maintenance checks by inserting a
mirror between the rear tires.
G02015 08/01
Tires and Rims
G2-7
RIM
Tire Removal
2. Attach a hydraulic bead breaker to the rim by

slipping the jaws of frame assembly over the
outer edge of flange (7, Figure 2-6). Make sure
the jaws of the frame are as near to the bead
seat band (6) as possible.
DO NOT weld or apply heat on the rim assembly

with the tire mounted on the rim. Resulting gases
inside the tire may ignite causing explosion of
tire.
When inflating tires always use a safety cage.
Never inflate a tire until the lockring is securely in
place. Do not stand in front of or over the lockring during inflation procedures. Never overinflate a tire. Refer to tire manufacturers
recommendations.
3. Following tool manufacturers instructions, move

tire bead in far enough to permit placing a
wedge between tire and flange at side of tool.
1. Place tire and wheel assembly in safety cage

and discharge all air pressure from tire.
7. Remove bead seat band (6) from rim (5) and

remove flange (7).
4. Repeat this procedure at locations approximately 90 from the first application. Continue
this procedure until tire bead is free from rim.
5. After bead is broken loose, insert flat of tire tool
in beading notch on lockring (8). Pry lockring up
and out of groove on rim.
6. Pry in on bead seat band (6) until O-ring (9) is
exposed. Remove O-ring.
Reposition wheel assembly and repeat removal procedure on opposite side of tire. Remove tire from rim.
FIGURE 2-6. FRONT WHEEL HUB AND RIM ASSEMBLY

1. Wheel Hub
2. Stud
3. Tire Inflation Hose
4. Swivel Connector
G2-8
5. Rim
6. Bead Seat Band
7. Side Flange
8. Lock Ring
Tires and Rims
9. O-Ring
10. Clamp Bracket
11. Flanged Nut
08/01 G02015
Tire Installation
1. Before mounting tire to rim, remove all dirt and
rust from rim parts, particularly the O-ring
groove and bead seats. It is advisable to touch
up all metal parts with a good anti-rust paint to
prevent bare metal from being exposed to the
weather.
NOTE: Do not allow paint, rust or other
contamination to cover mating faces of lockring (8,
Figure 2-6) and rim (5).
Check to be sure that proper rim parts are used

for reassembly, use of incompatible parts may
not properly secure the assembly resulting in
violently flying parts upon inflation.
2. If tire inflation hose and hardware were
removed, reinstall in rim. Position hose assembly for proper routing.
3. Install inner flange on rim. Coat beads of tire
with tire mounting soap solution.
Prying against tire bead may cause damage to

tire bead and will cause air leaks.
5. Install outer flange (7, Figure 2-6) in position

and install bead seat band (6). Push in on bead
seat band to expose O-ring groove in rim.
6. Lubricate new O-ring (9) with soap solution and
install in groove of rim.
7. Install lockring (8) and tap into place with lead
hammer. Lockring lug must fit into slot of
rim.
8. With tire inside safety cage, remove valve core
from valve stem and inflate tire to seat beads of
tire and O-ring as specified by tire manufacturer.
Use a safety cage whenever possible. Stand to

one side as tire is being inflated. Never start
inflating unless lockring is securely in place. DO
NOT stand in front of or over lockring when
inflating.
9. If beads of tire and O-ring do not seat within one
minute, raise tire slightly and tap bead seat
band. This will help the air pressure to push the
tire bead out into position.
10. As soon as seating has been accomplished,
install valve core and inflate tire to recommended tire pressure.
4. Position tire over rim and work tire on as far as

possible without prying against the beads. Any
damage to tire bead will destroy air seal and
cause air leaks at these points.
G02015 08/01
Tires and Rims
G2-9
NOTES
G2-10
Tires and Rims
08/01 G02015
SECTION G3
FRONT WHEEL HUB AND SPINDLE
INDEX
FRONT WHEEL HUB AND SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3

WHEEL HUB AND SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Installation - Wheel Hub and Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-6
Disassembly - Wheel Hub and Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
Cleaning and Inspection - Wheel Hub and Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
Assembly - Wheel Hub and Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-9
Wheel Bearing Adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-9
Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-10
Seal Assembly Gap Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-11
STEERING CYLINDERS AND TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-12
Spherical Bearing Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-12
Removal - Steering Cylinder and Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-13
Installation - Steering Cylinder and Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-14
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-14
TOE-IN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-15
G03017 08/02
Front Wheel Hub and Spindle
G3-1
NOTES
G3-2
08/02 G03017
FRONT WHEEL HUB AND SPINDLE

WHEEL HUB AND SPINDLE ASSEMBLY
The following instructions will cover the complete
removal, installation, disassembly, assembly and
bearing adjustment of front wheel hub and spindle. If
only brake service is to be performed, refer to Section J, Brake Circuit.
Preparation
illuminated.
Do not loosen or disconnect any hydraulic brake

line or component until engine is stopped, Key
switch is OFF for 90 seconds and drain valves on
brake accumulators are opened.

console.
Removal
Remove the front tire and rim assembly. Refer to
Section G, Tires and Rims, Front Tire and Rim Removal
1. Close hydraulic pump shut-off valves.
2. Disconnect speed sensor connector(s) (5, Figure 3-1). Tie cables back away from the spindle
to prevent damage during spindle removal.
NOTE: The left wheel has two speed sensors
installed.
3. Disconnect disc brake cooling oil hoses (4) at
inlet and outlet ports on the brake housing.
FIGURE 3-1. FRONT WHEEL & SPINDLE

INSTALLATION
1. Spindle
2. Brake Housing
Drain
3. Disc Brake Housing
G03017 08/02
4. Brake Cooling Hose

5. Speed Sensor
Connector
Disconnect brake apply line. Cap hoses and

ports to prevent contamination. Remove the oil
in the brake housing and hub bearings by
removing hex plug (2) and draining into a suitable container.
4. Remove the lubrication lines from the tie rod
and steering cylinder.
5. Disconnect the tie rod and steering cylinder rod
from the spindle being removed. Refer to
Removal - Steering Cylinder and Tie Rod, in
this section.
G3-3
8. Remove 16 of the arm attachment capscrews

(5) as follows:
The front spindle, brake and wheel hub assembly

weighs approximately 10,670 lbs. (4840 kg). Be
certain lifting device is capable of lifting the load.
6. Position a fork lift under the wheel hub and
spindle assembly as shown in Figure 3-2. Use
blocking as necessary to keep the assembly
level.
7. Remove capscrews and washers (1, Figure 33) securing retainer plate (2) to spindle structure
and suspension. To prevent thread damage,
loosen capscrews in a circular pattern, in torque
increments of 500 ft. lbs. (678 N.m). Remove
retainer plate.
NOTE: A tool may be fabricated locally to aid in
spindle removal. Refer to Section M, Special Tool
Group for fabrication information. Usage of this tool is
described in the following steps.
FIGURE 3-2. SPINDLE AND WHEEL HUB

REMOVAL
(TYPICAL)
G3-4
a. Refer to Figure 3-5 (spindle removal tool)

and remove the capscrews in the steering
arm designated by an "X".
b. Remove the capscrews using a circular pattern and torque increments of 500 ft. lbs.
(678 N.m). Do not attempt to remove each
capscrew in one sequence!
9. Run a tap (1.25 in. - 12 UNF) in the threads
after the capscrews are removed.
10. Using several 1.25" UNF x 8.00" long, grade 8
capscrews and hardened flatwashers (see Figure 3-4 for Komatsu part numbers), install the
spindle removal tool on the bottom of the steering arm. Lubricant, such as chassis lube, is recommended for use on the washers and threads
of the capscrews.
NOTE: Multiple washers may be required to allow the
pusher capscrews to be effective. One or two
washers can be installed with the pusher tool in place
to gauge the washer height required to prevent
capscrews from bottoming out. The minimum
recommended thread engagement is 1.62 in. (41
mm).
FIGURE 3-3. WHEEL HUB AND SPINDLE

REMOVAL
1. Capscrews
2. Retainer Plate
3. Spindle
4. Steering Arm
5. Arm Retainer
Capscrews
08/02 G03017
FIGURE 3-4. SPINDLE REMOVAL TOOL

INSTALLATION
1. Capscrew
(P/N KC7095)
2. Hardened Washer
(P/N WA0366)
3. Removal Tool
4. Steering Arm
5. Spindle
6. Suspension Piston
FIGURE 3-5. SPINDLE REMOVAL TOOL

1. Capscrew Insertion
Holes (X)
2. Tool Structure
13. Tighten the capscrews, again to the maximum

specified torque. Using a large hammer and
heat as specified in the previous step, carefully
tap the top surface of the spindle.
Heavy components and high forces are involved
in this procedure. Use caution at all times when
applying force to these parts. Sudden release of
the spindle could cause components to move
forcefully and unexpectedly.
11. Install the remaining capscrews in the holes
marked "X" (Figure 3-5). Progressively increase
the torque in a circular pattern until the tapered
piston breaks loose, or 1580 ft. lbs. (2142 N.m)
torque is reached.
12. If the specified torque is reached and the
tapered parts have not separated, apply heat to
the spindle at two places, 180 apart. Do not
exceed 850F (454C) saturated temperature
of the spindle.
G03017 08/02
NOTE: In extreme cases, it may be necessary to

remove additional steering arm retaining capscrews
and use additional pusher capscrews to apply more
force.
14. Lower the wheel hub and spindle assembly
away from suspension piston rod. Use care during removal to prevent damage to the suspension piston rod taper and the tapered spindle
bore.
15. Move the spindle and hub assembly to a clean
work area for repair.
G3-5
Installation - Wheel Hub and Spindle Assembly

1. Clean spindle bore and suspension rod taper to
be certain they are free of rust, dirt, etc.
2. Lubricate spindle bore and suspension rod
taper with multi-purpose grease Number 2 with
5% Molybdenum Disulphide.
Use of anti-seize compounds that contain copper are prohibited from use on spindle bores and
rod tapers. These lubricants can cause severe
damage. Only use multi-purpose grease Number
2 with 5% Molybdenum Disulphide.
7. Install steering cylinder into steering arm. Use

EH4638 sleeve alignment tool (included in tool
group) to position spacers and bearing during
pin insertion. Tighten pin retaining nut to 750
75 ft. lbs. (1017 102 N.m) torque.
8. Install tie rod on steering arm using EH4638
alignment tool. Tighten pin retaining nut to 750
75 ft. lbs. (1017 102 N.m) torque.
9. Connect lubrication lines.
10. Install the brake system cooling hoses using
new O-rings in the flange fittings. Install the
brake apply line. Be certain drain plug (2, Figure
3-1) is installed.
3. Position spindle and wheel hub assembly on

fork lift or similar lifting device as shown in Figure 3-2.
11. Reconnect the speed sensor cables.
4. Raise the spindle and wheel hub assembly into

position.
13. Be certain hydraulic pump shut-off valves are

open.
5. Secure spindle to suspension using retainer

plate (2, Figure 3-3) and capscrews (1). Tighten
capscrews using the following procedure:
a. Tighten capscrews uniformly to 500 ft. lbs.
(678 N.m) torque.
b. Continue to tighten capscrews in increments
of 250 ft. lbs. (339 N.m) to obtain a final
torque of 1995 100 ft. lbs. (2705 135
N.m).
6. If removed, install steering arm. Tighten capscrews to 1995 100 ft. lbs. (2705 135 N.m)
torque.
G3-6
12. Install wheel and tire as described in Section G,

Front Tires amd Rims - Installation.
14. Start the engine. Move the hoist control lever to

the FLOAT position to allow hydraulic oil to circulate through the brake cooling system, and fill
the front wheel hub and disc brake assembly
with oil.
15. Bleed air from brake apply lines as described in
Section J, Wet Disc Brake Assembly - Wet Disc
Brake Bleeding Procedure.
16. Shut off the engine. Check hydraulic tank oil
level and refill if necessary.
17. Inspect the brake assembly and all hose connections for leaks.
08/02 G03017
Disassembly - Wheel Hub and Spindle Assembly

1. Remove the wheel hub and spindle as covered
in "Removal" before proceeding to Step 2.
Remove any dirt and mud from the assembly.
12. Attach a lifting eyes and an overhead hoist to

the brake assembly. Carefully lift the assembly
off the hub.
2. To aid in complete disassembly of the wheel

hub and spindle assembly, support the assembly in a vertical (hub cover up) position using a
fabricated spindle stand.
Refer to Section "J" for brake assembly rebuild

instructions.
13. Remove and discard seal carrier O-ring (38).
3. Install six, 0.50 in. -13 x 0.75 in. long socket

head capscrews (34, Figure 3-6) through the
disc brake back plate into the mating holes in
the seal retainer. Tighten securely.
14. Remove speed sensor gear (35) and shims

(36).
NOTE: The capscrews installed in Step 3 will secure

the seal carrier and face seal assembly to the brake
housing during brake removal. DO NOT rotate the
wheel hub.
16. Remove capscrews (31) and hardened flatwashers (32). Remove brake adapter (19) and
discard O-rings (22 & 25).
4. Disconnect speed sensor cables. Loosen sensor clamping capscrews and remove speed
sensors (16).
5. Remove capscrews (20) and hardened flatwashers (21) securing brake adapter (19) to
brake housing.
6. Remove the capscrews and washers that
secure cover (5). Remove the cover and discard O-ring seal (41).
7. Remove capscrews (11) and hardened flatwashers (12). Remove bearing retainer (13)
and shims (8).
8. Attach a lifting device to the wheel hub/brake
assembly and carefully lift it straight up and off
the spindle.
9. Remove outer bearing cone (7) and retainer pin
(40).
10. Remove spindle cap (10) and O-ring (9).
11. Rotate hub vertically 180 and place on blocking
to prevent damage to wheel studs and
machined surfaces.
10. Remove capscrews (14) and washers (15)
securing seal carrier (37) sensor gear (35) and
shims (36) to wheel hub.
11. Remove capscrews (23) and hardened washers
(24) securing brake assembly inner gear to
wheel hub.
G03017 08/02
15. If bearings require replacement, press cups (6 &

29) from the wheel hub.
17. Remove inner bearing cone (28) and retainer

pin (39).
18. Remove bearing spacer (27).
Cleaning and Inspection - Wheel Hub and Spindle

Assembly
1. Clean all metal parts in fresh cleaning solvent.
2. Inspect wheel hub studs (2, Figure 3-6) and
replace if damaged or broken.
NOTE: If new studs are installed, coat the hole in the
hub and serrated portion of the stud with an antiseize compound prior to installation. DO NOT coat
threads.
3. Inspect tapped hole threads and re-tap if necessary.
4. Inspect bearing seating surfaces in hub and on
spindle. Inspect bearing spacer. Use a stone to
carefully dress high spots that may interfere
with re-assembly.
5. Inspect all other machined surfaces for damage.
6. Always use new O-ring seals during assembly.
G3-7
FIGURE 3-6. FRONT WHEEL SPINDLE, HUB & BRAKE ASSEMBLY

1. Wheel Hub
2. Stud
3. Capscrew
4. Washer
5. Cover
6. Outer Bearing Cup
7. Outer Bearing Cone
8. Shims
9. O-Ring
10. Spindle Cap
11. Capscrew
12. Hardened Washer
14. Capscrew
G3-8
15. Washer
16. Speed Sensor
17. Sensor Bracket
19. Brake Adapter
20. Capscrew
21. Hardened Washer
22. O-ring
23. Capscrew
24. Hardened Washer
25. O-ring
26. Spindle
27. Bearing Spacer
28. Inner Bearing Cone
29. Inner Bearing Cup

30. Seal Assembly
31. Capscrew
32. Hardened Washer
33. Drain Plug
34. Socket Head Capscrew
35. Speed Sensor Gear
36. Shims
37. Seal Carrier
38. O-ring
39. Bearing Retainer Pin
40. Bearing Retainer Pin
41. O-ring
08/02 G03017
Assembly - Wheel Hub and Spindle Assembly
NOTE: All mating surfaces of wheel and brake

components must be clean and dry during
assembly. No thread lubricant is permitted on
these surfaces.
1. Position the spindle vertically (hub end up).
2. Check bearing cones (7 & 28, Figure 3-6) for a
slip fit on spindle (26).
3. Check the threads in the bearing retainer holes
in the end of the spindle to be certain the capscrews will thread freely. If not, re-tap the
threads.
4. Install bearing cups (6 & 29) in the wheel hub
(1)as follows:
a. Preshrink the cups by packing them in dry
ice, or by placing them in a deep-freeze unit.
8. Install a new O-ring (9) onto spindle cap (10).

Lubricate the O-ring with clean hydraulic oil.
Install the cap into the end of spindle (26). The
tapped holes on the spindle cap must face the
outside for disassembly purposes.
Wheel Bearing Adjustment:

9. Install bearing retainer (13) onto the spindle
without any shims. The thickness of the retainer
is etched on the surface of the retainer. This
side should be facing outward. Use 4, equally
spaced capscrews in order to secure the
retainer. Two capscrews must be positioned
adjacent to the 0.50 in. (12.7 mm) diameter
access holes in the retainer.
10. Seat the wheel bearings using the following procedure:
a. Tighten the 4 capscrews to 80 ft. lbs. (108
N.m) torque. Rotate the wheel hub at least 3
full revolutions.
b. Tighten the 4 capscrews to 160 ft. lbs. (217
full revolutions.
NOTE: Do not cool below -65F (-54C).

b. Install cups in wheel hub bores.
c. Repeat Step 10-b until torque is maintained.
c. After cups have warmed to ambient temperature, press the cups tight against hub shoulder as follows:
d. Loosen the 4 capscrews and rotate the hub

at least three revolutions.
1.) Inner Cup (29) - Apply 23 tons (20,860 kg) force.

2.) Outer Cup (6) - Apply 21 tons (19,050 kg) force.
5. Install spacer (27). If necessary, tap lightly to
seat the spacer against the spindle. The spacer
must fit tightly against the spindle shoulder.
6. Install pin (39) in the pin groove and install inner
bearing cone (28) over the pin and against the
spacer. (The cone is a loose fit on the spindle.)
7. Install wheel hub (1) onto spindle (26). Install
outer pin (40) and outer bearing cone (7).
NOTE: To assure bearing lubrication during initial
operation lightly lubricate the bearings with hydraulic
oil.
The brake assembly should not be installed at

this time in order to facilitate the bearing adjustment procedure.
G03017 08/02
e. Tighten the 4 capscrews to 60 ft. lbs. (81

full revolutions.
f. Tighten the 4 capscrews to 100 ft. lbs. (136
full revolutions.
g. Repeat Step 10 - f until torque is maintained.
11. Using a depth micrometer, measure and record
the distance between the face of bearing
retainer (13) and spindle (26) through each of
the two 0.50 in (13 mm) diameter access holes.
12. Add the two dimensions measured in step 11
and divide the sum by 2 to obtain the average
depth.
13. Subtract the retainer plate thickness (etched on
the surface of the retainer plate (13) from the
result calculated in Step 12.
14. Assemble a shim pack to equal the dimension
calculated in Step 13 within 0.001 in (0.0254
mm).
G3-9
NOTE: Measure the shims individually for accuracy.

The above procedure results in a shim pack which
will provide a nominal 0.020 in. (0.508 mm) preload
for the bearings after assembly.
Example:
Step 12 (average depth)
Step 13 subtract etched dim.
Step 14 Required shim pack
1.416 in.
-1.375 in.
= 0.041 in.
NOTE: After a shim pack has been determined, the

shim pack, spindle, wheel hub, spacer, and bearings
are now an interdependent group. If any of the parts
are replaced, the shim pack is no longer valid, and a
new pack must be calculated.
15. Remove bearing retainer (13), outer cone (7),
retainer pin (40), and wheel hub (1) from spindle (26) for installation of the brake assembly.
Brake Installation
16. Position the wheel hub vertically on blocks with
the inner bearing bore at the top.
17. Assemble the brake to the hub as follows:
a. Install nine 0.020 in. (0.51 mm) thick shims
(36) on top of the wheel hub flange at each
of the six gear/seal retainer mounting locations. NOTE: Shims may be installed on
either side of speed sensor gear (35) for
speed sensor alignment.
b. Install speed sensor gear (35).
c. Install new O-ring (38) in the groove in the
hub. Ensure the O-ring is not twisted. Lubricate the O-ring.
d. Install lift eyes on the brake assembly and
attach to an overhead hoist.
e. Lower the brake assembly onto the hub
while aligning the hub and seal carrier
mounting holes.
NOTE: Do not remove the shipping bars until the
inner gear ring of the brake assembly is attached to
the hub.
a. Install capscrews (14) and washers (15) from
under hub flange. Tighten the capscrews to
standard torque.
b. Align the brake hub holes with the wheel hub
and install hardened flatwashers (24) and
capscrews (23). Tighten the capscrews to
1995 100 ft. lbs. (2705 136 N.m).
c. Remove shipping bars from brake assembly.
18. Install a new O-ring (25) to brake adapter (19).
Place the assembly into position on the spindle.
G3-10
19. Install hardened flatwashers (32) and capscrews (31). Tighten capscrews to 1995 100
ft. lbs. (2705 136 N.m).
Socket head capscrews (34) are installed to position the seal carrier on the brake back plate after
assembly and prior to installation on the hub/
spindle. In the next step, it may be necessary to
loosen these capscrews, slightly to align the
brake assembly holes with the brake adapter.
NOTE: The following instructions must be performed
carefully to prevent damage during assembly to
brake adaptor O-ring seal (22).
20. Prior to installing the hub and brake assembly
on the spindle, install four alignment studs on
the brake adapter (in place of capscrews (20).
Space the studs 90 apart to ensure the brake
assembly is properly aligned during the following steps.
a. Install a new O-ring (22) onto the brake
adapter shoulder. Be certain the O-ring is not
twisted and properly seated.
b. Lubricate the O-ring with petroleum jelly or
chassis grease.
21. Attach an overhead hoist to wheel hub and
brake assembly. Rotate hub 180 in preparation
for lowering onto spindle.
NOTE: The hoist must be rigid enough to prevent
"springing" or "jerking" as the hub and brake
assembly is lowered into position.
22. Lift the hub over the spindle and slowly lower
while aligning the brake mounting holes with the
alignment studs.
a. When the brake piston housing is approximately 0.50 in. (13 mm) from the adaptor,
install four capscrews (20) and flatwashers
(21) spaced evenly in between the alignment
studs.
b. Carefully pull the brake and wheel hub
assembly into position by tightening the capscrews evenly and in small increments.
c. Do Not allow the assembly to "cock" (angle).
If the assembly is cocked, lift the assembly,
and inspect O-ring (22) for damage. Replace
the O-ring if necessary, and repeat the procedure.
08/02 G03017
23. After the brake assembly is properly positioned

on the adapter and the four capscrews are
snug, remove the alignment studs.
Remove socket head capscrews (34) securing
seal retainer (37) to brake assembly (18).
Install the remaining brake adapter/brake
assembly mounting capscrews (20) and hardened flatwashers (21). Tighten the capscrews
to 1995 100 ft. lbs. (2705 136 N.m).
24. Install bearing retainer pin (40) in groove in
spindle. Align and slide outer bearing cone (7)
over pin. Lubricate the bearing with clean
hydraulic oil.
25. Install shim pack (8), retainer (13), capscrews
(11), and washers (12). Tighten the capscrews
alternately in several successive increments
while rotating the hub. Final torque is 750 75
ft. lbs. (1017 100 N.m).
26. Install a new O-ring (41) on cover (5). Install the
cover, capscrews, and washers. Tighten the
capscrews to standard torque.
FIGURE 3-7. MEASURING SEAL GAP

1. Spindle
2. Wheel Hub
3. Seal Carrier
4. Capscrews
5. Shims
6. Brake Back Plate
Seal Assembly Gap Check

After the assembly of the wheel and brake is complete, the gap between seal carrier (3, Figure 3-7)
and the brake assembly back plate (6) must be measured and adjusted if necessary.
The ideal gap is 0.433 in (11.0 mm). If necessary, the
gap must be adjusted, using shims as required to
maintain a minimum gap of 0.423 in (10.75 mm) to
0.443 in (11.25 mm) maximum.
27. Measure seal gap as follows:
a. Measure gap, dimension "A", Figure 3-7 at
three, equally spaced places and record the
results.
b. Add the three dimensions and divide the
result by 3 to obtain the average gap width
28. If average gap width is not between the minimum and maximum allowable range, loosen the
seal retainer capscrews (4, Figure 3-6) and add
shims (5) as required to reduce the gap or
remove shims to increase the gap. The quantity and thickness of shims at each of the six
locations must be equal.
30. Install speed sensor(s) (16, Figure 3-6) in support bracket(s) (17). Adjust sensor gap as follows:
a. Rotate hub to position the top of a gear tooth
directly under the sensor tip.
b. Insert a 0.060 in (1.5 mm) feeler gauge
between sensor tip and gear tooth. Loosen
and adjust sensor clearance.
c. Lock the sensor in place.
d. Rotate hub 180 and verify clearance
remains within 0.040 in (1.0 mm) minimum to
0.080 in (2.0 mm) maximum.
31. Install speed sensor cables.
32. Install hub and spindle assembly on suspension
per instructions in Installation.
29. Re-tighten seal retainer capscrews to standard

torque and measure gap as described in Step
28. If necessary, repeat Step 29 until the proper
gap is maintained.
G03017 08/02
G3-11
STEERING CYLINDERS AND TIE ROD

The steering cylinders and tie rod mounting arrangements are similar. The removal, installation, and
bearing wear limits are applicable to both.
Spherical Bearing Wear Limits
It is necessary to determine the condition of spherical bearings on steering linkage components for
optimum steering performance. Ball diameter new
dimensions and maximum allowable wear specifications are listed in Table 1. Bearings that exceed the
maximum wear limits must be replaced.
If premature wear of the bearings is evident, check
the automatic lubrication system to ensure the
proper amount of lubrication is being received at the
joint(s) in question. If lubrication is done manually,
ensure that a sufficient amount of grease is being
applied on a regular basis. Refer to Section P, Lubrication and Service, for information on proper lubrication intervals.
Use extreme caution when performing maintenance on any vehicle with an active steering
system. Serious injury or death can result from
contact with moving parts. Always keep a safe
distance from crush points.
TABLE 1. STEERING SPHERICAL BEARING

WEAR SPECIFICATIONS
Spherical Bearing Ball
Diameter (New)
4.31 in.
(109.47 mm)
Maximum Allowable Wear
0.043 in.
(1.09 mm)
It is also important to ensure that steering linkage

components are tightened to the proper torque. Use
the proper torque specifications listed in this section
for steering linkage components.
This dimension represents

maximum joint wear limit.
NOTE: Pin (3) should

be perpendicular with
surface D when
checking wear.
FIGURE 3-8. SPHERICAL BEARING WEAR LIMITS

1. Outer Race
2. Ball
G3-12
3. Pin
4. Bearing Housing
08/02 G03017
Removal - Steering Cylinder and Tie Rod

1. With engine shut down and key switch OFF,
allow at least 90 seconds for the accumulator
to bleed down. Turn the steering wheel to
make sure no hydraulic pressure is present.
Block front and back of rear wheels.
2. Disconnect hydraulic and lubrication lines at
the steering cylinders. Plug all line connections
and cylinder ports to prevent contamination of
hydraulic system.
3. Remove locknuts (9, Figure 3-9), capscrews

(3) and retainers (10) from both ends of
assembly.
4. Remove pins (16) from each end of assembly
and move assembly to clean work area.
The bearing spacers and the washers are

secured by the pin. Take measures to prevent
components from falling during removal of pin.
FIGURE 3-9. STEERING CYLINDER AND TIE ROD INSTALLATION

9. Locknut
5. Tie Rod End
1. Steering Cylinder
14. Capscrew
10. Retainer
6. Capscrew
2. Tie Rod Assembly
15. Washer
11. Bearing
7. Locknut
3. Capscrew
16. Pin
12. Spindle Arm
8. Washer
4. Spacer
17. Frame
G03017 08/02
G3-13
Installation - Steering Cylinder and Tie Rod

NOTE: Sleeve alignment tool, part number EH4638
included in tool group, should be used to hold
bearing spacers (4, Figure 3-9) and spherical
bearings (11) in position when pins are inserted
during assembly.
1. Align steering cylinder (1) or tie rod end (5)
bearing bore with pin bores in spindle or frame.
Insert bearing spacers (4) and washer (8).
NOTE: Tie rod is to be installed with clamping bolts
toward the rear of the truck.
2. Install pins (16), capscrews (3) and retainers

(10) and secure with locknut (9). Tighten to
750 75 ft. lbs. (1017 100 N.m).
3. Connect hydraulic and lubrication lines to their
respective ports. Operate steering and check
for leaks and proper operation.
Bearing Replacement
1. Remove capscrews (2, Figure 3-10) and lockwashers (3). Remove bearing retainer (4).
2. Press bearing (1) out of bore in steering cylinder or tie rod end.
3. Press new bearing into bore.
Always install pin retaining capscrews from the

top with the locknut on the bottom side at steering arm as shown in Figure 3-9.
4. Install bearing retainers with capscrews and

lockwashers. Tighten capscrews to standard
torque.
FIGURE 3-10. TYPICAL BEARING INSTALLATION

(Steering Cylinder Shown for Reference)
1. Bearing
2. Capscrew
3. Lockwasher
G3-14
4. Bearing Retainer
5. Rod End
08/02 G03017
TOE-IN ADJUSTMENT
1. The steering system must first be centered in
the straight ahead position. Shut down engine
and turn key switch OFF. Allow at least 90 seconds for the accumulators to bleed down. Do
Not turn the steering wheel. Block front and
back of the rear wheels.
2. Check toe-in by measuring the distance
between the centers of the front tires. These
measurements should be taken on a horizontal
centerline at front and rear of tires. Refer to Figure 3-11.
3. Radial tires should have equal measurements
(zero toe-in).
4. Loosen clamp locknuts on tie rod and rotate tie
rod as necessary to obtain correct toe-in setting.
5. When adjustment is complete, tighten clamp
locknuts (7, Figure 3-9) on tie rod to 310 31 ft.
lbs (420 42 N.m).
6. Remove blocks from rear wheels.
930E TOE-IN DATA
in. (cm)
Nominal tie-rod length, radial tires. 144.37 (366.7)

(Zero toe-in)
FIGURE 3-11. MEASURING TOE-IN
G03017 08/02
G3-15
NOTES
G3-16
08/02 G03017
SECTION G4
REAR AXLE HOUSING ATTACHMENT
INDEX
REAR AXLE HOUSING ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
PIVOT EYE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-4
PIVOT EYE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
ANTI-SWAY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
G04014 06/03
Rear Axle Housing Attachment
G4-1
NOTES
G4-2
06/03 G04014
REAR AXLE HOUSING ATTACHMENT

PIVOT PIN
Removal
1. Park the truck on firm, level surface and block
the front and rear of all tires.
The truck body must be empty and resting on the

frame before attempting this procedure.
2. Release all brakes.
3. Charge the rear suspensions with nitrogen until
the pistons are fully extended.
4. Place blocks or stands under each frame member beneath the hoist cylinders.
FIGURE 4-1. PIVOT PIN ASSEMBLY

Blocks must be securely in place before lowering
the frame. Check the blocks on the wheels to
make sure they are in place.
5. Release the nitrogen from the front suspensions.
6. Release the nitrogen from the rear suspensions.
7. Attach a hoist to the lift eye at the top of the
pivot eye to control downward movement of the
front of the axle housing.
1. Truck Frame
2. Capscrew
3. Lockwasher
4. 12 Pt. Capscrew
5. Lock Plate
6. Sleeve
7. Pivot Pin
8. Spacer
9. Cover Ring
10. 12 Pt. Capscrew
11. Locknut
12. Puller Holes
13. Bearing
15. Pivot Eye Structure
16. Bearing Carrier
17. Clamp
Installation
1. Raise pivot eye (15, Figure 4-1) into position.
8. Disconnect the pivot eye bearing lube line.

Remove the ground wire between the pivot eye
and frame.
2. Be certain the inner race of the spherical bearing is aligned.
9. Remove capscrew (2, Figure 4-1) and lockwasher (3).
3. Install cover rings (9) and spacers (8). Install pin

(7).
10. Remove capscrews (4). Remove lock plate (5).

11. Install puller using tapped holes (12) in head of
pin. Remove pin (7).
NOTE: Placement of a pry bar or jack between the
mounting structure and pivot eye may be necessary
to push the pivot eye downward and away from the
mount structure. Spacers (8) and cover rings (9) will
fall free.
4. Position lock plate (5) by lining up the capscrews with the capscrew holes in the pin.
Install the capscrews.
5. Rotate the pin and lock plate to align capscrews
(2) with holes in frame mounting structure.
a. Install capscrews (2) and lockwashers (3).
b. Tighten capscrews (2) to 175 ft. lbs. (237
N.m) torque.
c. Tighten capscrews (4) to 1715 ft. lbs. (2325
N.m) torque.
G04014 06/03
G4-3
6. Install the ground wire and the lubrication line.

Pressurize the lube line to assure bearing (13)
receives grease.
7. Install clamps (17) onto cover rings (9). Tighten
the clamps just enough to hold the covers in
place.
8. Charge the front suspension as described in
Oiling and Charging Procedures, Section H.
Assembly
1. Setup an appropriate tool to press spherical
bearing (4, Figure 4-2) into bearing carrier (3).
Be certain bearing outer race is flush with bearing carrier sides.
2. Install bearing retainers (2) using capscrews (5)
and locknuts (6). Tighten the capscrews to 575
ft. lbs. (779 N.m).
9. Charge the rear suspensions with nitrogen to

fully extend the pistons.
10. Remove the blocks or stands from beneath the
frame.
11. Release the nitrogen from the rear suspension
and charge according to the procedure in Oiling
and Charging Procedures, Section H.
Before removing the blocks from the wheels,

make sure the parking brake is applied.
12. Remove the blocks from wheels.
PIVOT EYE BEARING

Disassembly
1. Remove capscrews and locknuts (5 and 6, Figure 4-2). Remove bearing retainers (2). Setup
an appropriate tool to press spherical bearing
(4) from bearing carrier (3).
2. Inspect all parts for wear or damage. Replace
any parts showing excessive wear or damage.
Spherical bearing outer race O.D.:
8.7500 - 8.7488 in. (222.25 - 222.22 mm)
Bearing bore I.D.:
5.9990 - 6.0000 in. (152.37 - 152.40 mm)
3. If bearing carrier (3) is damaged or worn, refer
to Pivot Eye Repair in this section for repair procedure.
FIGURE 4-2. PIVOT EYE BEARING

INSTALLATION
1. Pivot Eye Structure
2. Bearing Retainer
3. Bearing Carrier
G4-4
4. Spherical Bearing
5. 12 Pt. Capscrew
6. Locknut
06/03 G04014
PIVOT EYE REPAIR
Assembly
If damage occurs to pivot eye (4, Figure 4-3), it may

be necessary to remove it from rear axle structure (1)
to facilitate repair and bearing replacement.
Removal
To remove the axle housing pivot eye:
1. Follow all preceding instructions in Pivot Pin Removal.
1. Setup an appropriate tool to press bearing carrier (3, Figure 4-2) into the bore of the pivot eye
structure.
NOTE: With parts to correct size, the fit of the
bearing carrier into the bore of the pivot eye structure
may be 0.001 - 0.003 in. (0.025 - 0.08 mm)
interference fit. Freezing the bearing carrier will
ease installation.
Be certain axle housing (1) and wheels are

blocked, securely.
2. Attach a lifting device to pivot eye (4). The
weight of the pivot eye is 762 lbs. (346 kg).
3. Remove capscrews (2) and flatwashers (3).
Remove pivot eye.
Disassembly
1. Remove spherical bearing (4, Figure 4-2) as
described in Pivot Eye Bearing - Disassembly.
2. If bearing carrier (3) is damaged or worn, setup
an appropriate tool to press the bearing carrier
out of the pivot eye structure bore.
Bearing carrier (new):
The lubrication groove in the bearing carrier

outer diameter must be aligned with the lubrication fitting hole in the pivot eye structure.
2. Press the bearing carrier into the bore. Be certain the carrier is pressed fully into the pivot eye
bore, flush with the sides.
3. Install spherical bearing (4) as described in
Pivot Eye Bearing - Assembly.
I.D. = 8.7484 0.0005 in. (222.209 0.013 mm)

O.D.= 9.7520 0.0005 in. (247.701 0.013 mm)
3. Inspect pivot eye structure bore for excessive
wear or damage.
Installation
1. Be certain the mating surfaces of axle housing
(1, Figure 4-3) and pivot eye (4) are clean and
not damaged.
2. Install an appropriate lifting device to the pivot
eye. The weight of the pivot eye is 762 lbs. (346
kg).
Pivot eye bore (new):

9.7500 0.0005 in. (247.650 0.013 mm)
3. Lift the pivot eye into position on the front of the

axle housing. Insert several capscrews (2) and
flatwashers (3) to align the parts. Remove the
lifting device.
4. Install the remaining capscrews and flatwashers. Tighten the capscrews alternately until the
pivot eye is properly seated. Tighten the capscrews to 1715 170 ft. lbs. (2325 231 N.m)
final torque.
FIGURE 4-3. PIVOT EYE ATTACHMENT

1. Rear Axle Structure
3. Flatwasher
2. Capscrew
4. Pivot Eye
G04014 06/03
G4-5
ANTI-SWAY BAR
NOTE: The anti-sway bar mounting arrangement is
identical at each end.
Removal
1. Position the frame and the rear axle housing to
allow use of a puller arrangement to remove
anti-sway bar pins (4, Figure 4-4) on the rear
axle housing and the frame.
2. Securely install blocking between the frame and
the axle housing.
3. Disconnect the lubrication lines.
4. Position a fork lift or attach a lifting device to
anti-sway bar (11). The weight of the anti-sway
bar is 325 lbs (147 kg).
5. Remove capscrews (9) and locknuts (10) at
each mount.
6. Attach a puller and remove pin (4) from each
end of the anti-sway bar.
7. Remove the anti-sway bar from the mounting
brackets.
FIGURE 4-4. ANTI-SWAY BAR ASSEMBLY
8. Remove bearing spacers (6).
Installation
1. Place pin (4, Figure 4-4) into position at the
front of the frame mount. Push the pin through
spacer (6), and rotate the pin to align retaining
capscrew (9) hole with the hole in mounting
structure (1).
2. Raise the anti-sway bar into position. The
weight of the anti-sway bar is 325 lbs (147 kg).
3. Push the pin through the spherical bearing,
insert the second spacer and continue pushing
into the other ear of the bracket. If necessary,
realign the pin with the retainer capscrew hole.
Install capscrew (9) and locknut (10).
4. Repeat the previous steps to install the remaining pin and spacers at the opposite end of the
bar. Start the pin into the bore of the axle housing mount from the rear of the truck.
5. Attach the lubrication lines. Pump grease into
the bearing to verify the line and the system is
operational.
6. Remove the blocking from between the frame
and the axle housing.
7. If necessary, recharge the suspensions. Refer
to Section H, Oiling and Charging Procedures.
G4-6
1. Mounting Structure
2. Capscrew
3. Lockwasher
4. Pin
5. Sleeve
6. Bearing Spacer
7. Retainer Ring
8. Bearing
9. Capscrew
10. Locknut
11. Anti-Sway Bar
Disassembly
1. Remove retainer rings (7, Figure 4-4) from the
bores of both ends of anti-sway bar (11).
2. Press out spherical bearings (8).
1. Inspect bearing bores of the anti-sway bar. If
the bores are damaged, repair or replace the
anti-sway bar.
2. Inspect bearing spacers (6) for damage or
wear.
Assembly
1. Press new bearings into the sway bar.
2. Install retainer rings (7). Be certain the rings are
properly seated in the grooves.
06/03 G04014
SECTION G5
REAR AXLE HOUSING
INDEX
REAR AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3

REAR AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
Cleaning and Inspection - Rear Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-5
Installation - Rear Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-5
WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Cleaning and Inspection - Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-7
Installation - Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-8
WHEEL MOTOR GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Filtering Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Particle Size Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Oil Sample Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-12
ELEMENT SPECIFICATION CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-13
G05018
Rear Axle Housing
G5-1
NOTES
G5-2
Rear Axle Housing
G05018
REAR AXLE HOUSING

REAR AXLE HOUSING
before attempting any repairs on propulsion system components!

Front wheels must be securely blocked to
prevent movement as brakes will be
released.
All electrical cables and hydraulic hoses
should be marked prior to removal.

hand hold when the engine is running.


Close the shut-off valves on the hydraulic

pumps to reduce amount of oil loss from
brake system.
Removal
1. Remove the dump body as outlined in Section
B, Dump Body. Block up truck and remove rear
tires as described in this Section G, Tires and
Rims.
2. Loosen hose clamps and disconnect wheel
motor cooling air duct from connection on front
center of housing.

safety of those working in the area of the wheel
motors, and possibly the electrical cabinet and
retarding grids. The following procedures will ensure
the electrical system is properly discharged before
repairs are started.
3. With the pump shut-off valves in the closed

position, remove drain plugs at bottom of brake
assemblies and drain oil from disc brakes.
Preparation
6. Remove cable grips at right front corner from

wheel motor cables (7), air pressure sensor/
rear light (8) and speed sensor (9) harnesses.
Slide cable grips forward on cables.

illuminated.
console. Place the GF cutout switch in the CUTOUT position.
4. Disconnect hydraulic hoses at manifold (4, Figure 5-1). Cap fittings and plug hoses to prevent
contamination.
5. Remove covers from access holes (17).
7. Remove cable grip mounting cover and slide

forward for access to brake cooling line clamp
inside axle housing.
8. Disconnect brake system cooling lines (2 & 10)
at each brake back plate. Disconnect brake
apply lines (11). Cap and plug openings.
9. Remove clamps (3) securing brake hoses to
spindles.
10. Open rear access cover and remove wing nuts
securing duct tube to axle housing. Remove
tube.

G05018
Rear Axle Housing
G5-3
FIGURE 5-1. REAR AXLE HOUSING AND WHEEL MOTORS

12. LH Wheel Motor
6. Relay Valve
13. Park Brake Line
7. Wheel Motor Power Cables
2. Brake Cooling Oil Return
14. RH Wheel Motor
8. Air Sensor/Rear Light Harness
3. Clamp
15. Capscrew
9. Speed Sensor Harness
4. Manifold
16. Hardened Flatwasher
10. Brake Cooling Oil Supply
5. Cooling Air Duct
17. Access Hole
11. Brake Apply Line
11. Open access covers inside axle housing.

12. Disconnect parking brake supply line (13). Disconnect and remove RH parking brake supply
line at tee.
13. Disconnect air sensor hose from duct.
14. Remove wheel motor cooling air exhaust duct
(5) from between wheel motors.
15. Disconnect wheel motor power cables (7) at
wheel motor terminals. Remove cable clamps
and pull cables from axle housing.
16. Disconnect air pressure sensor/rear light harness (8) inside axle housing and remove
clamps. Disconnect speed sensor harness (9)
connectors and remove clamps. Pull both harnesses from axle housing.
G5-4
17. Remove automatic lube system hoses and

clamps attached to housing. Secure hoses to
frame to prevent interference during axle housing removal.
18. Remove rear suspensions. Refer to Section H,
Rear Suspensions.
19. Remove anti-sway bar as described in Section
G, Rear Axle Housing Attachment.
20. Remove pivot pin as described in Section G,
Rear Axle Housing Attachment.
21. Remove wheel motors as described in this
section.
22. Attach overhead hoist or crane to lift eyes on
rear axle housing and move from rear of
frame.
Rear Axle Housing
G05018
Cleaning and Inspection - Rear Axle Housing

1. Thoroughly clean the capscrew holes and
wheel motor mounting faces. Re-tap holes if
threads are damaged.
Installation - Rear Axle Housing

1. Position axle housing under frame.
2. Align pivot pin bores and install pivot pin. Refer
to Section G, Rear Axle Housing Attachment.
2. Check wheel motor mounting faces for nicks,

scratches or other damage. Inspect all welds
and repair as necessary.
3. Install anti-sway bar. Refer to Section G, Rear

Axle Housing Attachment.
3. Inspect pivot pin bearing. If worn or damaged,

refer to Section G, Rear Axle Housing Attachment - Pivot Eye Bearing, and repair as
required.
5. Connect auto lube system hoses and clamps.
4. Inspect brake system relay valve (6, Figure 5-1)

and hoses for leaks. Inspect manifold (4) hose
connections and repair leaks or damaged
hoses.
4. Install rear suspensions, as described in Section H, Rear Suspensions.

6. Route wheel motor cables (7, Figure 5-1) into
housing and clamp in place. Install cable grip
mounting plate and cable grips.
7. Install speed sensor harness (9, Figure 5-1)
through housing. Install cable grip.
8. Install air sensor/light harness through housing,
clamp in place and install connectors. Install
cable grip.
9. Install wheel motors, cables, brake lines and
tires as described on the following pages.
10. Connect hoses to manifold (4) at front of housing.
11. Install air duct (5). Close duct inspection covers
and install duct tube in rear opening of axle
housing.
12. Reconnect wheel motor cooling air duct and
clamp securely.
13. Open pump shut-off valves. Service hydraulic
system.
G05018
Rear Axle Housing
G5-5
WHEEL MOTOR
before attempting removal of the wheel motors or
any repairs on the propulsion system components!
Front wheels must be securely blocked to

prevent movement as brakes will be
released.
All electrical cables and hydraulic hoses
should be marked prior to removal.
Close the shut-off valves on the hydraulic
pumps to reduce amount of oil loss from
brake system.

hand hold when the engine is running.



safety of those working in the area of the wheel
motors, and possibly the electrical cabinet and
retarding grids. The following procedures will ensure
the electrical system is properly discharged before
repairs are started.
Preparation
illuminated.
2. Place the drive system in the rest mode by turning the Rest switch on the instrument panel ON.
3. Shut down the engine using the keyswitch.
Place the GF cutout switch in the CUTOUT
position.
Removal
NOTE: If suitable equipment is available to lift wheel
motor assembly from the axle housing it is not
necessary to remove the truck body. The equipment
used must be capable of lifting and supporting the
weight of the complete wheel motor assembly,
39,975 lbs. (18,132 kg.), must be mobile and must be
capable of aligning the wheel motor to the axle
housing mounting flange during installation. If the
wheel motor must be removed by use of a crane or
overhead hoist. Refer to Section B, Dump Body for
removal instructions.
1. Raise the rear of truck as described in this section, until tires clear the ground. Use support
stands or cribbing to block under rear housing.
2. Remove the inner and outer wheels from wheel
motor. Refer to tire and wheel removal instructions in this Section G, Tires and Rims. Be certain additional capscrews have been installed to
provide support for the wheel motor transmission housing while the rear tires are removed.
3. With the pump shut-off valves in the closed
position, remove the drain plug at bottom of
brake assembly and drain oil from disc brake
housing.
4. Remove covers from access holes (17, Figure
5-1)
5. Disconnect brake system cooling lines (2 & 10)
at brake back plate. Disconnect brake apply
lines (11). Cap and plug openings.
6. Remove clamps (3) securing brake hoses to
spindles.


tube.


G5-6
9. Disconnect parking brake supply line for the

motor to be removed. Disconnect air sensor
hose if necessary.
(5) from between wheel motors.
Rear Axle Housing
G05018
11. Disconnect wheel motor power cables (7) at

wheel motor terminals. Disconnect speed sensor cable at connector in center of housing.
12. Tie up cables and hoses as necessary to prevent damage during wheel motor removal.
Each complete wheel motor assembly weighs

approximately 41,105 lbs. (18,645 kg). Be certain
lifting device is capable of handling the load
safely.
13. Attach lifting device to wheel motor assembly.
DO NOT allow lifting device to contact brake
housing.
14. Remove capscrews (15) and hardened flatwashers (16) securing wheel motor to rear
housing.
15. Move wheel motor assembly out of axle housing, using care to prevent damage to brake
hoses if not removed previously.
16. Refer to appropriate GE service information for
wheel motor repair instructions.
Cleaning and Inspection - Wheel Motor
1. Thoroughly clean the capscrew holes and
mounting faces of the rear housing and the
wheel motor.
2. Re-tap holes if threads are damaged.
3. Check mounting faces of wheel motor and rear
housing for nicks, scratches or other damage.
High tightening force is required on wheel motor

mounting capscrews. Repeated tightening will
cause capscrew material to fatigue and break.
DO NOT reuse wheel motor mounting capscrews
and washers more than twice after original installation. The mounting hardware must be replaced
after the third use.
The following method is suggested to control the "3 Use" maximum:
Punch mark the capscrew heads with a center punch
after each tightening as follows:
Initial Installation . . . . . . . . . . . . . . . .Zero marks
Second Installation . . . . . . . . . One punch mark
Third Installation . . . . . . . . . . . .Two punch marks
Before installation, inspect each capscrew for any
defects and number of punch marks. Replace capscrews and washers if two punch marks are evident;
do not reuse if any defect is suspected. Hardware
showing signs of rust, corrosion, galling, or local
yielding on any seat or thread surfaces should be
replaced. Replace mounting hardware if the truck
was operated with the wheel motors in a loose joint
condition. Replace wheel motor mounting hardware
with original Komatsu parts.
The hardened flat washers used in this application
are punched during the manufacturing process,
therefore, they must be assembled with the punch lip
away from head of the mounting capscrews to prevent damage to the fillet between capscrew head and
shank. Refer to Figure 5-2.
4. Check components inside axle housing. Inspect

brake system relay valve (6, Figure 5-1) and
hoses for leaks. Inspect manifold (4) hose connections and repair leaks or damaged hoses.
5. Inspect wheel motor power cables, terminals,
cable grips, and clamps. Replace any cables or
hardware that is damaged or worn.

properly secured in their wood or other non-ferrous cable cleats. If clamps are cracked or broken, replace them with new parts. Inspect cable
insulation and replace entire cable if insulation is
damaged.
G05018
FIGURE 5-2. MOUNTING HARDWARE

1. Washer
Rear Axle Housing
2. Capscrew
G5-7
Installation - Wheel Motor

1. Install two guide pins 180 apart in the rear
housing.
The complete wheel motor assembly weighs

approximately 41,105 lbs. (18,645 kg). Be certain
lifting device is capable of handling the load
safely.
2. Lift the wheel motor into position on the axle
housing. Ensure all cables and lines are clear
before installation. If brake system hoses (2,
10, & 11, Figure 5-1) have not been removed,
guide hoses through the spindle holes during
installation
The wheel motors must be properly aligned

before installing onto the axle housing. The
wheel motor has markings which help determine
installation orientation. Two sets of dimples are
located at the 3 oclock and 9 oclock positions.
A centerline symbol marks the 12 oclock position of the wheel motor. Refer to Figure 5-3.
The axle housing also contains dimples at the 3
oclock and 9 oclock positions next to the wheel
motor mounting rings. Refer to Figure 5-4.
When installing the wheel motors, ensure the
markings on both components line up. The top
capscrew hole on the axle housing may also be
determined by counting the holes in between
the two sets of punch marks. The top hole on
the axle housing should line up with the CL
stamping on the wheel motor.
FIGURE 5-3. WHEEL MOTOR DIMPLE MARKINGS
G5-8
Rear Axle Housing
G05018
5. Connect brake apply line (11) to the port on the

brake assembly back plate.
6. Using new O-rings, install brake cooling lines.
7. Seal gap around brake cooling hoses (see sealant specification below) where cooling hoses
pass through spindle holes. Install clamps (3).
MASTIC SEALANT
Vendor Product Name:
Punch Marks
Uniseal 310S Sealant
Description:
2.00 in. wide x 0.125 in. thick x 120 in.

long roll
Vendor Source:
Uniseal
1800 W. Maryland Street
Evansville, IN 47712
Other sources may

throughout the world.
FIGURE 5-4. AXLE HOUSING DIMPLE MARKINGS
3. Install lubricated capscrews and flat washers

securing wheel motor to rear axle housing.
Snug up all capscrews until wheel motor is
seated against axle housing flange at all points.
Final tighten (alternating capscrews 180 apart)
to 1480 ft. lbs. (2007 N.m) torque.
4. Connect power cables (7, Figure 5-1) to their
appropriate location on the wheel motor. Connect speed sensor cable.
be
available
NOTE: Brake system hoses must be sealed where

they pass through axle spindle holes to prevent
cooling air loss.
8. Connect air sensor hose, if removed. Install
park brake apply hose (13).
9. Install inspection covers on access holes (17).
10. Install air duct (5). Close duct inspection covers
and install duct tube in rear opening of axle
housing.
11. Open pump shut-off valves.

properly secured in their wood or other non-ferrous cable cleats. If clamps are cracked or broken, replace them with new parts. Inspect cable
insulation and replace entire cable if insulation is
damaged.
12. Check wheel motor oil level. Rotate a magnetic

plug to the 6 oclock position and remove the
plug. The oil level should be even with the bottom of the plug opening. Refer to Figure 5-5. Fill
as necessary.
13. Check hydraulic tank oil level before and after
engine start-up and brake bleeding procedure.
Service as necessary.
14. Bleed the brake apply line according to the
instructions in Section J, Wet Disc Brake
Assembly, Wet Disc Brake Bleeding Procedure.
G05018
Rear Axle Housing
G5-9
FIGURE 5-5. WHEEL MOTOR OIL LEVEL
15. Remove temporary capscrews previously

installed in wheel motor transmission housing
mounting flange. Install tires and rims using procedures outlined earlier in this section.
16. Raise truck, remove support stands. Lower
truck and remove jack.
G5-10
Rear Axle Housing
G05018
WHEEL MOTOR GEAR OIL

Filtering Requirements
Wheel motor gear oil must be changed (or filtered) at
the first 500 hours of operation and every 2500 operating hours, thereafter. Filtering synthetic oil for reuse
is recommended, and can significantly extend the life
of the oil. Due to their additive formulation, GE
approved oils may last up to a year (5-6 filter cycles),
or possibly longer. After a year, the synthetic oil must
be analyzed by the oil manufacturer if continued use
is desired. A 10 micron filter must be used for filtering
the oil.
Viscosity of filtered oil must be monitored by oil analysis to ensure proper lubrication. Viscosities below
the condemning limit indicates entry of contamination
that will affect the oil film and lubricating quality. The
condemning limit for 680 oil, is 53cSt when tested at
212 F (100 C), and 588cSt at 104 F (40 C). This
value can be used along with element tracking of
phosphorus, calcium, and zinc to verify correct oil
viscosity. Ensure the appropriate viscosity value is
being maintained for the approved oil you are using.
If the viscosity of the oil is below the acceptable limit,
the oil should be rechecked. If the second test fails,
dispose of the oil. Fill the wheel motor with new, GE
approved oil. The contaminated oil should be properly disposed of according to local regulations.
If the viscosity of the oil is below the condemning

limits, the oil may be contaminated with hydraulic oil. Ensure all joints are properly sealed before
filling the wheel motor with fresh oil. If hydraulic
oil continues to contaminate the wheel motor,
serious damage to internal components may
result.
Particle Size Analysis

When filtering synthetic oil for reuse, the oil must be
monitored to determine when filtering is necessary.
The process of monitoring the oil for this purpose is
particle size analysis. The test consists of passing a
beam of light through the oil as it passes through a
clear tube. A computer analyzes the quantity and
size of particles contained in the oil.
G05018
Particles that are smaller than 5 microns in size are

not large enough to cause any gear or bearing failures. Particles over 25 microns can damage bearings and must be filtered from the oil.
General Electric (GE) recommends that the oil be
tested according to the International Standards Organization's ISO Particle Analysis 4406. This standard
documents the size and number of particles permitted in the lubricant. This is an extremely important
measurement of the condition of the oil.
An "ISO Cleanliness Code" is used to document the
number and size of the contaminates that can be tolerated in a specific application of a lubricant. An
example of an "ISO Cleanliness Code" would be 18/
13. The first number (18 in this example) applies to
the allowable number of particles between 5 - 15
microns in size. The second number (13 in this
example) applies to the allowable number of particles
between 15 - 25 microns. If the particle count identified by the "ISO Cleanliness Code" is exceeded or
there are particles present larger than 25 microns,
the oil should be filtered.
GE recommends that a Cleanliness Code of 18/13
be used for motorized wheels. Oil qualified for reuse
must be filtered to 10 microns absolute.
If particle analysis yields a result of greater than 18
for the top number or greater than 13 for the lower
number the motorized wheel oil should be filtered to
10 microns absolute. On occasion, one should check
the results of the filtering process to assure the filtering process is yielding the desired results. Should the
result be unacceptable, check the filter type, particle
size, and condition prior to filtering again.
Flushing
The transmission of the wheel motor must be flushed
using the same oil that is used in normal operation.
The use of solvents or low viscosity oils are not
acceptable.
After flushing to remove contamination from the
wheel motor, the transmission should be filled with
new or filtered oil. A sample should be taken for analysis after 100 hours of operation. If results of the oil
analysis are within the acceptance range, the wheel
motor may return to the 250 hour interval for oil analysis. If the results of the analysis are not within the
acceptance range, immediately contact your area GE
or Komatsu service representative. Large quantities
of loose material in the oil may be an indication of
imminent wheel motor failure.
Rear Axle Housing
G5-11
Oil Sample Analysis

Spectrographic oil analysis results should be examined prior to sun pinion gear inspection. The trends of
element parts per million (ppm) or sudden ppm element changes can estimate the present condition of
the wheel motor and also predict the immediate
future of the mechanical components within the
wheel motor.
While examining oil sample history, the most important characteristic to look for is a rapid increase in the
presence of an element in the oil such as iron (Fe).
Rapid changes in element content indicate that a
component(s) may be deteriorating. In many cases
oil analysis can help detect which component may be
deteriorating and the cause of the failure.
Oil sampling must be done every 250 hours of operation. The sample must be taken within a half an hour
of truck shut down and within an hour of actual truck
operation. Oil samples that are not taken under this
stipulation will not convey an accurate measurement
of wheel motor condition.
When taking an oil sample, position one of the magnetic plugs in the six oclock position on the wheel.
Oil samples should be taken from this plugged hole
using a flexible tube that is 18 inches (457 mm) in
length. The tube must be inserted downward exactly
12 inches (305 mm) toward the bottom of the torque
tube.
A gradual rise of elements between oil samples is

normal. Only when a sharp increase occurs is there
evidence that a mechanical failure is imminent. Levels of elements that indicate mechanical stress differ
from element to element. Additionally, oil sampling
criteria established for each element may differ at
each mine site due to factors such as uphill or downhill hauling, grades, and speeds.
Elements for the wheel motor that can be detected
with oil analysis are iron (Fe), chromium (Cr), nickel
(Ni), copper (Cu), silicon (Si), phosphorus (P), zinc
(Zn), and calcium (Ca). Monitoring and plotting levels
of these elements should aid in identifying operational status of the wheel motor. Rapid changes or
high levels of these elements are indicators that
problems exist in the mechanical components.
As stated above, some guidelines for analyzing oil
samples can be given, but specific levels should be
established at the operating mine site. The element
type, maximum ppm, maximum spike allowable
between 250 hour interval oil samples, oil sample
indicators, and possible causes and actions are
listed in the following charts. These charts provide
basic guidelines for analysis of oil sampling information.
When a sample is extracted from the wheel motor

and placed in a clear bottle, the appearance, as well
as odor of the oil should be inspected. Note any
burning smells or other odors typical of fatigued or
contaminated oil. Check the oil for cloudiness, large
particles, and filming. Any of these conditions indicate a problem.
G5-12
Rear Axle Housing
G05018
ELEMENT SPECIFICATION CHARTS
Element
Max ppm
Iron (Fe)
600
Max spike
200
100
Indications of oil samples

If iron levels are high and other
elements are slightly elevated:
Possible cause of elevated ppm's

"Soft" iron contamination. Sources are likely to
be casting material.
If iron levels are high and other

elements ppm's are rising rapidly:
"Hard" iron contamination. Sources are likely

to be bearing, gears, etc.
Action: A sun pinion and magnetic plug inspection should be done immediately. The magnetic plugs should be
inspected for metal chips and shavings. The sun pinion and low speed planet gears should be inspected for wear
or spalling per GE GDY-85/106 AC Motorized Wheel Component Inspection and Reuse Criteria (GEK-91680). If
the low speed planet gears fail to meet the inspection criteria the wheel should be removed, disassembled, and
gears replaced. If the low speed planet gears meet the re-use criteria, but the sun pinion fails to meet the reuse criteria, then replace the sun pinion. Once the sun pinion has been replaced drain the oil and replace with fresh oil.
This wheel should then be monitored closely and replaced if the iron level spikes again.
Element
Chromium
(Cr)
Max ppm
Max spike
10

If chromium is high and iron is high:

A bearing failure is likely in progress.
Action: The oil should be resampled immediately and a gear train inspection completed. If resampling shows high
chrome, the wheel should be removed from service, disassembled, and the bearings and gears inspected.
Element
Max ppm
Max spike
Nickel (Ni)
10

If nickel is high and iron is high or rising: Nickel is likely from one or more of the gears.
Action: This could indicate a condition such as gear tooth pitting or spalling. The oil should be resampled immediately and a gear train inspection completed. If the resampling of the oil shows high nickel and chromium, the wheel
should be removed from service, disassembled, and the bearings and gears inspected.
Element
Max ppm
Max spike
15
Copper (Cu)
50
20

If copper is high with iron high:
If copper is high with other elements
low:

High iron will produce high copper from the thrust
washers and bearings.
A thrust washer is rapidly wearing with the likely cause
of the sun pinion gear thrusting inboard or outboard.
Action: This often indicates a normal wear condition such as minor thrust washer wear. It can also be an indicator
of bearing wear. If bearing wear is a concern review the chromium readings in conjunction with the copper readings. If both the copper and chromium readings spike; remove the wheel from service, disassemble the wheel, and
inspect the bearings. If the only elevated reading is that of copper or lead; remove the sun pinion and check the
outer thrust washer for wear. If the outer thrust washer has worn less than the depth of the oil lubricating grooves
then reassemble the sun pinion, filter the oil and continue to monitor. If the outer thrust washers have worn more
than the depth of the oil lubricating grooves then replace the outer thrust washers, reassemble the sun pinion, filter
the oil and continue to monitor.
G05018
Rear Axle Housing
G5-13
Element
Max ppm
Max spike
Calcium (Ca)
40
20

If calcium, zinc, and phosphorus are
high:

Hydraulic oil has entered the drive train.
Action: If calcium and zinc spike then look at the oil viscosity. If the oil viscosity is below the 53 cSt at 100 C (212
F) or 588 cSt at 40 C (104 F) condemning limit, the oil should be resampled immediately. If the resampling still
shows a spike in calcium and low viscosity remove the wheel, disassemble, and replace the internal brake seals.
The oil removed from a low viscosity wheel should be disposed of and not reused under any circumstances. If the
oil viscosity is above 53 cSt at 100 C (212 F) or 588 cSt at 40 C (104 F) then monitor the wheel for any further
changes in viscosity
Element
Zinc (Zn)
Max ppm
75
Max spike
40 If zinc, phosphorus, and calcium are high: Hydraulic oil has entered the drive train.
25 If zinc is high without high calcium and
phosphorus:
High mechanical wear of components is

occurring.
Action: If zinc and calcium increase proportionally then look at the oil viscosity. If the oil viscosity is below the 53
cSt at 100 C (212 F) or 588 cSt at 40 C (104 F) condemning limit, the oil should be resampled immediately. If
the resampling still shows a spike in calcium and low viscosity remove the wheel, disassemble, and replace the
internal brake seals. The oil removed from a low viscosity wheel should be disposed of and not reused under any
circumstances. If the oil viscosity is above 53 cSt at 100 C (212 F) or 588 cSt at 40 C (104 F) then monitor the
wheel for any further changes in viscosity.
Element
Max ppm
Phosphorus
400
(P)
Max spike
150

If phosphorus, zinc, and calcium are
high:

Hydraulic oil has entered the drive train.
Action: If the oil viscosity is below the 53 cSt at 100 C (212 F) or 588 cSt at 40 C (104 F) condemning limit, the
oil should be resampled immediately. If the resampling still shows a spike in phosphorus and low viscosity, remove
the wheel, disassemble, and replace the internal brake seals. The oil removed from a low viscosity wheel should
be disposed of and not reused under any circumstances. If the oil viscosity is above 53 cSt at 100 C (212 F) or
588 cSt at 40 C (104 F) then monitor the wheel for any further changes in viscosity.
Element
Max ppm
Silicon (Si)
50
Max spike
20
25

If silicon is high with other elements high: High wear of components.
If silicon is high with other elements low: Dirt has entered the drive train. Flush wheel
motor.
Action: Flush the wheel motor and monitor element levels.

To fully utilize oil sampling analysis, complete information should be kept with the truck. Necessary information
includes: the truck identification number at the mine site, truck serial number, side of truck the wheel motor is on,
dates when wheel motors are changed (include serial numbers of wheels), the type of oil, viscosity of the oil, sample date, hours on wheel, hours on oil, and element count. Refer to the chart below. Information in this format can
be easily sent to equipment manufactures and gives required information to analyze the results of oil samples.
Separate records for each wheel motor should be kept in this format.
Contamination can reduce sun pinion gear life significantly, as well as the rest of the drive train. Additional
component (sun pinion gear, etc.) inspections may be required, in addition to normal maintenance interval
inspections, if oil samples from a wheel motor show elements are above normal or rapidly elevating.
G5-14
Rear Axle Housing
G05018
G05018
Rear Axle Housing
G5-15
NOTES
G5-16
Rear Axle Housing
G05018
SECTION H
HYDRAIR II SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
REAR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
OILING AND CHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-1
H01013
Index
H1-1
NOTES
H1-2
Index
H01013
SECTION H2
FRONT SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Installation - Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-4
"TURN-OF-THE-NUT" Tightening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-6
MINOR REPAIRS (LOWER BEARING & SEALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-7
Removal - Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-7
Installation - Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-7
MAJOR SUSPENSION REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-9
H02013 03/03
Front Suspensions
H2-1
NOTES
H2-2
Front Suspensions
03/03 H02013
FRONT SUSPENSION
The HydrairII suspensions are hydro-pneumatic
components containing oil and nitrogen gas. The oil
and gas in the four suspensions carry the gross truck
weight less wheels, spindles and rear axle assembly.
The front suspension cylinders consist of two basic
components; a suspension housing attached to the
truck frame and a suspension rod attached to the
front spindle.
Check valves and orifice dampening holes control
suspension travel to provide good ride qualities on
haul roads under loaded and empty conditions.
The front suspension rods also act as kingpins for
steering the truck.
The HydrairII suspension cylinder requires only
normal care when handling as a unit. However, after
being disassembled these parts must be handled
carefully to prevent damage to the machined surfaces. Surfaces are machined to extremely close tolerances and are precisely fitted. All parts must be
completely clean during assembly.
Removal
1. Park unloaded truck on hard level surface.
Block wheels and set parking brake. Remove
front wheel and tire. Refer to Section G, Tires
and Rims. Remove front wheel hub and spindle
as covered in Section G, Front Wheel Hub and
Spindle.
2. Remove boot clamp and boot from around suspension.
3. Discharge nitrogen pressure from suspension
by removing cap from charging valve (5, Figure
2-1). Turn the charging valve swivel nut (small
hex) (2, Figure 2-2) counterclockwise 3 full
turns to unseat valve seal (DO NOT turn more
than three turns). DO NOT TURN LARGE HEX
(4) (see DANGER below). Wearing face mask
or goggles, depress valve stem until all nitrogen
pressure has been relieved.
Make certain only the swivel nut (2) turns. Turning the complete charging valve assembly may
result in the valve assembly being forced out of
the suspension by the gas pressure inside.
4. After all nitrogen pressure has been relieved,
loosen large hex (3) and remove charging valve
assembly. Discard O-ring seal.
FIGURE 2-1. SUSPENSION CHARGING VALVE

1. Suspension Housing
2. Cap Structure
H02013 03/03
3. Pressure Sensor
Port
4. Vent Plug
5. Charging Valve
FIGURE 2-2. CHARGING VALVE INSTALLATION

1. Valve Cap
2. Swivel Nut (Small
Hex)
Front Suspensions
3. Charging Valve
Body (Large Hex)
4. Vent Plug
H2-3
5. Place a suitable container under suspension

cylinder. Remove bottom drain plug (19, Figure
2-8) and allow cylinder to drain completely. A
properly charged front suspension cylinder
contains 25.8 gallons (98 l) of oil.
NOTE: Front HydrairII suspensions are equipped
with lower bearing retainer puller holes. If only rod
wiper, rod seals, bearing, O-ring and backup ring
replacement is required, it will not be necessary to
remove suspension from truck. Refer to Minor Repair
s (Lower Bearing & Seals) for bearing retainer
removal and installation.
6. If major suspension rebuild is required, continue
removal procedure.
7. Attach fork truck or suitable lifting device to suspension. Secure suspension to lifting device.
The front HydrairII suspension weighs approximately 6150 pounds (2790 kg). Be certain the lifting device to be used is of sufficient capacity to
handle load.
8. Remove capscrews and washers (1, Figure 23) and nuts and washers (2).
9. Remove capscrews and washers (8), and nuts
and washers (10).
10. Remove capscrews and washers (6), and spacers (9).
11. Move suspension to a clean work area for disassembly.
FIGURE 2-3. SUSPENSION INSTALLATION

1. Capscrews, Washers 6. Capscrews, Washers
7. Piston
2. Nuts, Washers
8. Capscrew, Washers
3. Housing
9. Spacer
4. Mounting Surface
10. Nuts & Washers
5. Shear Bar
Installation - Front Suspension

Use the following procedure for preparing mounting
surfaces and mounting hardware.
1. The mounting surface of both the suspension
and the frame must be clean and dry. Use a
cleaning agent that does not leave a film after
evaporation, such as trichlorethylene, tetrachlorethylene, acetone or lacquer thinner.
When using a cleaning agent, follow the manufacturer's instructions for use, proper ventilation
and/or use of breathing apparatus.
H2-4
2. Inspect suspension and frame mounting surfaces and spotfaces for flatness. Surface finish
must not exceed 250 (RMS) (medium tool cut).
Surface flatness must be within 0.010 in. (0.254
mm).
3. Clean and dry all capscrews, nuts and washers
as stated in Step 1, above.
NOTE: The use of dry threads in this application

is not recommended. Due to the high tightening
forces required to load these capscrews, dry
threads may cause damage to tools.
Front Suspensions
03/03 H02013
4. Lubricate capscrew threads, capscrew head

seats, washer face, and nut seats with a rust
preventive compound. Approved sources are:
AMERICAN ANTI-RUST GREASE #3-X from

Standard Oil Division of American Oil Company.
RUSTOLENE
Company.
GULF NORUST #3 from Gulf Oil Company.
RUST BAN 326 from Humble Oil Company.
1973 RUSTPROOF from the Texas Company.
RUST PREVENTIVE GREASE-CODE 312 from

the Southwest Grease and Oil Company.
grease
from
Sinclair
Oil
NOTE: If none of the rust preventive greases listed

above are available for field assembly, use one of the
following lubricants:
SAE 30 weight oil.
5% Molybdenum - Disulphide Grease
1. Hardened Flat
Washer
High tightening force is required to load front

suspension mounting capscrews. Repeated
tightening operations will cause capscrew material to fatigue and break. DO NOT reuse mounting
hardware (capscrews, hardened washers, and
nuts) more than twice after original installation (3
total- see NOTE below). Replace capscrews,
washers and nuts after third use.
NOTE: The following method is suggested to control
the "3 - Use" maximum:
Punch mark the capscrew heads with a center punch
after each tightening as follows:
Initial Installation . . . . . . . . . . . No punch marks.

Second Installation . . . . . . . . . One punch mark.
Third Installation . . . . . . . . . . Two punch marks.
Suspension mounting capscrews are specially

hardened bolts to meet or exceed Grade 8
specifications. Replace only with bolts of correct
hardness. Refer to the Komatsu Parts Catalog for
correct part number. Before installation, inspect each
capscrew for any defects and number of punch
marks. Replace capscrew and related hardware if
two punch marks are evident; do not reuse if any
defect is suspected. Hardware showing signs of rust,
corrosion, galling or local yielding on any seat or
thread surfaces should be replaced. Replace all
suspension mounting hardware, if the truck was
operated with the suspension mounting in a loose
joint condition.
H02013 03/03
FIGURE 2-4. INSTALLATION OF HARDENED FLAT

WASHER
2. Capscrew
NOTE: Special hardened flat washers are punched

during the manufacturing process, therefore when
used under the capscrew head they must be
assembled with the inside diameter radius of the hole
toward the head (punch lip away from head) to
prevent damage to the fillet between capscrew head
and shank. See illustration above.
5. Attach fork truck or lifting device to suspension
and mount suspension to the truck frame making certain shear bar (5, Figure 2-3) is flush with
end of suspension keyway. Install fourteen capscrews (1, 6, 8) with hardened washers and
nuts. (A flatwasher is used under each capscrew head and each nut.) The four bottom
holes tapped into suspension housing require
capscrews (6) with hardened washers, and
spacers (9) only.
6. The capscrews are now ready for tightening
using the "turn-of-the-nut" Tightening Procedure
described on the following page.
NOTE: The "turn-of-the-nut" tightening procedure
was developed for high strength capscrews (grade 8
or better) in this joint application only. Do not use this
tightening method for other joint types or capscrews
of lesser grade/size.
Front Suspensions
H2-5
1.) Mark a reference line on a corner of the

hexagonal capscrew head or nut and the
mounting surface opposite this corner as
shown. Then mark the position located
60 or 120 clockwise relative to the first
reference line on the mounting surface.
Refer to Figures 2-5 and 2-6.
"Turn-Of-The-Nut" Tightening Procedure

a. Tighten all fourteen capscrews (1, 6, 8, Figure 2-3) to 400 40 ft.lbs. (542 5 N.m)
torque. Use a torque wrench of known calibration.
b. Maintain this torque on the top two corner
capscrews and the bottom outer four capscrews (item 8, the 4 bottom capscrews with
nuts).
2.) To insure that the opposite end of the

turning member, either the capscrew
head or nut remains stationary, scribe a
reference mark for this check.
c. Loosen the 8 remaining capscrews and then

tighten again using "turn-of-the-nut" tightening procedure as follows:
3.) Each corner of a hexagon represents 60.

The turning member, either the capscrew
head or nut, is turned until the marked
corner is adjacent with the marked reference line. Ensure that the opposite end of
the turning member has NOT turned during the tightening procedure.
d. For the four, 6.0 in. (15 cm) long capscrews

(1, Figure 2-3) at the upper mount, tighten
capscrews initially to 70 ft. lbs. (95 N.m)
torque; then advance capscrew head 60
using steps d-1.) through d-3.). Refer to Figure 2-5.
NOTE: Do not exceed 4 RPM tightening

speed. Do not hammer or jerk wrench
during the tightening procedure.
e. Loosen the top two corner capscrews (1)
and the bottom outer four capscrews (8, the
4 bottom capscrews with nuts).
1.) Tighten the top, two corner 6.0 in. (15 cm)
capscrews to 70 ft. lbs. (95 N.m) torque,
then use "turn-of-the-nut" method to
advance capscrew heads 60.
FIGURE 2-5. REFERENCE MARKS FOR 60

DEGREE ADVANCE
2.) Tighten the bottom, outer four 14.0 in. (36

cm) capscrews to 200 ft. lbs. (271 N.m)
torque, then use "turn-of-the-nut" method
to advance capscrew heads 120.
(6.0 in. (15 cm) Capscrews)

For the four inner, 14.0 in. (36 cm) long
capscrews (6, Figure 2-3), tighten capscrews initially to 100 ft. lbs. (136 N.m)
torque; then advance capscrew head 120
using steps d-1) through d-3). Refer to Figure 2-6.
NOTE: If for any reason, these fasteners need to be

checked for tightness after completing the above
procedure; loosen and inspect all 14 capscrews and
repeat entire process, starting with cleaning and
lubricating capscrews, washers, and nuts. In
addition, the capscrew head will need to be
appropriately marked to show an additional use.
7. Charge suspension with dry nitrogen to fully
extend suspension piston before installing front
wheel hub and spindle.
8. Install wheel, spindle, and tire according to
instructions in Section G.
FIGURE 2-6. REFERENCE MARKS FOR 120

DEGREE ADVANCE
14.0 in. (36 mm) Capscrews
H2-6
9. Service the suspension. For instructions refer to

Section H, Oiling and Charging Procedures.
10. Install suspension boot and secure with clamp.
Front Suspensions
03/03 H02013
MINOR REPAIRS (LOWER BEARING &

SEALS)
Removal - Bearing Retainer
If only rod wiper, rod seals, bearing, O-ring and
backup rings are to be replaced, refer to steps below
for lower bearing retainer removal.
1. Remove lower bearing retainer capscrews and
hardened washers (20 & 21, Figure 2-6). Install
pusher bolts into tapped holes in retainer
flange.
2. Tighten pusher bolts evenly and prepare to support bearing retainer as it exits the suspension
housing. Remove retainer assembly (18).
3. 3. Remove wiper (29), rod seal (28), step seal
(27), O-ring (22), backup ring (23) and lower
bearing insert (24).
Installation - Bearing Retainer

1. Install new rod seal (28), step seal (27) and rod
wiper (29).
When installing backup rings with rod seal (28)

and step seal (27), be certain radius is positioned
toward the seal and the white dot is positioned
away from the seal as shown in Figure 2-8.
2. Install new O-rings (22) and backup rings (23)
in their appropriate grooves in the lower bearing
retainer (18). Install new bearing (24).
NOTE: Backup rings must be positioned toward the
flange of bearing retainer as shown in Figure 2-9.
3. Install temporary, guide bolts to ensure bolt hole
alignment as bearing retainer is seated. Lift
lower bearing retainer (18) assembly into place
and carefully start into suspension housing.
4. Install capscrews and hardened washers (20 &
21). Tighten capscrews to 500 ft. lbs. (678
N.m) torque.
5. Install wheel, tire and spindle assembly. Refer
to Section G for installation instructions.
H02013 03/03
FIGURE 2-7. PISTON ROD REMOVAL

1. Capscrew
3. Capscrew
5. Upper Bearing
Retainer
6. Housing
7. Piston
8. Mounting Holes
Front Suspensions
9. Steel Ball (2 each)

10. Roll Pin
11. Nut
12. Piston Stop
13. Key
14. Upper Bearing
15. O-Ring & Backup
Ring
16. Cap Structure
H2-7
FIGURE 2-8. FRONT SUSPENSION

1. Housing
2. Cap Structure
3. Capscrew
4. Hardened Washer
5. O-Ring
6. Backup Ring
7. Capscrew
8. Hardened Washer
9. Charging Valve Assy.
10. Vent Plug
11. Plug (Pressure Sensor Port)
12. Upper Bearing
Retainer
13. Piston Stop
14. Nut
15. Roll Pin
H2-8
Front Suspensions
16. Steel Check Ball

17. Piston
18. Lower Bearing
Retainer
19. Plug
20. Capscrew
21. Hardened Washer
22. O-Ring
23. Backup Ring
24. Lower Bearing
25. Key
26. Upper Bearing
27. Step Seal
28. Rod Seal
29. Rod Wiper
03/03 H02013
MAJOR SUSPENSION REBUILD

Disassembly
NOTE: Refer to your Komatsu distributor for
HydrairII repair information and instructions not
covered in this manual.
1. With suspension held in a vertical position (end
cap up), remove capscrews (1, Figure 2-7) and
hardened washers (2). Attach hoist to end cap
structure (16) and lift end cap out of suspension
housing (6) until piston stop (12) contacts upper
bearing retainer (5). Remove capscrews (3)
and hardened washers (4). Lift cap structure
and bearing from housing.
2. Remove roll pin (10), nut (11), piston stop (12)
and key (13). Separate cap and bearing.
Remove O-rings and backup rings (15).
Remove bearing (14).
When installing backup rings with rod seal (28)

and step seal (27), be certain radius is positioned
toward the seal and the white dot is positioned
away from the seal as shown in Figure 2-8.
2. Install new O-rings (22) and backup rings (23)
in their appropriate grooves in the bearing
retainer (18).
NOTE: Backup rings must be positioned toward
bearing retainer bolt flange as shown in Figure 2-9.
3. Rotate the suspension 180.

NOTE: Steel balls (9) will fall free when the housing
is rotated.
4. Attach lifting device to the piston (7) and carefully lift out of housing.
5. Remove capscrews and washers (20 & 21, Figure 2-8). Install pusher bolts and remove lower
bearing retainer (18).
6. Remove and discard rod seal (28) step seal
(27) and rod wiper (29). Remove and discard Orings (22) and backup rings (23). Remove lower
bearing (24).
FIGURE 2-9. BACK-UP RING REPLACEMENT
Assembly
NOTE: All parts must be completely dry and free of
foreign material. Lubricate all interior parts with clean
Hydrair suspension oil. Refer to the Oil and
Nitrogen Specifications Chart in Section H, Oiling
and Charging Procedures.
Use care not to damage the machined or plated
surfaces, O-rings or seals when installing piston
assembly.
1. Install new rod seal (28, Figure 2-8), step seal
(27), and rod wiper (29).
H02013 03/03
3. Install lower bearing (18) into lubricated suspension housing. Install capscrews and hardened lockwashers (20 & 21) through bearing
flange and into tapped holes in housing. Tighten
4. Install new backup rings and O-rings (15, Figure 2-7) in end cap grooves. Backup rings must
be positioned toward the flange on the end cap.
5. Install new bearing (14) on upper bearing
retainer (5).
6. Slide upper bearing retainer assembly over cap
structure rod (16).
Front Suspensions
H2-9
7. Install key (13) and piston stop (12) on cap

structure rod. Make sure piston stop is fully
seated against the rod shoulder. Install locknut
(11) against piston stop. Tighten locknut one
half turn further, until hole for the roll pin (10) is
in alignment. Install roll pin.
10. Apply a light coating of petroleum jelly to the

seals, wiper and bearings. With suspension
housing in a vertical position, carefully lower the
piston rod and end cap assembly into the bore
of the cylinder housing to its fully retracted position
8. Attach a lifting device to top side of end cap

assembly. Lower assembly down on piston (7).
Insert steel balls (9) in holes in piston prior to
fully seating bearing on top of piston. A small
amount of petroleum jelly will prevent the balls
from dropping out during assembly.
11. Install capscrews and hardened washers (1 & 2)

and tighten to 500 ft. lbs. (678 N.m) torque.
9. Install upper bearing retainer (5) onto piston

rod. Secure bearing in place with new capscrews (3) and hardened washers (4). Tighten
capscrews to 500 ft. lbs. (678 N.m) torque.
NOTE: Always use new capscrews (3, Figure 2-7)
during assembly. Used capscrews will be stressed
and fatigued because of loads imposed on these
capscrews during operation.
H2-10
12. Install bottom plug (19, Figure 2-8) and tighten

to 13 ft. lbs. (17.5 N.m) torque.
NOTE: If suspension is to be stored, put in two pints
(1.0 l) of a rust preventive oil. This oil must be
drained when suspension is put into service.
13. Install charging valve and new O-ring (5, Figure
2-1). Lubricate O-rings with clean Hydrair oil
before threading into end cap. Tighten large hex
of charging valve to 16.5 ft. lbs. (27.4 N.m)
torque.
Front Suspensions
03/03 H02013
SECTION H3
REAR SUSPENSIONS
INDEX
REAR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Installation - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
Disassembly - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6
Cleaning and Inspection - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6
Assembly - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6
H03013 3/03
Rear Suspensions
H3-1
NOTES
H3-2
Rear Suspensions
3/03 H03013
REAR SUSPENSIONS
The Hydrair II suspensions are hydro-pneumatic
components containing oil and nitrogen gas. The oil
and gas in the four suspensions carry the gross truck
weight less wheels, spindles and final drive assembly. The rear suspension cylinders consist of two
basic components; a suspension housing attached to
the rear axle housing, and a suspension rod attached
to the frame.
Removal
The Hydrair II suspension cylinder requires only

normal care when handling as a unit. However, after
being disassembled these parts must be handled
with extreme care to prevent damage to the
machined surfaces. Surfaces are machined to
extremely close tolerances and are precisely fitted.
All parts must be completely clean during assembly.
TABLE 1. TOOL LIST FOR SUSPENSION PIN

REMOVAL
Part Number
Description
Quantity
EJ2847
Pin Removal Tool
EJ2848
Cylinder
EJ2849
Hand Pump
EJ2850
Shackle
MM0093
Capscrew
(M16 x 2 x 70 mm)
NOTE: Suspension mounting pins must contain

threaded holes at the inboard end of each pin in
order to use the removal tools listed above. If the
pins do not contain the necessary holes, new pins
may be purchased, or a rework of the pins is
necessary. Refer to Figure 3-4 for pin rework details.
1. Remove capscrews, washers, and shield (2,
Figure 3-1) from the suspension.
FIGURE 3-2. CHARGING VALVE

FIGURE 3-1. REAR SUSPENSION INSTALLATION
1. Mounting Pins
2. Piston Rod Shield
H03013 3/03
3. Suspension Cylinder
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
Rear Suspensions
6. Valve Body
7. O-Ring
8. Valve Stem
9. O-Ring
H3-3
2. Remove charging valve cap, (1, Figure 3-2)

loosen small hex (4) on charging valve and
turn counterclockwise three full turns to unseat
valve seal. Connect suspension charging kit.
Make certain only the swivel nut turns. Turning

the complete charging valve assembly may result
in the valve assembly being forced out of the
suspension by the gas pressure inside.
3. If necessary, charge the suspension to be
removed with dry nitrogen until the rod is
exposed approximately 5.0 in. (127 mm).
4. Place stands or cribbing under the truck frame
at each hoist cylinder mount.
5. Open valve on suspension charging kit to
release nitrogen from the suspension. Disconnect charging kit.
6. Disconnect lubrication lines. Disconnect pressure sensor cable.
FIGURE 3-3. SUSPENSION MOUNTING PIN

Typical, top & bottom
1. Pin
2. Retainer Capscrew
3. Locknut
4. Bearing Spacer
5. Retainer Ring
7. Position a fork lift under the suspension housing, above the lower mounting pin. Secure suspension to fork lift.
The rear HydrairII suspension weighs approximately 2,470 pounds (1120 kg.). Be certain the
capacity of the lifting device used is sufficient for
lifting this load.
NOTE: The mounting arrangement for the top and
bottom pins is identical.
8. Remove locking capscrew (4, Figure 3-4) from
the lower suspension pin that is to be removed.
The locking capscrew on the remaining cylinder
must remain installed.
6. Bearing
7. Capscrew
8. Washer
9. Sleeve
12. Apply pressure to the cylinder using the hand

pump (not shown).
Do not exceed 10 tons of force when applying

pressure to the cylinder. Damage to the tool or
suspension components may result, as well as
personal injury to maintenance personnel.
9. Install pin removal tool (1) to each lower pin

using the capscrews listed in Table 1. Tighten
the capscrews to a torque of 177 17 ft.lbs
(240 24 Nm).
10. Attach both shackles (2) to cylinder (3).
11. Attach each shackle to pin removal tools (1), as
shown above.
FIGURE 3-4. REAR SUSPENSION

PIN REMOVAL TOOL
1. Pin Removal Tool
3. Cylinder
2. Shackle
4. Locking Capscrew
H3-4
Rear Suspensions
3/03 H03013
13. When the cylinder reaches the end of its stroke,

remove one of the shackles from the cylinder
and connect the cylinder shackle directly to the
pin removal tool. This is necessary to pull the
pin the remaining distance.
14. Remove the pin from the lower mounting.
15. Install the tool on the upper pin and repeat the
pin removal process. (If the pin does not contain
the necessary puller holes, an alternative
removal method is needed.)
16. Remove the cylinder from the truck.
17. If it is necessary to remove the remaining rear
suspension cylinder, insert the pins back into
the upper and lower mountings.
18. Secure the pins using locking capscrews (4),
and repeat the removal process.
Installation - Rear Suspension

1. Inspect mounting bore sleeves (9, Figure 3-3)
and bearing spacers for damage or wear.
Check fit of pins in bores prior to installing suspension. Replace worn or damaged parts.
2. As noted earlier, all pins must have 2 threaded
holes at the inboard ends of the pin for future
pin removal tool usage. Install new pins or
rework the existing pins per Figure 3-5.
3. Secure suspension to fork lift and raise into
position. (Suspension assembly should be
retracted as far as possible prior to installation.)
4. Position top suspension eye with its spherical
bearing, between the ears on the frame as
shown in Figure 3-3. Be certain the upper and
lower mounting eyes are aligned and the vent
plugs are positioned to the rear.
5. Lubricate all pin to bearing and pin to sleeve
contact surfaces with Anti-Seize. Lubricating
the pin surfaces aids in removal and installation,
as well as prevention of rust and corrosion.
6. Align the retaining capscrew hole in pin (1, Figure 3-3) with the hole in the mounting bore.
Drive in far enough to hold pin in position.
7. Insert spacer (4) and continue to drive the pin in
through the spherical bearing. Insert the
remaining spacer and continue to drive the pin
in until the retaining capscrew hole is aligned
with the hole in the pin.
8. Install capscrew (2) and locknut (3). Tighten to
343 ft. lbs. (465 N.m) torque. If further alignment of the capscrew and hole are necessary,
install a pin removal tool onto the pin. Use the
tool in conjunction with a large pipe wrench or
other suitable device to align the locking capscrew holes.
9. Lower the suspension housing until the lower
mount bearing aligns with the bore in the rear
axle housing and repeat the above procedure to
install the bottom pin. Mounting components in
the top and bottom joints are identical.
FIGURE 3-5. SUSPENSION PIN REWORK
10. Install the nitrogen charging kit and add nitrogen

to raise frame off stands or cribbing, or use a
lifting device if available.
11. Connect lubrication lines and pressure sensor.
12. Service the suspension. For instructions, refer
to Section H, Oiling and Charging Procedures.
13. Install piston rod shield (2, Figure 3-1) with the
capscrews, flat washers, and lockwashers.
H03013 3/03
Rear Suspensions
H3-5
Disassembly - Rear Suspension

NOTE: The suspension should be placed in a fixture
which will allow it to be rotated 180 vertically.
1. Depress charging valve stem to insure all nitrogen gas pressure has been released prior to
removing charging valve. Wear face mask or
goggles while relieving nitrogen gas.
2. Remove charging valve cover. Remove charging valve (12, Figure 3-6). Remove and discard
charging valve O-ring. Remove vent plug (14).
3. Remove protective shields (8), if installed.
Place the suspension in a vertical position (piston rod down), and drain the suspension oil
through the vent port. A properly charged rear
suspension cylinder contains 10.2 gallons (39 l)
of oil.
4. Rotate the suspension 180. Remove socket
head capscrews (18) and pull piston assembly
(5) from housing (1). The housing bearing (21)
will be removed with the piston assembly.
5. Remove capscrew and hardened washers (2 &
3). Remove piston bearing (4) from piston rod.
Remove ball checks (22) from piston. Slide the
housing bearing (21) off of the piston.
6. Remove and discard wiper seal (15), rod seal
(16), step seal (17), O-ring (20), and backup
ring (19) from housing bearing.
7. Remove vent plug (7).
8. If the spherical bearings (6, Figure 3-3) require
replacement, remove the retainer rings (5).
Press bearing out of bore.
Cleaning and Inspection - Rear Suspension
1. Clean all parts thoroughly in fresh cleaning solvent. Use a solvent that does not leave a film
after evaporation, such as trichlorethylene, acetone or laquer thinner.
NOTE: If other repairs are necessary, refer to your

local Komatsu distributor for repair information and
instructions not covered in this manual.
Assembly - Rear Suspension
Assembly must be accomplished in a clean, dust free
work area. All parts must be completely clean, dry
and free of rust or scale. Lubricate all interior parts
and bores with fresh suspension oil. Refer to the Oil
and Nitrogen Specifications Chart in Section H, Oiling and Charging Procedures.
1. Install spherical bearings (6, Figure 3-3) in the
eyes of the piston rod and cylinder housing.
2. Place the ring retainers (5) in position to secure
the bearings.
3. Install the piston rod vent plug (7, Figure 3-6).
4. Install the wiper seal (15), rod seal (16), and
step seal (17). When installing backup rings
with rod seal (16) and step seal (17), be certain radius is positioned toward the seal and
the white dot is positioned away from the
seal as shown in Figure 3-6.
5. Install O-ring (20) and backup ring (19) on the
bearing (21). Backup rings must be positioned
toward the flange of the bearing.
6. Slide the bearing (21) onto the lubricated piston
rod (5).
7. Place the ball checks (22) in the piston and
install the piston rod bearing (4) with the capscrews and hardened washers (2 & 3). Tighten
the capscrews to standard torque.
8. With the lubricated housing (1) held in a vertical
position, slide the piston assembly part way into
the housing. Slide the loose housing bearing
down onto the housing and fasten with socket
head capscrews (18). Tighten the capscrews to
standard torque. Use care during piston installation to prevent damage to machined and
chrome surfaces.
9. Install vent plugs (11 & 14). Install shield (8).
When using cleaning agents follow the solvent

manufacturer's instructions.
NOTE: If suspension is to be stored, put in two pints

(1.0 l) of a rust preventive oil. This oil must be
drained when suspension is put into service.
2. Dry all parts completely using only dry, filtered

compressed air and lint free wiping materials.
10. Using new O-ring, install charging valve.

Tighten large hex of charging valve to 16.5
ft.lbs. (22.4 N.m) torque.
3. Inspect all parts for evidence of wear or damage. Inspect plated surfaces for scratches,
nicks or other defects. Replace or repair any
damaged parts.
H3-6
Rear Suspensions
3/03 H03013
1. Housing
2. Capscrews
3. Hardened Flatwashers
4. Piston Bearing
5. Piston Rod
6. Bleeder Screw
7. Vent Plug
8. Shield
9. Capscrew
10. Washers
11. Vent Plug
12. Charging Valve
13. Plug (Sensor)
14. Vent Plug
15. Wiper Seal
16. Rod Seal
17. Step Seal
18. Socket Head
Capscrew
19. Backup Ring
(See Note)
20. O-Ring
21. Housing Bearing
22. Ball Check
FIGURE 3-6. REAR SUSPENSION ASSEMBLY
H03013 3/03
Rear Suspensions
H3-7
NOTES
H3-8
Rear Suspensions
3/03 H03013
SECTION H4
SUSPENSION OILING AND CHARGING PROCEDURE
INDEX
SUSPENSION OILING AND CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
EQUIPMENT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
Hydrair Charging Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
Installation of Charging Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
Removal of Charging Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-4
Support Blocks For Oiling And Charging Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-4
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-5
Front Suspension Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-5
Front Suspension Nitrogen Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-6
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-7
Rear Suspension Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-7
Rear Suspension Nitrogen Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-8
OIL AND NITROGEN SPECIFICATIONS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-10
H04015 10/03
Oiling and Charging Procedures
H4-1
NOTES
H4-2
10/03 H04015
SUSPENSION OILING AND CHARGING PROCEDURE

GENERAL
EQUIPMENT LIST
These procedures cover the oiling and charging of

HydrairII suspensions on Komatsu 930E dump
trucks.
Hydrair Charging Kit
Jacks and/or Overhead Crane
Support Blocks (Front and Rear) for:

Oiling Height Dimensions
Nitrogen Charging Height Dimensions
Hydrair Oil (See Specifications Chart)
Friction Modifier (See Specifications Chart)
Dry Nitrogen (See Specifications Chart)
Suspensions which have been properly charged will

provide improved handling and ride characteristics
while also extending the fatigue life of the truck frame
and improving tire wear.
NOTE: Inflation pressures and exposed piston
lengths are calculated for a normal truck gross
vehicle weight (GVW). Additions to truck weight by
adding body liners, tailgates, water tanks, etc. should
be considered part of the payload. Keeping the truck
GVW within the specification shown on the Grade/
Speed Retard chart in the operator cab will extend
the service life of the truck main frame and allow the
HydrairII suspensions to produce a comfortable
ride.
Hydrair Charging Kit

Assemble service kit as shown in Figure 4-1 and
attach to container of pure dry nitrogen (8).
Installation of Charging Kit
1. Remove protective covers and charging valve
caps from suspensions to be charged.
2. Turn "T" handles (1, Figure 4-1) of adapters (2)
completely counterclockwise.
All HydrairII suspensions are charged with compressed nitrogen gas with sufficient pressure to
cause injury and/or damage if improperly handled. Follow all safety instructions, cautions, and
warnings provided in the following procedures to
prevent any accidents during oiling and charging.
Proper charging of HydrairII suspensions requires
that three basic conditions be established in the following order:
1. Oil level must be correct.
2. Suspension piston rod extension for nitrogen
charging must be correct.
3. Nitrogen charge pressure must be correct.
For best results, Hydrair II suspensions should be
charged in pairs (fronts together and rears together).
If rears are to be charged, the fronts should be
charged first.
NOTE: For longer life of suspension components, a
friction modifier should be added to the suspension
oil. See Specifications Chart, Figure 4-5 at the end of
this chapter.
NOTE: Set up dimensions specified in the charts
must be maintained during oiling and charging
procedures. However, after the truck has been
operated, these dimensions may vary.
H04015 10/03
FIGURE 4-1. HYDRAIR CHARGING KIT

NOTE: Arrangement of parts may vary from
illustration above, depending on charging kit P/N.
1. T Handle Valve
2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas (Specifications Figure 4-5)
H4-3
3. Ensure outlet valves (3) and inlet valve (4) are

closed (turned completely clockwise).
4. Turn swivel nut (small hex) on charging valve
three full turns counterclockwise to unseat the
valve.
5. Attach charging valve adapters (2) to each suspension charging valve stem.
Support Blocks For Oiling And Charging

Dimensions
Prior to starting oiling and charging procedures, supports should be fabricated which will maintain the
correct exposed piston rod extensions.
6. Turn "T" handles (1) clockwise (this will depress

core of charging valve and open the gas chamber of the suspension).
7. Open both outlet valves (3).
NOTE: By selective opening and closing of outlet
valves (3), and inlet valve (4), suspensions may be
charged separately or together.
Removal of Charging Kit
1. Close both outlet valves (3).
2. Turn "T" handles (1) counterclockwise to
release charging valve cores.
3. Remove charging valve adapters (2) from
charging valves.
4. Tighten swivel nut (small hex) on charging
valve. If a new charging valve is being used,
tighten swivel nut to 10.5 ft. lbs. (14.2 N.m)
torque, then loosen and retighten swivel nut to
10.5 ft. lbs. (14.2 N.m) torque. Again loosen
swivel nut and retighten to 4 ft. lbs. (5.4 N.m)
torque. Replace valve cap (1) and tighten to 2.5
ft. lbs. (3.3 N.m) torque (finger tight).
5. Install charging valve caps and protective covers on both suspensions.
H4-4
Rear support blocks for nitrogen charging are no

longer necessary. Rear suspensions still require
support blocks for oil charging.
Exposed piston rod extensions are specified for both
oil level and nitrogen charging for HydrairII suspensions. These dimensions are listed in the tables
below Figures 4-2 and 4-4. Measure dimensions
from the face of the cylinder gland to the machined
surface on the spindle at the front suspension. Measure from the face of the cylinder gland to the piston
flange at the rear suspension.
Support blocks may be made in various forms. Mild
steel materials are recommended. Square stock or
pipe segments [1 in. (25 mm) minimum] may be
used. Blocks must be capable of supporting the
weight of the truck during oiling and charging procedures while avoiding contact with plated surfaces
and seals on the suspension. Refer to Figure 4-2 for
front suspension support block placement and Figure
4-4 for rear support block placement.
10/03 H04015
FRONT SUSPENSION
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the
wheels.
2. Thoroughly clean area around the charging
valve on the suspensions. Remove the protective covers from the charging valves.
All HydrairII suspensions are charged with compressed nitrogen gas with sufficient pressure to
cause injury and/or damage if improperly handled. Follow all the safety notes, cautions and
warnings in these procedures to prevent accidents during servicing and charging.
2. Remove charging valve cap. Turn the charging

valve swivel nut (small hex) counterclockwise
three full turns to unseat valve seal. DO NOT
turn the large hex. The charging valve body
has a bleeder groove in its mounting threads,
but for safety of all personnel the valve body
must not be loosened until all nitrogen pressure has been vented from the suspension.
3. Depress the charging valve core to release
nitrogen pressure from the suspension. When
all nitrogen has been vented to the atmosphere,
the suspension should have collapsed slowly
and be seated solidly on the support blocks.
Remove top fill plug next to the charging valve
(Figure 4-2).
Front Suspension Oiling
When blocks are in place on a suspension, they

must be secured with a strap or other means to
avoid accidental discharge. An unsecured block
could fly loose as weight is applied, presenting
the possibility of serious injury to nearby personnel and/or damage to the equipment. Overhead
clearance may be reduced rapidly and suddenly
when nitrogen pressure is released!
friction modifier should be added to the suspension
oil. See the Oil and Nitrogen Specifications Chart,
Figure 4-5, at the end of this chapter.
1. Position and secure oiling height dimension
blocks in place (Figure 4-2). When nitrogen
pressure is released, suspensions will lower
and rest on the blocks. Ensure the blocks do
not mar or scratch the plated surfaces of the
pistons or damage wiper seals in the lower
bearing retainer. Support blocks must seat on
the spindle and the cylinder housing. The
blocks should be positioned 180 apart to provide stability.
Wear a face mask or goggles while relieving

nitrogen pressure.
H04015 10/03
FIGURE 4-2. FRONT SUSPENSION

FRONT SUSPENSION DIMENSIONS (EMPTY)
TRUCK MODEL
& OPTIONS
OILING
HEIGHT
In. (mm)
CHARGING
HEIGHT
In. (mm)
CHARGING
PRESSURE
psi (kPa)
930E-1*
1.0 (25.4)
9.0 (229)
440 (3034)
930E-2*
930E-3*
1.0 (25.4)
9.0 (229)
425 (2930)
* with standard Rock Body

Note: If truck starts to lift off blocks before charging pressure
is attained, STOP CHARGING.
H4-5
4. Fill the suspension with clean Hydrair oil (with

6% friction modifier) until the cylinder is full to
the top of the fill plug bore. Drip pans should be
used and all spillage cleaned from outside of
the suspension. Allow the suspension to stand
for at least 15 minutes to clear any trapped
nitrogen and/or bubbles from the oil. Add more
suspension oil if necessary. Install a new fill
plug O-ring, and install the plug.
Front Suspension Nitrogen Charging
2. Tighten valve body (large hex, 6) to 16.5 ft. lbs.

(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated by turning counterclockwise three full turns.
Dry nitrogen is the only gas approved for use in

HydrairII suspensions. Charging of these components with oxygen or other gases may result in
an explosion which could cause fatalities, serious injuries and/or major property damage. Use
only nitrogen gas meeting the specifications
shown in chart (Figure 4-5).
3. Install the Hydrair charging kit and a bottle of
pure dry nitrogen. Refer to Installation of Charging Kit in this section.
Lifting equipment (crane or hydraulic jacks) must

be of sufficient capacity to lift the truck weight.
Be certain that all personnel are clear of lift area
before lift is started. Clearances under the truck
may be suddenly reduced.
1. If removed, install the charging valve with new
O-ring (9, Figure 4-3). Lubricate the O-ring with
clean Hydrairoil.
4. Charge the suspensions with nitrogen gas to 2

in. (50.8 mm) greater than the charging height
listed in Figure 4-2. Close inlet valve (4, Figure
4-1).
5. Remove the oiling blocks from the suspensions
and install the nitrogen charging blocks. Secure
the blocks to prevent accidental dislodging.
NOTE: Use caution to prevent damage to plated cylinder surfaces and oil seals when installing the
blocks.
6. Remove the center hose from manifold (6).
7. Open inlet valve (4) until the pressure has
dropped below the pressure listed in Figure 4-2,
and then close the valve.
8. Install the center hose to manifold (6).
9. Charge the suspensions to the pressure listed
in Figure 4-2. Do Not use an overcharge of
nitrogen to lift the suspensions off of the charging blocks.
10. Close inlet valve (4, Figure 4-1). Leave outlet
valves (3) open for five minutes in order to allow
the pressures in the suspensions to equalize.
11. Close outlet valves (3) and remove charging kit
components. Refer to Removal of Charging Kit.

1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
H4-6
6. Valve Body
7. O-Ring
8. Valve Stem
9. O-Ring
12. If charging valve is being reused, tighten swivel

nut (4, Figure 4-3) to 4 ft. lbs. (5.4 N.m) torque.
13. If a new charging valve is being used, tighten
swivel nut to 10.5 ft. lbs. (14.2 N.m) torque,
then loosen and retighten swivel nut to 10.5 ft.
lbs. (14.2 N.m) torque. Again loosen swivel nut
and retighten to 4 ft. lbs. (5.4 N.m) torque.
Replace valve cap (1) and tighten to 2.5 ft. lbs.
(3.3 N.m) torque (finger tight).
10/03 H04015
14. Install the protective guard over the charging

valve.
15. Raise the truck body in order to extend the front
suspensions and allow for removal of the nitrogen charging blocks. Ensure that sufficient
overhead clearance exists before raising the
body. If the suspensions do not extend after
raising the body, turn the steering wheel from
stop to stop several times. If the suspensions
still do not extend enough to allow for removal
of the blocks, use a crane or floor jacks to raise
the truck and remove the blocks.
The front Hydrair suspensions are now ready for
operation. Visually check the extension with the truck
both empty and loaded. Record the extension dimensions. Maximum downward travel is indicated by the
dirt ring at the base of the piston. Operator comments on steering response and suspension rebound
should also be noted.
REAR SUSPENSION
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the
wheels.
2. Thoroughly clean the area around the charging
valve on the suspensions. Remove the protective covers from the charging valves and the
metal covers from the suspension piston.
When the blocks are in place on a suspension,

they must be secured in place with a strap or
other means to insure the blocks staying in place
while being used. An unsecured block could fly
loose as weight is applied, presenting the possibility of serious injury and/or damage.
friction modifier must be added to the suspension oil.
See the Oil and Nitrogen Specifications Chart, Figure
4-5, at the end of this chapter.
Rear Suspension Oiling

1. If the suspensions are extended, position and
secure oiling height dimension blocks (supports) in place (See Figure 4-4) so the blocks
are seated between the piston flange and the
cylinder housing. Ensure the blocks do not mar
or scratch the plated surfaces on the piston or
damage the wiper seals in the cylinder barrel.
Support blocks must seat on the piston flange
and the cylinder housing. The blocks should be
positioned 180 apart to provide stability.
Make certain all personnel are clear and support

blocks are secure before relieving nitrogen pressure from the suspension. Use a face mask or
goggles when venting nitrogen.
2. Remove charging valve cap. Turn the charging
valve swivel nut (small hex) counterclockwise
three full turns to unseat valve seal. DO NOT
turn the large hex. The charging valve body
has a bleeder groove in its mounting threads,
but for safety of all personnel, the valve body
must not be loosened until all nitrogen pressure has been vented from the suspension.
H04015 10/03
H4-7
3. Depress the charging valve core to release

nitrogen pressure from the suspension. When
nitrogen pressure has been vented to the atmosphere, loosen and remove the fill plug. The
suspension should have collapsed slowly as
gas pressure was released. Truck weight is now
supported by the support blocks.
4. Use a plastic tube to help bleed off trapped air
inside the piston. Remove vent plugs and the
bleeder screw. Fill the suspension with clean
Hydrair oil (with 6% friction modifier) until
clean oil comes out of the port where the
bleeder screw and plug were removed from the
side of the housing. Drip pans should be used
and all spillage cleaned from the outside of the
suspension. Install the bleeder and vent plugs.
Continue to fill the oil until it reaches the fill port.
Allow the suspension to stand for at least 15
minutes to clear any trapped nitrogen and/or air
bubbles from the oil. Add oil if necessary, and
install the fill plug.
Rear Suspension Nitrogen Charging
Lifting equipment (overhead or mobile cranes, or

hydraulic jacks) must be of sufficient capacity to
lift the truck weight. Be certain that all personnel
are clear of lift area before lift is started. Clearances under the truck may be suddenly reduced.
Ensure the automatic apply circuit has not

applied the service brakes during truck maintenance. If the front brakes are applied during rear
suspension charging, the axle cannot pivot for
frame raising / lowering, and the rear suspension
may be unable to move up or down.
1. If removed, install charging valve with new Oring (9, Figure 4-3). Lubricate the O-ring with
clean Hydrairoil.
2. Tighten valve body (large hex, 6) to 16.5 ft. lbs.
(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated by turning counterclockwise three full turns.
FIGURE 4-4. REAR SUSPENSION

REAR SUSPENSION DIMENSIONS (EMPTY)
TRUCK MODEL
& OPTIONS
930E-1,
930E-2,
930E-3
OILING
HEIGHT
In. (mm)
CHARGING
HEIGHT
In. (mm)
*CHARGING
PRESSURE
psi (kPa)
1.0 (25.4)
7.5 (190)
215 (1482)
Dry nitrogen is the only gas approved for use in

HydrairII suspensions. Charging of these components with oxygen or other gases may result in
an explosion which could cause fatalities, serious injuries and/or major property damage. Use
only nitrogen gas meeting the specifications
shown in chart (Figure 4-5).
3. Install the Hydrair charging kit and a bottle of
pure dry nitrogen. Refer to Installation of Charging Kit in this section.
4. Charge the suspensions with nitrogen gas to 2
in. (50.8 mm) greater than the charging height
listed in Figure 4-4.
5. Slowly release gas until the suspensions match
the charging height listed in Figure 4-4.
* Note: Charging pressures are for reference only and may vary
depending on body weights.
H4-8
10/03 H04015
6. Close inlet valve (4, Figure 4-1). Leave outlet

valves (3) open for five minutes in order to allow
the pressures in the suspensions to equalize.
7. Ensure both of the suspension cylinders are
extended the same distance 10 mm (0.39 in.).
If the difference in the extension from side to
side exceeds 10 mm, check the front suspensions for equal extension. Adjust the front as
necessary.
NOTE: A low left front suspension will cause the right
rear suspension to be high. A low right front
suspension will cause the left rear suspension to be
high.
8. Close outlet valves (3) and remove charging kit
components. Refer to Removal of Charging Kit
in this section.
9. If the charging valve is being reused, tighten
swivel nut (4, Figure 4-3) to 4 ft. lbs. (5.4 N.m)
torque.
H04015 10/03
10. If a new charging valve is being used, tighten

swivel nut to 10.5 ft. lbs. (14.2 N.m) torque,
then loosen and retighten the swivel nut to 10.5
ft. lbs. (14.2 N.m) torque. Again, loosen the
swivel nut and retighten to 4 ft. lbs. (5.4 N.m)
torque. Replace valve cap (1) and tighten to 2.5
ft. lbs. (3.3 N.m) torque (finger tight).
11. Install the protective guards over the charging
valves and install the metal covers over the piston rods.
The rear Hydrair suspensions are now ready for
operation. Visually check piston extension both with
the truck loaded and empty. Record the extension
dimensions. Maximum downward travel is indicated
by the dirt ring at the base of the piston rod. Operator
comments on steering response and suspension
rebound should also be noted.
H4-9
OIL AND NITROGEN SPECIFICATIONS CHART

HYDRAIR II OIL SPECIFICATIONS
Ambient Temperature
Range
-30F & above

(-34.5C & above)
Part No.
Approved Sources
VJ3911
(need to add
6% of
AK3761)
Sunfleet TH Universal Tractor Fluid

Mobil 424
Chevron Tractor Hydraulic Fluid
Mobil D.T.E. 15
Conoco Power Tran III Fluid
Texaco TDH Oil
Petro Canada Duratran Fluid
Amoco Ultimate Motor Oil 5W-30
Shell Canada Donax TDL
AK4063
Suspension Oil (premixed with

6% Friction Modifier)
AK4064
-55F & above

(-48.5C & above)
5 Gallon container
55 Gallon container
VJ5925
(need to add
6% of
AK3761)
Emery 2811, SG-CD,

5W-30
Mobil Delvac I, 5W-30
Petro Canada Super Arctic Motor

Oil, 0W-30
Conoco High Performance
Synthetic Motor Oil, 5W-30
AK4065
Suspension Oil (premixed with

5 Gallon container
AK4066
55 Gallon container
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and VJ5925
oils are supplied in 5 gallon (19 Liter) cans.
OIL CAPACITY OF A PROPERLY CHARGED SUSPENSION CYLINDER

Front
Rear
930E-1
24.3 gallons (92 liters)
930E-2
930E-3
FRICTION MODIFIER
FRICTION MODIFIER Mixing Instructions

(94% Suspension oil, 6% Friction Modifier)
Part Number
Suspension Oil
Amount of Friction Modifier to add
AK3761
(5 Gallon container of
1 gallon of suspension oil
add 7.7 oz.
5 gallons of suspension oil
add 38.4 oz.
55 gallons of suspension oil
add 3.3 gal.
NITROGEN GAS (N2)SPECIFICATIONS

Nitrogen gas used in Hydrair II
Suspension Cylinders must meet or
exceed CGA specification G-10.1 for
Type 1, Grade F Nitrogen Gas
Property
Value
Nitrogen
99.9% Minimum
Water
32 PPM Maximum
Dew Point
-68F (-55C) Maximum
Oxygen
0.1% Maximum
FIGURE 4-5. SPECIFICATIONS CHART
H4-10
10/03 H04015
SECTION J
BRAKE CIRCUIT
INDEX
BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
BRAKE CIRCUIT COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-1
BRAKE CIRCUIT CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-1
WET DISC BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
J01027
Index
J1-1
NOTES
J1-2
Index
J01027
SECTION J2
BRAKE CIRCUIT
INDEX
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3

SERVICE BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
SECONDARY BRAKING AND AUTOMATIC APPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5
PARKING BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5
BRAKE LOCK CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-6
WARNING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-6
Rear Axle Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-8
J02027
Brake Circuit
J2-1
NOTES
J2-2
Brake Circuit
J02027
BRAKE CIRCUIT
The Komatsu truck is equipped with an all-hydraulic
actuated wet disc service brake system. The brake
system utilizes Type C-4 hydraulic oil provided by the
brake/steering pump from the main hydraulic tank for
brake application. Brake disc cooling during truck
operation is provided by the hoist circuit pump
through the hoist valve. A disc type parking brake,
located in the rear axle housing, is attached to each
wheel motor. The fundamental function of the brake
system is to provide an operator the control he needs
to stop the truck in either a slow modulating fashion
or in as short a distance as reasonably possible.
Outlined below are the functions that Komatsu feels
are necessary for safe truck operation:
Warn the operator as soon as practical of a
serious or potentially serious loss of brake
pressure so proper action can be taken to stop
the truck before the secondary system is
exhausted of power.
Provide secondary brake circuits such that any
single failure leaves the truck with sufficient
stopping power.
Automatically apply service brakes if low
pressure warnings are ignored and pressures
continue to decrease.
Wheel brake lock to relieve the operator from
holding the brake pedal while at the dump or
shovel.
Spring applied park brake for holding, not
stopping, the truck during periods other than
loading or dumping.
Brake system that is easy to diagnose and
perform necessary service.
The following brake circuit description should be
used in conjunction with the hydraulic brake system
schematic, refer to Section R.
The brake system consists of several major valve
components; the foot operated dual circuit treadle
valve, hydraulically operated dual relay valves, and
the brake manifold. The dual circuit treadle valve is
the only component located in the operator's cab.
The remainder of the system, including the dual relay
valve for the front brakes, brake manifold, two accumulators, and electrical components, are located in a
weatherproof cabinet (Figure 2-1) behind the cab.
The hydraulic components cabinet is easily accessible for brake system diagnostic and service work.
J02027
The dual relay valve for the rear brakes is located in

the rear axle housing. Two additional accumulators
are mounted on the frame rail, behind the right front
tire.
The brake manifold contains dual circuit isolation
check valves, accumulator bleed down valves, and
valves for brake lock, park brake and automatic apply
functions. All of these components are screw-in cartridge type valves.
In the Komatsu truck, there are two independent
means of brake actuation by the operator; the service
brake pedal and brake lock switch. Additionally, the
brakes will apply automatically if the brake system
supply drops below a predetermined pressure.
SERVICE BRAKE CIRCUIT

This portion of the system provides the operator the
precise control he needs to modulate (feather) brake
pressure to slowly stop the truck or develop full brake
effort to stop as quickly as possible. The heart of this
circuit is the treadle operated, dual circuit brake
valve. This valve enables the operator to control the
relatively high pressure energy within the brake
accumulators directed to the brakes. There are two
valves in the dual brake valve. One supplies pressure to a dual relay valve to provide apply pressure
for the brakes on the front axle. The other supplies
pressure to a dual relay valve to provide apply pressure for the brakes on the rear axle.
As the brake pedal is depressed, each valve within
the dual circuit brake valve simultaneously delivers
fluid from its respective accumulators to the dual
relay valves which deliver fluid to the wheel brakes at
a pressure proportional to both pedal position and
force. The further the pedal is depressed, the higher
the brake force, giving a very positive feel of control.
Brake accumulators have two functions; storing
energy for reserve braking in the event of a failure
and, provide rapid oil flow for good brake response.
Depression of the brake pedal also actuates the stop
light pressure switch, which in turn actuates stop and
service brake indicator lights and propulsion interlock.
Brake Circuit
J2-3
FIGURE 2-1. HYDRAULIC COMPONENTS CABINET

16. Front Brake Accum. Bleed (NVF)
17. Automatic Apply Valve
18. Low Accum. Test Port (LAP1)
19. Rear Brake Accum. Bleed (NVR)
20. Low Brake Pressure Switch
21. Park Brake Pressure Switch
22. Stop Light Pressure Switch
23. Brake Lock Degradation Switch
24. Rear Brake Pressure Test Port (BR)
25. Front Brake Pressure Test Port (BF)
26. Manifold
27. Brake Warning Delay Timer
28. Brake Warning Relay
29. Supply Pressure Test Port
30. Brake Lock Pressure Test Port
1. Rear Brake Accumulator

2. Charging Valve
3. Front Brake Accumulator
4. Charging Valve
5. Relief Valve (Hoist-Power Down)
6. Hoist Pilot Valve
7. Dual Relay Valve
8. Differential Pressure Switch
9. Park Brake Release (Plug Port)
10. Brake Cabinet
11. Brake Lock Shuttle Valve
12. Brake Manifold
13. Pressure Reducing Valve (PR)
14. Brake Lock Solenoid (SV1)
15. Park Brake Solenoid (SV2)
J2-4
Brake Circuit
J02027
SECONDARY BRAKING AND

AUTOMATIC APPLY
Normal Operation (key switch on, engine running)
A fundamental function of the secondary brake system is to provide reserve braking in the event of any
single failure. For this reason, the system is divided
into multiple circuits, each with its own isolation
check valve, two accumulators, and circuit regulator.
The secondary system becomes whatever circuit(s)
is operable after a failure. If the failure is a jammed
treadle valve, then the brake lock becomes the secondary system, otherwise, either of the two brake circuits would be the secondary system.
Parking brake switch ON

The parking brake solenoid (15, Figure 2-1) is
de-energized. The oil pressure in the parking
brake lines return to tank and the springs in
the parking brake will apply the brake. The
parking brake pressure switch (21) will close,
completing a path to ground, and illuminating
the parking brake light on the overhead
display panel.
Parking brake switch OFF
The parking brake solenoid is energized. The
oil flow is routed from the park brake
solenoid, to the park brake calipers for
release. The parking brake circuit is protected
against accidental application by monitoring a
wheel motor speed sensor to determine truck
ground speed. The park brake will not apply
until the truck is virtually stopped. This
eliminates park brake damage and will extend
brake adjustment intervals.
The four brake accumulators perform two functions;

to provide rapid flow for good response and to store
energy for secondary braking. The check valves
assure this energy is retained should a failure occur
in the brake system supply or an accumulator circuit.
An additional check valve located between the supply line from the brake/steering pump and the brake
manifold, provides additional protection against pressure loss if the oil supply is interrupted.
If a failure occurs in the pump, steering or either
brake accumulator circuit, a low brake pressure
warning light (on the overhead display panel in the
cab) and an audible alarm will actuate and the vehicle should be stopped as soon as practical. When
the pressure in one accumulator circuit is less than
the preset level, all the service brakes will be automatically applied. Automatic brake application is
accomplished by the "automatic apply valve" (PS),
located in the brake manifold. This valve senses the
lower brake accumulator pressure, and when the
pressure is less than 1650 psi (11.4 MPa), the valve
shifts, operating the brake treadle valve hydraulically
which in turn applies pressure to the dual relay
valves and applying all the brakes.
Regardless of the nature of location of a failure,
sensing the lowest brake accumulator circuit pressure assures two to four full brake applications after
the low brake warning light and buzzer, and before
automatic apply. This allows the operator the opportunity to safely stop the truck after the warning has
turned on.
If the key switch is turned OFF (park brake

switch ON or OFF), the park brake will not
apply until vehicle speed is less than 1/3 MPH
(0.5 km/h).
If a loss of hydraulic supply pressure occurs,
with the parking brake switch OFF, the
parking brake solenoid will still be energized.
The supply circuit (that lost pressure) is still
open to the parking brake calipers. To prevent
park brake pressure oil from returning to the
supply circuit, a check valve (in the park
brake circuit) traps the oil, holding the parking
brake in the released position.
NOTE: Normal internal leakage in the parking brake
solenoid may allow leakage of the trapped oil to
return back to tank, and eventually allow park brake
application.
PARKING BRAKE CIRCUIT

The parking brakes are spring applied and hydraulically released.
NOTE: Whenever the park brake solenoid is deenergized, a spring in the solenoid valve will shift the
spool, diverting oil pressure from the parking brakes
to direct the oil back to the hydraulic tank.
J02027
Brake Circuit
If 24 volt power to the solenoid is interrupted,

the park brake will apply at any vehicle
speed. The spring in the solenoid will cause it
to shift, opening a path for the oil pressure in
the park brake line to return to tank and the
springs in the parking brake will apply the
brake. The parking brake pressure switch
(21) will close, completing a path to ground,
illuminating the parking brake light on the
overhead display panel and interrupting
propulsion.
J2-5
BRAKE LOCK CIRCUIT

The primary function of the brake lock is to provide a means for the operator to hold the vehicle while at the shovel
or dump. The brake lock only applies the rear service brakes. It may also provide a second means to stop the truck
in the event the primary means (brake valve) malfunctions. By turning on the dash mounted toggle switch, a solenoid valve (14, Figure 2-1) and pressure reducing valve (13) will apply unmodulated pressure oil at 2000 psi (13.8
MPa) to fully actuate the rear brakes. A shuttle valve (11) in the rear brake line provides the independence from the
brake treadle valve for brake application.
WARNING CIRCUIT
The brake warning circuit is equipped with a low
brake pressure warning light (on the overhead display panel) and an audible alarm (in the cab) to alert
the operator of low brake pressures. Several electrical sensors, a relay and delay timer are used to
detect brake system problems. (See Figure 2-1 for
the following component references.)
Pressure sensor, system supply pressure
Located on the pump pressure sensing manifold.
When system supply pressure drops below 2300
psi (15.8 MPa), the low steering pressure light,
low brake pressure light and buzzer will turn on.
Pressure switch, low brake pressure (20)
Located on the brake manifold. When the
accumulator with the lower pressure falls below
1850 psi (12.7 MPa), the low brake pressure light
and buzzer will turn on.
Differential pressure switches (8)
Located on the dual controller valve (foot treadle)
and on each dual relay valve. During brake
application, if the difference in brake apply
pressure between the front and rear circuits is
greater than a preset level, the differential
pressure switch located on the dual controller
valve will turn on the low brake pressure light and
buzzer. If the difference in brake apply pressure
between the left and right circuits of the front or
rear wheel brakes is greater than a preset level,
the differential pressure switch located on the
dual relay valve at either the front or rear wheels
will turn on the low brake pressure light and
buzzer. The pressure differential switches
complete a path to ground in order to turn on the
low brake pressure light and buzzer. The
differential pressure switches provide detection of
faults such as a brake line rupture, poor brake
valve tracking, line blockage, excessive brake
displacement or air trapped in the system.
J2-6
Brake lock degradation switch (23)

Located on the junction block (26) in the
hydraulic components cabinet. When the brake
lock switch is turned on, the brake lock solenoid
(14) and brake warning relay are energized. The
brake warning relay switches the electrical
connection from the differential pressure switch
to the brake lock degradation switch (23). If the
brake lock apply pressure is less than 1000 psi
(6.9 MPa), a path to ground will be completed
and the low brake pressure light and buzzer will
turn on.
Brake warning relay (28)
Located on the RH wall of the hydraulic
components cabinet. When the brake lock switch
is turned on, the brake warning relay is energized
and switches the electrical connection from any
of the differential pressure switches to the low
brake lock degradation switch. When the brake
lock switch is turned off, the relay is de-energized
and switches the connection from the brake lock
degradation switch to the differential pressure
switches.
Brake warning delay timer (27)
Located on the RH wall of the hydraulic
components cabinet. The delay timer is
connected in series between the low brake
pressure light/buzzer and the brake warning
relay. If any of the differential pressure switches
or the brake lock degradation switch completes a
path to ground, the delay timer will not complete
the circuit for 1.2 seconds. This will allow
sufficient time for the hydraulic brakes to reach
the proper pressures after actuation to avoid
false warnings.
Brake Circuit
J02027
FIGURE 2-2. BRAKE VALVE

(FULL CUT-AWAY)
1. Actuator Cap
2. Adjustment Collar
3. Nut
4. Actuator Plunger
5. Wiper Seal
6. Poly-Pak Seal Assembly
7. Glyde Ring Assembly
8. Regulator Springs (B1)
9. Plunger Return Spring
10. Spring Seat
11. Spool Return Spring (B1)
12. Regulator Sleeve (B1)
13. Regulator Spool (B1)
14. Reaction Plunger (B1)
15. Base Plate
17. Regulator Sleeve (B2)
18. Regulator Spool (B2)
19. Spool Return Spring (B2)
20. Regulator Springs (B2)
21. Staging Seat
A. Adjustment Collar Maximum
Pressure Contact Area
B. Automatic Apply Piston Area
C. PX Port
D. Tank Port
E. Reactionary Pressure Area
F. Brake Apply Port
G. Orifice
H. Supply Port
NOTE:
B1 - Rear Brakes
B2 - Front Brakes
J02027
Brake Circuit
J2-7
Rear Axle Brake Lines

For reference to the brake lines that connect to the
rear axle housing, refer to Figure 2-3.
NOTE: If hoses (4, Figure 2-3) and (10) are switched,
the rear brakes will be slow to apply and slow to
release.
FIGURE 2-3. REAR BRAKE HOSES

1. BS - Left & Right Brake Cooling Oil Supply
2. LBR - Left Brake Cooling Return Line
3. T - Return To Tank
4. P1 - Pressure Inlet From Accumulator
5. Axle Housing
6. Wheel Motor
7. RBR - Right Brake Cooling Return Line
8. RBP - Right Brake Pressure Test Port
9. LBP - Left Brake Pressure Test Port
10. PX - Pilot Inlet/Brake Apply Line
11. PB - Parking Brake
J2-8
Brake Circuit
J02027
SECTION J3
BRAKE CIRCUIT COMPONENT SERVICE
INDEX
BRAKE CIRCUIT COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J3-3
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Rebuild Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-8
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-8
Actuator Base Threaded Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-8
Boot and Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-8
Valve Body Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-8
Regulator Sleeve O-Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Actuator Plunger O-ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J3-9
Assembly of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
DIFFERENTIAL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
VALVE BENCH TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-12
Test Set Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-13
Brake Valve Output Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-13
Differential Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-13
Final Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-14
Installation Of Brake Pedal Actuator Assembly to Brake Valve . . . . . . . . . . . . . . . . . . . . . . . J3-15
Installation of Retard Pedal To Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-15
DUAL RELAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
J03025 06/03
Brake Circuit Component Service
J3-1
DIFFERENTIAL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-20
VALVE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-21
Test Set Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-22
Brake Valve Output Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-22
Differential Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-23
HYDRAULIC BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Brake Accumulator Bleed Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
ACCUMULATORS - HYDRAULICS
COMPONENTS CABINET . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-26
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-27
ACCUMULATORS - FRAME MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-30
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-30
ACCUMULATOR CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-31
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) . . . . . . . . . . . . . . . . . . . . . . . . J3-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-32
Disassembly and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-32
Potentiometer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-34
J3-2
06/03 J03025
BRAKE CIRCUIT COMPONENT SERVICE

BRAKE VALVE
The brake pedal assembly combines the dynamic
retarding control with service brake control functions.
As the pedal is depressed, the first portion of pedal
travel actuates an internal potentiometer which provides an electrical signal to the propulsion system,
signalling a request by the operator for retarding. The
electrical signal is modulated by the operator as he
continues to depress the pedal, increasing the level
of retarding effort from minimum to maximum. Further pedal depression after maximum retarding
request is achieved, results in service brake application from minimum to maximum when the pedal is
fully depressed. A slight increase in pedal resistance
can be felt when service brake actuation occurs.
Additionally, indicator lights on the overhead display
panel in the cab will turn on as dynamic retarding is
applied. A second lamp will turn on when service
brakes are applied.
Valve holds pressure when in the neutral

position.
Varying output
depressed.
pressure
with
pedal
fully
NOTE: The following information discusses the

operation, test and repair of the hydraulic brake valve
assembly only. Refer to Section E for information
concerning the retarding control portion of the pedal.
The brake valve is a pressure modulating valve,
actuated mechanically (brake pedal) or hydraulically
through the automatic apply valve (8, Figure 3-1).
The brake valve controls the pressure delivered to
the front and rear service brake dual relay valves
which provide the apply pressure for the front wheel
and rear wheel disc brake assemblies. Apply pressure can be modulated from zero to maximum braking effort by use of the foot pedal.
Rebuild Criteria
If any one of the following conditions exist, the brake
valve should be removed and repaired:
Excessive cam rock in pedal actuator.
Any sign of external leakage.
Internal leakage at the tank port must be less
than 100 cc/minute with the valve in the released
position and system pressure supplied to the
"P1" and "P2" inlet ports.
Tank port leakage must be less than 250 cc/
minute with valve pilot or manual applied at 2750
psi (18,960 kPa) system pressure.
Failure of the pedal to return to full release
position.
J03025 06/03
FIGURE 3-1. BRAKE ACCUMULATOR

BLEEDDOWN
1. Rear Brake Accumulator
2. Charging Valve
3. Front Brake Accumulator
4. Charging Valve
5. Brake Manifold
6. Accumulator Bleed Down Valve (Front)
7. Accumulator Bleed Down Valve (Rear)
J3-3
Installation
Removal
If the brake valve is to be removed from the vehicle
for repair or adjustment, additional equipment will be
required as outlined in disassembly, assembly.
NOTE: Minor repairs and service adjustment may not
require the removal of the brake valve.
Before disconnecting pressure lines, replacing

components in the hydraulic circuits, or installing test gauges, always bleed down hydraulic
steering and brake accumulators. The steering
accumulators can be bled down with engine shut
down, turning the key switch OFF and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur.
Open bleed down valves (6 & 7, Figure 3-1)
located on the brake manifold. This will allow
both accumulators for the rear brakes and both
accumulators for the front brakes to bleed down.
Before disabling brake circuit, be sure truck
wheels are blocked to prevent possible roll-away.
1. Securely block the wheels to prevent possible
roll-away.
2. Place selector switch in NEUTRAL, turn the rest
switch ON. Turn key switch OFF to shut down
engine and allow 90 seconds for steering system accumulators to bleed down. Open valves
(6 & 7, Figure 3-1) to bleed down all four brake
accumulators.
1. Place the brake valve assembly into position

and secure in place with capscrews and lockwashers. Tighten capscrews to standard
torque.
2. Remove plugs from brake valve assembly and
hydraulic lines. Install fittings and connect lines
to brake valve assembly and tighten. Connect
differential pressure switch to harness.
NOTE: Prior to checking the brake valve operation,
the steering system must have the proper nitrogen
precharge in the steering accumulators (refer to
Section L, Hydraulic System for steering accumulator
precharge procedure). In addition, the brake system
lines must be bled of air and the brake accumulators
must also be precharged with nitrogen (refer to brake
accumulator precharge procedures, this section).
3. Connect electronic retard pedal connector to
truck harness.
4. With the engine shut down and key switch OFF,
open both brake accumulator bleed down
valves (6 & 7, Figure 3-1). Precharge both
accumulators mounted on brake manifold (5) to
1400 psi (9.65 MPa).
5. Remove charging kit from brake manifold accumulators and install on external accumulators
located behind right front tire. Precharge both
accumulators to 1400 psi (9.65 MPa).
3. Remove access panel in front of operator's cab.
NOTE: For best performance, charge the

accumulators in the temperature conditions the
vehicle is expected to operate in. During the
precharge, allow temperature of the nitrogen gas to
come into equilibrium with the ambient temperature.
4. Tag and remove all hydraulic lines from brake

valve. Plug lines and ports to prevent possible
contamination. Remove all valve fittings except
the fitting at port "PX". Disconnect wiring harness at differential pressure switch connector.
6. Close both accumulator bleed down valves

after all four accumulators have been properly
charged.
5. Disconnect retard pedal harness.

6. In the cab at the brake valve, remove capscrews and lockwashers securing the brake
valve assembly to the mounting structure.
7. Slide brake valve downward and remove from
cab.
7. Start the engine. Partially apply the brakes and

open the supply plug at each wheel to bleed air
from brake lines and brakes. Close supply plug
after bubbles disappear.
8. Check for fluid leaks at the brake valve.
8. Move brake valve assembly to a clean work

area for disassembly.
J3-4
06/03 J03025
DISASSEMBLY
NOTE: If not already removed, remove electronic
retard pedal (16, Figure 3-2) from brake pedal by
removing pivot shaft (8).
NOTE: During disassembly, precision machined
parts should be ink marked or tagged to ensure
proper reassembly and minimize adjustment time.
All items must be placed back into the bores from
which they were removed.
1. Match mark each section of the brake valve

prior to disassembly.
2. Drain all oil from all ports of the valve by rotating the valve over a suitable container.
3. Secure brake valve in an upright position in a
vice.
4. Remove the brake pedal actuator (17, Figure
3-2) by removing the retaining clips (2), then
remove the pivot shaft (3) with a punch and
hammer.
5. Remove the four button head allen screws (3,
Figure 3-3) securing the boot retainer plate (4).
6. Remove the boot retainer plate (4), boot (2),
and actuator cap (1) as an assembly by grasping the boot and gently lifting from the valve
body.
FIGURE 3-2. BRAKE VALVE / RETARD PEDAL

ASSEMBLY
1. Brake Valve
2. Retainer Clip
3. Pivot Shaft
4. Bushings
5. Shims
6. Retainer Clip
7. Nylon Bearing
8. Pivot Shaft
9. Place 0.025 in. Shim
Here
10. Jam Nut
11. Capscrew
12. Pedal Structure
J03025 06/03
13. Pad
14. Nut
15. Capscrew
16. Electronic Retard Pedal
Assembly
17. Brake Pedal Actuator
18. Spring Pivot (Lower)
19. Spring
20. Spring Pivot (Top)
21. Set Screw
22. Jam Nut
23. Differential Pressure
Switch
J3-5
NOTE: The spools (12), reaction plungers (21, 22)

and spool return springs (20) may fall out at this time.
Keep parts separate so they may be installed in the
same bores from which they were removed.
17. Remove and discard the O-ring (30) from the
counterbore in the base of the valve body.
18. With the controller upright on the work bench,
hold the valve with one hand and push the "B1"
actuator plunger (3) down with the other hand
until the regulator sleeve (19) pops loose.
19. Repeat the above procedure to loosen the "B2"
regulator sleeve.
20. Turn the valve on its side on the work bench
and remove the regulator sleeves (19) from the
valve body.
FIGURE 3-3. ACTUATOR CAP & BOOT

1. Actuator Cap
2. Boot
3. Capscrew
4. Retainer Plate
5. Capscrew
6. Actuator Base
7. Threaded Insert
NOTE: Throughout the following steps, it is important

to keep the circuits and circuit components identified
as to which side of the unit they came from. For a
given circuit, all the components have a tolerance
stack which could vary. Keep the "B1" and "B2" parts
separate.
21. Remove the spools (12), reaction plungers (21,
22) and spool return springs (20) from the regulator sleeves (19).
7. Remove capscrews (36, Figure 3-4) and the differential pressure switch (35). Refer to Differential Pressure Switch for further switch repair
instructions.
8. Remove and discard the seals (27 & 28).
9. Loosen the plunger locknuts (2). Loosen the
socket head capscrew from the adjustment collars (1).
22. Remove the plunger return springs (10), regulator springs (8 & 10), and spring seats (11) from
the valve body.
23. Remove the actuator plungers (3) by pushing
down (toward the bottom of the valve) on the
actuator plunger with your hand until the actuator plunger slides out.
10. Unscrew and remove the adjustment collars.
24. Remove the staging seat (6). Remove and discard packing (5).
11. Remove the two socket head capscrews (5, Figure 3-3) that retain the actuator base (6) to the
valve body.
25. Remove the Glyde ring assembly (7) from the

actuator plunger.
12. Remove the actuator base from the valve body.

13. Remove controller from vice.
14. Remove the four capscrews (34, Figure 3-4)
and washers (33) from the base of the valve.
15. Remove the base plate (32).
26. Remove the O-rings (14, 16 & 18) and teflon

back-up rings (13, 15 & 17) from the regulator
sleeves and discard.
27. Remove the wiper seals (23), poly-pak seals
(25), and the orange back-up rings (24) from
the actuator section of the valve and discard.
16. With the valve upright, the retaining plug (31)

should fall out. If the plug does not fall out,
lightly tap to dislodge the plug.
J3-6
06/03 J03025
FIGURE 3-4. BRAKE VALVE

1. Adjustment Collar
2. Nut
3. Actuator Plunger
4. Stud
5. Packing
6. Staging Seat
7. Glyde Ring Assembly
8. Regulator Spring
9. Regulator Spring
J03025 06/03
10. Plunger Return Spring

11. Spring Seat
12. Regulator Spool
13. Back-up Ring
14. O-Ring
15. Back-up Ring
16. O-Ring
17. Back-up Ring
18. O-Ring
19. Regulator Sleeve
20. Spool Return Spring

23. Wiper Seal
24. Back-up Ring
25. Poly-Pak Seal
26. Valve Body
27. Seal
28. Seal
29. Set Screw Orifice Plug
30. O-Ring
31. Retaining Plug
32. Base Plate
33. Washer
34. Capscrew
Switch
36. Capscrew
J3-7

1. Clean all metal parts with solvent and air dry.
2. Inspect the plunger (3, Figure 3-4) for wear on
the sides where it moves through the seals. If
axial grooves are seen or if any wear is apparent, replace the plunger.
3. Place the regulating spool (12) into its sleeve
(19). Push the spool lightly through the sleeve.
The spool must be able to move freely and
smoothly the entire length of the sleeve. If it
cannot, it must be replaced. Never replace just
the spool or sleeve. They must be replaced as a
matched set.
4. Inspect each spring carefully for cracks or
breaks. Any spring with a crack or break must
be replaced. Also, if the valve was not reaching
proper regulated pressure, replace all regulator
springs.
5. Inspect the threaded inserts (7, Figure 3-3) in
the actuator base. If any of the threads are
damaged, the inserts must be replaced.
6. Lubricate all parts with a thin coat of clean type
C-4 hydraulic oil. Take care to keep components protected from contamination.
scraper. Clean thoroughly to remove all adhesive or particles of the old boot.
3. Apply a thin bead of Loctite Prism 410 onto
the upper sides of the cap. Apply the bead to
the two long sides only. Do not apply it to the
rounded ends, these must not be sealed to
allow the boot to "breathe".
4. Carefully position the cap into the new boot
groove wiping off the excess glue.
5. Position the boot such that it conforms to the
contour of the cap, then set aside. Adhesive
requires about 30 minutes to cure.
Valve Body Seal Installation
1. Install the poly-pak seal (3, Figure 3-5) in the
seal groove first. Position the seal in the groove
so that the internal O-ring inside the poly-pak
seal is facing down toward the bottom of the
valve.
2. Make sure the internal O-ring is still seated
inside the poly-pak seal (3) and did not get dislodged during installation. Position the poly-pak
seal to the bottom of the groove.
ASSEMBLY
Actuator Base Threaded Inserts
1. If any inserts (7, Figure 3-3) were removed
from the actuator base (6), position the actuator
base upside down on the work bench and support directly under each of the four floor mounting holes.
2. Install the threaded inserts into the actuator
base by tapping lightly with a small hammer
until the insert flanges become flush with the
actuator base. Be sure the base is supported to
avoid breaking the base.
3. Thoroughly clean the actuator base and set
aside.
Boot and Cap
1. Examine the boot (2, Figure 3-3) for any
cracks, tears, or other damage. If damage is
evident, the boot must be replaced. To replace
the boot, follow the procedure below.
2. Remove the boot from the actuator cap (1) and
discard the old boot. Thoroughly clean the sides
of the cap by scraping the lip where the cap
contacts the boot. Use a knife or suitable
J3-8
FIGURE 3-5. VALVE BODY SEAL INSTALLATION

1. Actuator Plunger
2. Valve Body
3. Poly - Pak Seal
4. Back-Up Ring
5. Wiper Seal
6. Actuator Base
06/03 J03025
3. Install the orange back-up ring (4) on top of the

poly-pak seal. Start by hand and then continue
to work into the groove either by hand or by
using an O-ring installation tool.
4. Install the wiper seal (5) in the top counterbore.
Position the seal in the groove so that the register lip is facing up toward the actuator.
5. Repeat Steps 1- 4 for the second bore.
Regulator Sleeve O-Ring Installation
1. Install an O-ring (2, Figure 3-6) onto the smallest groove (on the top) of the regulator sleeve
(3). Install O-ring (5) onto the middle groove on
the regulator sleeve. Install O-ring (6) onto the
largest groove (on the bottom) on the regulator
sleeve.
2. Install a split nylon back-up ring (4) onto each
side of the O-ring (5) located in the middle of
the regulator sleeve.
3. Install one split nylon back-up ring behind the
O-ring (2) located at the top end of the sleeve.
This O-ring is the smallest of the three O-rings.
Position the back-up ring so that it is next to the
top of the regulator sleeve. The top of the
sleeve is the end with the smallest O.D.
4. Repeat Steps 1-3 for the second regulator
sleeve.
Actuator Plunger O-ring Installation
1. Install an O-ring (7, Figure 3-4) into the O-ring
groove located at the large diameter end of the
actuation plunger (3).
2. Install a split Glyde ring over the O-ring. (Twist
and squeeze the split Glyde ring into a small circle before installing to insure a tight fit over the
O-ring).
FIGURE 3-6. SLEEVE SEAL PLACEMENT

1. Back-Up Ring
2. O-Ring
3. Regulator Sleeve
4. Back-Up Ring
5. O-Ring
6. O-Ring
4. Install the "B1" actuation plunger (3) into the

"B1" circuit. Be careful not to damage or cut the
Glyde ring during installation. Observe the
Glyde ring assembly through the tank port as
the plunger is being installed. (Refer to Figure
3-7) It may be necessary to work the Glyde
rings past the sharp edge in the body to prevent
damage to the seal. Make sure the actuation
plunger is completely seated and bottomed.
3. Repeat Steps 1 & 2 for the second plunger.
Assembly of Valve
NOTE: Start with either side (circuit) of the valve and
build that side complete through Step 4. before
starting on the other side (circuit). Be careful to
assemble components into the circuit from which
they were removed.
1. If removed, install stud (4, Figure 3-4) in
plunger (3). Tighten nut (2).
2. Install new packing (5) on staging seat (6) and
insert in plunger bore.
3. Lightly lubricate the actuation plunger Glyde
ring (7).
J03025 06/03
FIGURE 3-7. GLYDE RING INSTALLATION

1. Actuator Plunger
2. Valve Body
3. Glyde Ring
4. Sharp Edges
J3-9
5. Repeat Steps 1 through 4 for the "B2" actuation

plunger.
13. Insert reaction plunger (21 or 22) into regulator

spool.
6. Install the plunger return spring (10, Figure 3-4),

regulator springs (8 & 9) and spring seat (11)
into the appropriate circuit. If spring seat does
not seat correctly on top of the control spring,
lightly shake the valve to correctly position the
spring seat.
14. Install regulator spool (12) into regulator sleeve

(19).
7. Lightly lubricate the regulator spool (12).

8. Install the regulator spool into the regulator
sleeve (19). The spherical end of the spool
should be at the top of the regulator sleeve. The
top of the sleeve is the end with the smallest
O.D.
NOTE: Check to insure that the spool will slide
smoothly and freely. Replace the entire sleeve
assembly and spool, if the spool does not slide
smoothly and freely.
9. Remove spool from sleeve before installing
sleeve into body.
10. Lightly lubricate the O-rings (14, 16, & 18) on
the regulator sleeve.
11. Install the regulator sleeve assembly into the
correct circuit in the valve. Make sure the spring
seat is correctly seated in the regulator spring
before installing the regulator sleeve assembly.
Push sleeve into bore until sleeve retaining
flange at the base of sleeve contacts the valve
body.
12. Install the spool return spring (20) into spool
(12).
J3-10
15. Repeat Steps 6 through 14 for the second circuit.

16. Lightly lubricate the large retainer plate O-ring
(30) and install into the counter bore in the bottom end of the valve.
17. Install the retainer plug (31) into the counter
bore on the bottom of the valve. Make sure
steps on the retainer plug are facing the counter
bore or toward the top of the valve.
18. Install the base plate (32) on top of the retainer
plug. Tighten the four allen screws (34) evenly,
alternating diagonally, to evenly seat the regulator sleeve assembly. Tighten to 140 - 150 in.
lbs. (15.8 - 16.9 N.m) torque.
19. Using new seals (27 & 28, Figure 3-4), install
pressure differential pressure switch assembly
(35) on valve body. Install socket head capscrews (36). Tighten capscrews to 140 - 150 in.
lbs. (15.8 - 16.9 N.m) torque.
20. Install the actuator base (6, Figure 3-3) on top of
the valve. Make sure to position properly for
correct port direction. Tighten the two socket
head capscrews (5) and tighten to 180 - 190 in.
lbs. (20.3 - 21.5 N.m) torque.
21. Screw the adjustment collars (1, Figure 3-4)
onto the top of the actuation plungers. Screw all
the way down until they bottom on the threads.
06/03 J03025
DIFFERENTIAL PRESSURE SWITCH

Differential pressure switch (1, Figure 3-8) on the
brake valve detects an imbalance in the brake apply
pressure between the front and rear brake circuits. If
the pressures differ more than 600 50 psi (4137
345 kPa), switch (3) will activate a warning horn and
lamp in the cab to alert the operator of a potential
brake system problem.
Disassembly
1. Remove the four socket head capscrews
attaching the differential pressure switch body
(1, Figure 3-8) to the valve body (2).
4. Using new O-ring (12), install switch assembly

(3). Tighten to 55 - 60 in. lbs. (6.2 - 6.8 N.m)
torque.
5. Turn valve over and install piston (9), spring (8)
and screw plug (7). Plug should be inserted
approximately 0.5 in. (13 mm) below edge of
body. Temporarily install plug (6) in screw plug
port.
NOTE: The adjustment of screw plug (7) controls the
switch actuation point. Refer to Valve Bench Test and
Adjustment, Differential Pressure Switch Adjustment
for calibration procedure.
2. Remove switch assembly (3) and O-ring (12).

3. Remove plugs (5, 6 & 11).
4. Insert a hex wrench through bottom port and
remove screw plug (7).
5. Remove spring (8) and piston (9).
6. Carefully push spool assembly (10) out of its
bore.
2. Inspect spool assembly (10, Figure 3-8) for
scoring and other evidence of damage. Inspect
spool bore in body (4). If seals are damaged,
entire differential switch assembly should be
replaced.
3. Lightly lubricate spool assembly and carefully
insert in bore. Spool must slide freely and
smoothly in bore. If there is binding, the entire
differential pressure switch assembly must be
replaced.
4. Lubricate piston (9) and insert in its bore. Piston
must move freely with no binding.
5. Inspect spring (8) for cracks, distortion, etc.
6. Attach an ohmmeter to switch assembly (3)
center terminal and switch body. Actuate the
switch plunger to verify contacts close when
plunger is depressed and contacts open when
released. Plunger must operate freely in switch
body.
FIGURE 3-8. DIFFERENTIAL PRESSURE
SWITCH
Assembly
1. Install plug (11, Figure 3-8). Tighten plug to 190
- 210 in. lbs. (21.5 - 23.7 N.m) torque.
2. Lightly lubricate Glyde rings on spool assembly
(10) and carefully insert in body (4) until it bottoms on plug (11).
3. Install plug (5). Tighten plug to 190 - 210 in.
lbs. (21.5 - 23.7 N.m) torque.
J03025 06/03
Switch Assembly
2. Valve Body
3. Switch Assembly
4. Body
5. Plug
6. Plug
7. Screw Plug
8. Spring
9. Piston
10. Spool Assembly
11. Plug
12. O-Ring
J3-11
VALVE BENCH TEST AND

ADJUSTMENT
Hose fittings for valve ports:
The following parts and test equipment will be

required to completely bench test and adjust the
brake valve. The differential pressure switch can
also be calibrated and operation tested.
Pressure gauges (3), 0-to-3000 psi (20,680
kPa).
Hydraulic pressure supply, regulated to 2750 psi
(18,960 kPa).
Hydraulic test stand, Refer to Figure 3-9.
1. Motor
2. Pump
3. System Pressure Gauge
4. Needle Valve
Port PX: . . . . . . . . . . . . . . . . .7/16 in., # 4 SAE

Ports P1, P2, B1 and B2: . . . . . 3/4 in., #8 SAE
Port T: . . . . . . . . . . . . . . . . .1 1/16 in., #12 SAE
Ohmmeter or continuity tester
NOTE: It is possible to check the pressures with the
brake valve installed and connected to the vehicle.
Remove the brake pedal assembly and actuator cap
and boot assembly to adjust individual brake circuit
pressures.
FIGURE 3-9. TEST BENCH SET UP

9. Simulated Brake Volume
5. Needle Valve
10. Rear Brake Pressure Gauge
6. Brake Valve
11. Relief Valve
7. Front Brake Pressure Gauge
8. Shut Off Valves
NOTE: Shut off valves (8) for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1, B2 Cylinders must be capable of a 10 cubic inch maximum displacement.
J3-12
06/03 J03025
Brake Valve Output Pressure Adjustment
Test Set Up Procedure

1. Position the valve in the fixture to allow plungers to be activated by hand using a lever (refer
to Figure 3-9).
1. Install the pedal pivot shaft pin in the actuator

base by itself without installing the pedal
assembly.
2. Attach the pilot input supply pressure to the pilot

port labeled "PX" on the rear of the valve.
2. By taking a screw driver or pry bar and placing it

under the pivot pin and on top of the threaded
plunger assembly, each circuit can be actuated
individually. Refer to Figure 3-9.
3. Attach the main supply input pressure to the Oring ports on the rear of the valve labeled "P1"
and "P2".
4. Attach the tank return line to the O-ring port
labeled "T" on the rear of the valve.
5. Attach the regulated output ports "B1" and "B2"
to the test lines. Pressure monitoring devices in
these two lines must be capable of 3000 psi
(20,680 kPa). Connect all ports. The connections should be according to the diagram shown
in Figure 3-9. All ports must be used and connected.
All ports must be used. Relieve pressure before

disconnecting hydraulic and other lines. Tighten
all connections before applying pressure.
Avoid spillage and contamination! Avoid contact
with hot oil if the machine has been operating.
The oil will be at very high pressure.
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
3. Gradually apply pressure on each circuit (one at

a time) to check for leaks around the plunger.
Make sure the adjustment collar is screwed all
the way down on the threads.
4. "B1" Adjustment: Adjust the adjustment collar
up (counter-clockwise) starting with one turn
increments until the output pressure at port "B1"
is 2400 75 psi (16,545 517 kPa) with the
adjustment collar contacting the actuator base
(fully actuated). Fine adjustment will require
turning the collar only in 1/8 turn increments.
5. "B2" Adjustment: Adjust the adjustment collar
up (counter-clockwise) starting with one turn
increments until the output pressure at port "B2"
is 2400 75 psi (16,545 517 kPa) with the
adjustment collar contacting the actuator base
(fully actuated). Fine adjustment will require
turning the collar only in 1/8 turn increments.
6. Tighten the setscrews in the adjustment collars
to 25 - 30 in.lbs. (2.8 - 3.4 N.m) torque. The
entire plunger may have to be rotated to get to
the capscrews.
7. Check pressures again after tightening the set
screws. If the pressures have moved out of
specified range, loosen the appropriate set
screw and re-adjust.
6. Start hydraulic pump and regulate output pressure to 2750 psi (18,960 kPa) at pressure
gauge (3). Pressure gauges (7 & 10) should
read zero.
8. Cycle each circuit 50 times using pilot apply.

This is done by closing needle valve (5) and
opening needle valve (4). Read pressure on
gauges (7 & 10). Close valve (4) and open
valve (5). The pressure gauges (7 & 10) should
read 0 psi.
7. Pilot supply circuit pressure must also be 2750

psi (18,960 kPa).
9. Recheck pressures after cycling. If they have

changed, re-adjust pressures.
8. Return line pressure during this test is not to

exceed 5 psi (34 kPa).
9. Test the valve with ISO 32 grade hydraulic oil at
120 10 F (49 3 C).
Differential Pressure Switch Adjustment

10. Attach an ohmmeter or continuity tester lead to
connector on the differential pressure switch
wire. Attach the other lead to the valve body.
Verify that switch contacts are open.
11. Remove plug (6, Figure 3-8) for access to
adjustment screw plug (7).
12. Insert pry bar under pivot pin to actuate the "B1"
section of valve.
J03025 06/03
J3-13
13. Slowly depress plunger until 600 30 psi (4137

345 kPa) is shown on the pressure gauge.
Adjust screw plug (7) in the bottom port of
differential pressure switch. If the contacts are
open, turn the plug counterclockwise until the
contacts close. If the switch contacts are
already closed, turn the plug counterclockwise until the contacts open, then turn
the plug clockwise until the contacts close
again.
14. Release plunger and depress again while
observing "B1" gauge and ohmmeter to verify
switch contacts close at the pressure specified
above. If not, readjust as necessary.
15. Insert pry bar under pivot pin to actuate the "B2"
section of valve.
16. Slowly depress plunger while observing ohmmeter and the pressure gauge on "B2". The
switch contacts should close at the pressure
specified in step 13. A slight adjustment may be
necessary.
17. Slowly depress both plungers equally from minimum to maximum application pressure. Switch
contacts must remain open.
18. Install plug (6) and tighten to 90 - 100 in. lbs.
(10.2 - 11.3 N.m) torque.
19. Shut down the test bench and relieve all
hydraulic pressure from the lines.

immediately.
20. Remove hoses from valve and remove valve
from test stand. Refer to instructions below for
pedal actuator installation prior to final test.
Final Test and Adjustment

The brake pedal actuator must be installed on the
brake valve body prior to final test and adjustment.
Refer to Installation of Brake Pedal Actuator to Brake
Valve.
NOTE: The Final Test and Adjustment procedure can
also be performed with the brake valve installed in
the truck. To perform final test with brake valve
mounted in the truck, install valve per instructions in
Installation. Install 3000 psi (20 682 kPa) gauges at
the "B1" and "B2" diagnostic test connectors in the
brake cabinet. Follow Steps 21. - 33. below for final
test.
21. Reinstall brake valve (with actuator pedal
attached) on the test stand following Steps 2
through 9 under Test Setup Procedure.
22. With test stand pump adjusted for 2750 psi
(18,960 kPa) or with engine running and brake
system supply pressure at or above 2750 psi
(18, 960 kPa), depress the pedal as quickly as
possible. The pressure on the output circuits
must reach the minimum pressure listed below
at port "B1" and port "B2" within 1.0 second.
Measurement of time begins the moment force
is applied to move the pedal.
Rear Brake - "B1": 2400 75 psi
(16,545 517 kPa)
Front Brake - "B2": 2400 75 psi
(16,545 517 kPa)
23. With "B1" and "B2" plugged into a strip chart
recorder, (if available) check the modulation by
slowly applying pressure until the maximum
pressure is reached. Make sure the pressure
increase is smooth and no sticking of the spools
is observed. Fully depress the pedal. Pressures
must remain within specification at "B1" and
"B2" for 20 seconds.
24. Adjust set screw (21, Figure 3-10) until the set
screw is not touching the actuator cap. Apply
Loctite 242 to the adjustment screw prior to
setting the deadband.
25. Set the deadband by placing a 0.010 in (0.254
mm) thick shim at location (9) between the
pedal structure and return stop boss on pivot
structure.
26. Adjust the set screw (21) until the set screw is
just touching the cap.
J3-14
06/03 J03025
27. Continue turning the set screw until pressure

begins to rise on one of the brake apply pressure gauges.
28. Back-off the set screw 1/8 turn.
29. Tighten the jam nut (22) and remove the shim
stock inserted in step 25.
30. Fully stroke the brake pedal actuator to check
that output pressure at port "B1" and "B2" are
within specifications.
NOTE: If pedal is adjusted properly, the spring and
spring pivots will not interfere with pedal travel.
31. If pressure is not within specifications, re-adjust.
If pressure is within specifications, apply a few
drops of Loctite to the jam nut.
32. Check internal leakage at port "T". Leakage
must be less than 100 cc/minute with the valve
in the released position and system pressure
supplied to the "P1" and "P2" inlet ports.
Installation Of Brake Pedal Actuator Assembly to

Brake Valve
1. Install jam nut (22, Figure 3-10) and set screw
(21) to brake pedal actuator (17).
2. Insert nylon bushings (4) into brake pedal actuator.
3. Install one retaining clip (2) to one end of pivot
shaft.
4. Align pedal structure to brake valve (1) and partially insert pivot pin. Move pedal structure to
the "B2" side of valve and insert shims (5)
between pedal structure and brake valve ear to
fill gap. Fully insert the pivot shaft (3). Install the
remaining retainer clip (2).
5. Assemble spring assembly (19) and install complete assembly to brake pedal actuator as
shown.
33. "T" port leakage must be less than 250 cc/

minute with valve pilot pressure or manual
applied.
Be sure to install spring assembly correctly, with
larger ball socket end pointing to the pedal structure and smaller end toward the valve assembly.
NOTE: When pedal is adjusted properly, the spring
assembly will not interfere with pedal travel.
Installation of Retard Pedal To Brake Pedal

1. Install nylon bearings (7, Figure 3-10) in retard
pedal.
2. Install retard pedal (16) to brake pedal actuator
(17) with pivot shaft (8). Install two retainer clips
(6).
3. With jam nut (10) loose, adjust capscrew (11)
until roller on retard pedal just contacts the
brake pedal actuator. Tighten jam nut (10).
J03025 06/03
J3-15
FIGURE 3-10. BRAKE VALVE AND PEDAL ASSEMBLY

1. Brake Valve
2. Retainer Clip
3. Pivot Shaft
4. Bushings
5. Shims
6. Retainer Clip
7. Nylon Bearing
8. Pivot Shaft
9. Place 0.010 in. Shim Here
J3-16
10. Jam Nut

11. Capscrew
12. Pedal Structure
13. Pad
14. Nut
15. Capscrew
16. Electronic Retard Pedal
Assembly
17. Brake Pedal Actuator
18. Spring Pivot (Lower)

19. Spring
20. Spring Pivot (Top)
21. Set Screw
22. Jam Nut
Switch
06/03 J03025
DUAL RELAY VALVE
Removal
The dual relay valves (one for front and one for rear
brake circuits) supply the apply pressure for each
disc brake assembly. When the operator depresses
the brake valve, hydraulic pressure, proportional to
the amount of brake valve application, is applied to
the pilot pressure circuit of each dual relay valve.
Regulated pressure (proportional to the pilot pressure applied) is then delivered from the "B1" and "B2"
ports of each dual relay valve to each wheel.
The regulated pressures supplied to each wheel are
equal. If a malfunction occurs, causing a pressure
differential greater than 600 psi (4137 kPa) between
the right and left brake apply circuit, a differential
pressure switch (3, Figure 3-11) mounted on the
valve activates a warning horn and lamp in the cab. If
a pressure differential greater than 600 psi (4137
kPa) occurs in the pilot circuit supplying the front and
rear dual relay valves, a differential pressure switch
mounted on the brake valve activates the warning
horn and lamp in the cab.
The dual relay valve for the front brake circuit is
located in the hydraulic components cabinet behind
the cab. The dual relay valve for the rear brake circuit
is located in the rear axle housing and requires
removal of the wheel motor cooling air duct components for access to the valve as described below.

components in the hydraulic circuits, or installing test gauges, always bleed down hydraulic
steering and brake accumulators. The steering
accumulators can be bled down with engine shut
down, turning the key switch OFF and waiting 90
seconds. Confirm the steering pressure is
wheel movement should occur.
Open bleed down valves (6 & 7, Figure 3-1)
located on the brake manifold. This will allow
both accumulators for the rear brakes and both
accumulators for the front brakes to bleed down.
1. Securely block the wheels of the truck.

2. Place selector switch in NEUTRAL, turn the rest
switch ON. Turn key switch OFF to shut down
engine and allow 90 seconds for steering system accumulators to bleed down. Open valves
(6 & 7, Figure 3-1) to bleed down all four brake
accumulators. Close valves after all pressure is
released.
NOTE: Follow Steps 3 & 4 below for the front valve
or Steps 5 through 9 for rear valve removal.
Front Brake Circuit:
3. Tag and remove all hydraulic lines from dual
relay valve. Plug lines and ports to prevent possible contamination. Disconnect wiring harness
at differential pressure switch connector.
4. Remove two capscrews and washers securing
valve to rear wall of cabinet. Remove valve and
move to clean work area for disassembly.
Rear Brake Circuit:
tube.
from between wheel motors.
8. Tag and remove all hydraulic lines from dual
relay valve. Plug lines and ports to prevent possible contamination. Disconnect wiring harness
at differential pressure switch connector.
9. Remove two capscrews and washers securing
valve to mounting bracket. Remove valve and
move to clean work area for disassembly.
Installation
1. Install dual relay valve in hydraulic components
cabinet (front brake circuit) or rear axle housing
(rear brake circuit). Install the two mounting
capscrews and lockwashers to secure valve.
Tighten capscrews to standard torque.
2. Remove hose and fitting caps and plugs and
attach hoses to the proper valve ports. Connect
differential pressure switch connector to wire
harness.
3. Start engine and check for leaks and proper
brake operation. Shut down engine.
4. For the rear valve, reinstall the wheel motor
cooling air duct between wheel motors. Close
access covers and reinstall tube in axle access
opening.
J03025 06/03
J3-17
FIGURE 3-11. DUAL RELAY VALVE & DIFFERENTIAL

PRESSURE SWITCH
1. Manifold Body
2. Valve Body
Switch Assembly
4. Packing
5. Plug
6. Sleeve Retainer
7. Capscrews & Washers
8. Reaction Plunger
J3-18
9. Sleeve
10. Seal
11. Spool Spring
12. Regulator Spool
13. Lower Spring Seat
14. Regulator Spring
15. Upper Spring Seat
16. Plunger
17. Sleeve
18. O-Ring
19. Plug
20. Capscrew
21. Backup Ring
22. O-Ring
23. Backup Ring
24. O-Ring
25. O-Ring
26. Switch
27. Body
28. Plug
29. Screw Plug
30. Spring
31. Piston
32. Spool Assembly
06/03 J03025
Disassembly
The parts installed in the valve body for the "B1" and
"B2" bores are identical, however the parts must not
be interchanged between the two bores.
1. Thoroughly clean valve to remove dirt accumulation. Drain all oil from all ports of the valve by
rotating the valve over a suitable container.
2. Use a felt tip pen to mark manifold body (1, Figure 3-11) and valve body (2) to ensure correct
reassembly.
NOTE: As the valve is disassembled, lay out parts in
order of disassembly, being certain to note the valve
body bore from which they are removed. Parts must
be reinstalled in the same bore from which they are
removed.
3. Secure valve in an upright position in a vice.
4. Remove capscrews securing the differential
pressure switch (3) to the valve body. Remove
and discard seals behind differential pressure
switch ports. Refer to Differential Pressure
Switch for disassembly.
5. Remove the two socket head capscrews (20)
retaining the manifold body (1) to the valve
body (2). Remove manifold body and discard Orings (18).
6. Remove plungers (16) and sleeves (17).
7. Remove controller from vice.
8. Remove the four capscrews and washers (7)
from the base of the valve.
9. Remove the sleeve retainer (6).
10. With the valve upright, the plug (5) should fall
out. If not, tap lightly to dislodge.
11. Remove the spools (12), reaction plungers (8)
and spool return springs (11). Keep parts separate so they may be installed in the same spool
from which they were removed.
12. Remove and discard the packing (4) from the
counterbore in the base of the valve body.
13. Turn the valve on its side on the work bench
and remove the sleeves (9) from the valve body.
14. Remove seal (10), O-rings (22 & 24), and
backup rings (21 & 23) and discard.
15. Remove spring seats (13 & 15) and regulator
springs (14).

2. Apply a light film of type C-4 hydraulic oil to
plungers (14, Figure 3-11) and insert in sleeves
(15). Sleeves must slide smoothly and freely in
sleeve bores. If parts do not slide smoothly or
excessive wear is apparent, replace both the
sleeve and plunger.
3. Apply a light film of oil to regulator spools (12)
and slide into bore of sleeves (9). Spools must
slide smoothly and freely in sleeve bores. If
parts do not slide smoothly or excessive wear is
apparent, replace both the sleeve and spool.
4. Inspect each spring carefully for cracks or
breaks. Any damaged spring must be replaced.
If the valve was not reaching proper regulated
pressure, replace the regulator springs.
5. Lubricate all parts with a thin coat of clean type
C-4 hydraulic oil. Take care to keep components protected from contamination.
Assembly
1. Install sleeves (17, Figure 3-11) in bores in top
of valve body (2).
2. Install plungers (16) in sleeves as shown in Figure 3-11.
3. Apply film of oil to O-rings (18) and position in
grooves on top of valve body.
4. Position manifold body (1) on valve body, aligning marks made during disassembly.
5. Secure manifold to valve body with two socket
head capscrews (20). Tighten capscrews finger
tight.
6. Assemble upper spring seat (15), spring (14)
and lower spring seat (13). Insert assembly into
bore from bottom of valve. Be certain upper
spring seat is positioned against plunger (16).
Repeat for other bore.
7. Install sleeve packing seal (10). Refer to Detail
"A" and "B", Figure 3-11 and install O-rings (22
& 24) and backup rings (21 & 23) in the sleeve
(9) grooves.
8. Apply a light film of oil to sleeve seals. Carefully
push sleeves (9) into their respective bores in
the valve body until flange at base of sleeves
contact valve body.
9. Assemble regulator spool (12) as follows:
a. Insert spool springs (11) into spool bore.
b. Insert reaction plungers (8) into spool bores
and springs.
J03025 06/03
J3-19
10. Install regulator spool assemblies into their

respective sleeve bores. The spherical end
must be inserted toward the spring seat. Push
into bore until contact is made with lower spring
seat.
11. Install sleeve retainer plug packing (4) in valve
body.
12. Check to be certain spring seats (13 & 15) are
properly positioned into the regulator springs
(14) and the reaction plunger (8) slides
smoothly in its bore. Install retaining plug (5) in
valve body counterbore.
13. Position sleeve retainer (6) on valve body.
Install the four capscrews and washers (7),
tightening capscrews evenly to properly seat
plug (5) in counterbore. Final tighten capscrews
to 140 - 150 in. lbs. (15.8 - 16.9 N.m) torque.
14. Tighten the two capscrews (20) holding the
manifold body (1) to the valve body (2) to 180 190 in. lbs. (20.3 - 21.5 N.m) torque.
15. Install plugs (19) in manifold body ports. Tighten
the larger (#8 SAE) plugs to 275 - 300 in. lbs.
(31.1 - 33.9 N.m) torque. Tighten the smaller
(#4 SAE) plugs installed in the "TC1" and "TC2"
ports to 90 - 100 in. lbs. (10.2 - 11.3 N.m)
torque.
16. Install differential pressure switch on valve body
using new seals. Tighten capscrews to 140 150 in. lbs. (15.8 - 16.9 N.m) torque.
DIFFERENTIAL PRESSURE SWITCH

Differential pressure switch (3, Figure 3-11) mounted
on the dual relay valve detects an imbalance in brake
apply pressure between the left and right wheels on
the front or rear brake circuits.
If the regulated output pressures at the B1 and B2
ports differ more than 600 psi (4137 kPa), the switch
(26) activates a warning horn and lamp to alert the
operator to a potential brake system problem.
Disassembly
1. Remove the four socket head capscrews
attaching the differential pressure switch body
(3, Figure 3-11) to the dual relay valve body (2).

2. Inspect spool assembly (32, Figure 3-11) and
bore for scoring and other evidence of damage.
If spool seals are damaged, the entire switch
assembly should be replaced.
3. Lightly lubricate spool assembly and insert in
bore. Spool must slide freely and smoothly in
bore. If there is binding, the entire differential
pressure switch assembly must be replaced.
4. Lubricate piston (31) and insert in its bore. Piston must move freely with no binding.
5. Inspect spring (30) for cracks, distortion, etc.
6. Attach an ohmmeter to switch assembly (26)
center terminal and switch body. Actuate the
switch plunger to verify contacts close when
plunger is depressed and contacts open when
released.
Assembly
1. Install one plug (28, Figure 3-11) in the spool
assembly bore. Tighten plug to 190 - 210 in.
lbs. (21.5 - 23.7 N.m) torque.
2. Lightly lubricate Glyde rings on spool assembly
(32) and carefully insert in valve body bore until
seated against the plug.
3. Install plug in other end of spool bore. Tighten
to 190 - 210 in. lbs. (21.5 - 23.7 N.m) torque.
4. Using new O-ring (25), install switch (26).
Tighten to 55 - 60 in. lbs. (6.2 - 6.8 N.m)
torque.
5. Turn valve over and install piston (31), spring
(30) and screw plug (29). Plug should be
inserted approximately 0.5 in. (13 mm) below
edge of valve body. Temporarily install plug in
screw plug port.
NOTE: Screw plug (29) adjustment controls switch
actuation point. Refer to Valve Test and Adjustment,
Differential Pressure Switch Adjustment for
calibration procedure.
2. Remove switch assembly (26) and O-ring (25).

3. Remove plugs (28).
4. Remove screw plug (29).
5. Remove spring (30) and piston (31).
6. Carefully push spool assembly (32) out of its
bore.
J3-20
06/03 J03025
VALVE TEST AND ADJUSTMENT

The following parts and test equipment will be
required to completely bench test the dual relay
valve. The differential pressure switch can be calibrated and its operation tested.
Pressure gauges (4), 0-to-3000 psi (20,680
kPa).
Hydraulic pressure supply, regulated to 2750 psi
(18,960 kPa).
Hydraulic test stand, Refer to Figure 3-12.
Hose fittings for valve ports:

Port "PX": . . . . . . . . . . .7/16 in.,#4 SAE O-ring.
Ports "B1" and "B2": . . . 3/4 in., #8 SAE O-ring.
Port "T": . . . . . . . . 1 1/16 in., #12 SAE O-ring.
Ohmmeter or continuity tester
NOTE: It is possible to check the pressures with the
dual relay valve installed on the truck by using the
brake treadle valve to modulate pilot pressure and
monitoring brake apply pressure in the appropriate
brake apply pressure lines.
FIGURE 3-12. DUAL RELAY VALVE BENCH TEST SETUP

1. Motor
2. Pump
3. Main Pressure Gauge
4. Pressure Regulator
(Pilot Pressure)
5. Needle Valve
(Pilot Pressure Release)
J03025 06/03
6. Needle Valve
(Pressure Bleed to Tank)
7. Pilot Pressure Gauge
8. Dual Relay Valve
9. LH Brake Apply Pressure
Gauge
10. RH Brake Apply Pressure
Gauge
11. Needle Valve

12. Needle Valve
13. Shut-off Valves
14. Simulated Brake Volume
15. Relief Valve
J3-21
Brake Valve Output Pressure Adjustment
Test Set Up Procedure

1. Setup valve on test stand as shown in Figure 312.
2. Attach the pilot input supply line to the port
labeled "PX" on the side of the valve.
1. With pump operating and supply and pilot pressure adjusted as described in setup instructions, inspect valve for leakage.
3. Attach the main supply input pressure line to

the port on the front of the valve labeled "P".
2. With 2400 psi (16,545 kPa) pilot pressure

applied, verify the following regulated output
pressures:
4. Attach the tank return line to the port labeled

"T".
"B1" port gauge (10) reads 2400 75 psi

(16,545 517 kPa)
5. Attach the regulated output ports "B1" and "B2"

to the test lines. Pressure monitoring devices in
these two lines must be capable of 3,000 psi
(20,680 kPa). Connect all ports. The connections should be according to the diagram shown
in Figure 3-12. All ports must be used and connected.
"B2" port gauge (9) reads 2400 75 psi

(16,545 517 kPa)
3. Close the pilot supply needle valve (5) and
open the pilot pressure release needle valve (6)
to bleed pressure back to the reservoir.
Pilot pressure gauge (7) should drop to 0 psi
(0 kPa).
Regulated output pressure lines "B1" and
"B2" should drop to 0 psi (0 kPa) on gauges
(10) and (9) respectively.
All ports must be used. Relieve pressure before

disconnecting hydraulic and other lines. Tighten
all connections before applying pressure.
immediately.
6. Start hydraulic pump and regulate output pressure to 2750 psi (18,960 kPa) at pressure
gauge (3). Pressure gauges (9 & 10) should
read zero.
7. Adjust pressure regulator (4) to set pilot supply
pressure to 2400 psi (16,545 kPa) on gauge (7).
8. Return line pressure during this test is not to
exceed 0 psi (0 kPa).
9. Test the valve with ISO 32 grade hydraulic oil at
120 10 F (49 3 C).
4. Repeat Steps 2 and 3 approximately 50 times

to cycle valve from minimum to maximum apply
pressure.
5. Verify output pressure remains within specification. If not, the valve must be rebuilt.
6. While observing pilot pressure gauge (7) and
regulated output pressure gauges (9 & 10),
apply pilot pressure slowly and steadily until
2400 psi (16,545 kPa) (maximum) pilot pressure is obtained.
Pilot pressure and regulated output pressure
must track within 50 psi (345 kPa) after the
pilot pressure reaches 100 psi (690 kPa).
7. Reduce pilot pressure to 0 psi (0 kPa). Apply
2400 psi (16,545 kPa) pilot pressure as quickly
as possible.
Regulated output pressure must increase to
2400 75 psi (16,545 517 kPa) within 1.0
second after pressure is applied to pilot line.
8. Check internal valve leakage from port "T" with
full supply pressure (port "P") applied:
With pilot pressure released, leakage must
not exceed 100 cc/minute.
With 2400 psi (16,545 kPa) pilot pressure
applied, leakage must not exceed 150 cc/
minute.
9. Adjust differential pressure switch using the following procedure.
J3-22
06/03 J03025
Differential Pressure Switch Adjustment

10. Attach an ohmmeter or continuity tester lead to
connector on differential pressure switch wire.
Attach other lead to valve body. Verify switch
contact is open.
11. Remove plug on bottom of valve body for
access to adjustment screw plug (29, Figure 311).
12. Open the "B1" regulated output circuit needle
valve (11, Figure 3-12) to bleed the pressure
back to tank. Adjust pilot pressure regulator for
0 psi (0 kPa) on gauge (7).
13. Slowly adjust regulator valve to obtain 600 psi
(4137 kPa) on the "B2" circuit pressure gauge
(9).
a. If switch contact has not closed, turn differential pressure switch adjustment screw (29,
Figure 3-11) counterclockwise until switch
contact just closes.
b. If switch contact closed before reaching 600
psi (4137 kPa), turn the screw plug counterclockwise until the contacts open, then turn
the plug clockwise until the contacts close.
14. Reduce pilot pressure until switch opens.
15. Slowly increase pilot pressure and verify switch
contacts close at 600 50 psi (4137 345
kPa).
J03025 06/03
16. Reduce pilot pressure. Close "B1" needle valve

(11, Figure 3-12) and open "B2" circuit needle
valve (12).
17. Slowly increase pilot pressure and verify switch
contacts close at 600 50 psi (4137 345 kPa)
as read on "B1" circuit gauge (10).
18. If necessary, adjust screw plug (29, Figure 3-11)
and repeat steps 12 through 17.
19. Install plug in switch adjustment port. Tighten to
90 - 100 in. lbs. (10.2 - 11.3 N.m) torque.
20. Shut down the test bench and relieve all
hydraulic pressure from the lines.
Be certain all hydraulic pressure has been

released prior to disconnecting hoses and valve.
immediately.
21. Remove hoses from valve and remove valve
from test stand.
J3-23
HYDRAULIC BRAKE ACCUMULATORS

Four hydraulic brake accumulators are installed on
the truck. Two identical accumulators are located on
the brake manifold in the brake control cabinet
behind the operator's cab. The left accumulator supplies the pressure necessary for actuation of the rear
service brakes. The right accumulator supplies pressure to activate the front service brakes.
Two larger volume accumulators, located on the RH
frame rail behind the tire, supplement the above
accumulators, one for the front and one for the rear
brake circuits.
Accumulators maintain high pressure. DO NOT

disconnect any hydraulic line from the accumulators or brake system until all hydraulic pressure
has been manually drained from accumulators.
Open manual drain valves located on the brake
manifold in the brake cabinet to drain pressurized oil. The manual bleeddown valve for the rear
accumulators is identified as "NVR". The manual
bleeddown valve for the front accumulators is
identified as "NVF".
Brake Accumulator Bleed Down Procedure
The four brake accumulators can be bled down by
rotating the manual bleeddown valves (NV1 and
NV2) counterclockwise. The valves are located on
the brake manifold in the hydraulic brake cabinet.
1. Turn handles counterclockwise to open valves.
2. Confirm accumulators are bled down by applying brake lock switch (key switch ON, engine
off) and applying brake pedal. The service
brake light should not come on.
3. Close bleeddown valves by rotating clockwise.
ACCUMULATORS - HYDRAULICS
COMPONENTS CABINET
Removal
1. Shut down engine to bleed steering accumulators. Exhaust all pressure from the brake system by opening accumulator manual drain
valves.
2. Remove the valve guard and "Dyna-seal" from
top of accumulators.
3. Depress valve core to release gas precharge
pressure from accumulator bladder. (Refer to
Figure 3-13).
4. Remove accumulator mounting bracket.
Loosen and remove accumulator from the
brake manifold. Plug opening on brake manifold
to prevent contamination.
5. Transfer accumulator to work area.
Installation
1. After service repairs or bench test has been
completed, move the accumulators to the brake
control cabinet. DO NOT precharge accumulators on the bench test.
2. Position the accumulators on the brake manifold. Tighten fittings securely. Install mounting
brackets. Secure mounting brackets in place
with capscrews and lockwashers. Tighten capscrews to standard torque.
3. Refer to Charging Procedure in this section.
4. Replace "Dyna-seal" and valve guard on top of
accumulators.
Disassembly
1. Securely clamp accumulator (preferably in a
chain vise). Make sure accumulator shell is
suitably protected by strips of padding or soft
metal on vise base.
2. Remove core from gas valve using valve core
tool. (Refer to Figure 3-13).
3. Remove pipe plug from plug and poppet.
4. Remove locknut from plug and poppet assembly using a spanner wrench and an adjustable
wrench. One for torque and one for countertorque. (Refer to Figure 3-14).
5. Remove spacer, Figure 3-15.
6. With palm of hand, push plug and poppet
assembly into the shell.
FIGURE 3-13. VALVE CORE REMOVAL
J3-24
7. Insert hand into shell and remove O-ring,

washer and anti-extrusion ring from plug. Fold
anti-extrusion ring to enable removal. (Refer to
Figure 3-16).
06/03 J03025
FIGURE 3-17. PLUG AND POPPET REMOVAL

8. Remove plug and poppet assembly from shell.
(Refer to Figure 3-17.)
FIGURE 3-14. LOCKNUT REMOVAL
9. With wrench on valve stem flats, remove the nut

from the valve stem.
10. Insert hand into shell fluid opening. Depress
bag and eliminate as much gas pressure as
possible.
FIGURE 3-15. SPACER REMOVAL

FIGURE 3-18. BLADDER REMOVAL
11. Grasp heel of the bladder and withdraw from
shell. (Refer to Figure 3-18).

1. After disassembly, clean all parts with an
approved cleaning solution.
2. Blow all parts dry with air and keep free from
foreign matter.
3. Check all rubber items for deterioration, abrasion marks, cracks, holes, bubbles or any similar defects.
FIGURE 3-16. ANTI-EXTRUSION RING REMOVAL
J03025 06/03
4. Replace all O-rings and any other items

deemed unsuitable for further usage.
J3-25
5. Bladder may be checked by inflating to normal

size and checking with a soapy solution. After
testing, deflate immediately.
7. Position name plate over valve stem and install

valve stem nut by hand (Figure 3-20). Remove
bladder pull rod.
6. Check plug and poppet valve for proper functioning.
8. Grasp threaded section of plug and insert poppet end into shell mouth.
Assembly
1. Replace shell in vise, if removed.
2. Pour a liberal amount of clean C-4 hydraulic oil
into shell to serve as a cushion.
3. With bladder assembly on bench, expel all air to
completely collapse bladder and fold bladder
longitudinally into a compact roll. To maintain
rolled condition of bladder, install gas valve core
into the valve stem, thereby preventing air from
entering the bladder.
9. Install anti-extrusion ring inside shell. Fold antiextrusion ring to enable insertion into shell.
Place anti-extrusion ring on plug and poppet
assembly with its steel collar toward shell
mouth.
10. Withdraw threaded end of plug through shell
mouth. (Refer to Figure 3-21).
4. Attach bladder pull rod to bladder valve stem.
FIGURE 3-21. PLUG ASSEMBLY

FIGURE 3-19. BLADDER INSTALLATION
5. Pass bladder pull rod through shell oil port and
out through valve stem opening. (Refer to Figure 3-19).
6. Pull bladder pull rod out of shell with one hand
while feeding bladder into shell with other hand.
FIGURE 3-20. VALVE STEM INSTALLATION
J3-26
11. Pull plug until seated solidly into position on

shell mouth opening.
12. Install valve core. Using dry nitrogen, slowly
pressurize bladder with sufficient pressure
[approximately 5 psi (34 kPa)] to hold plug and
poppet assembly in place.
FIGURE 3-22. WASHER INSTALLATION
06/03 J03025
13. Install washer onto plug and poppet assembly

and push until seated against anti-extrusion
ring. (Refer to Figure 3-22).
Charging Procedure
1. Mount hose assembly gland nut on pressure
regulator.
14. Install O-ring over plug and poppet assembly

and push until seated. DO NOT TWIST ORING.
15. Install spacer with smaller diameter of the
shoulder toward shell.
16. Install locknut on plug and poppet assembly and
tighten securely. This will squeeze O-ring into
place. (Refer to Figure 3-23).
Pure dry nitrogen is the only gas approved for

use in brake accumulators. Accidental charging
of oxygen or any other gas in this component
may cause an explosion. Be sure pure dry nitrogen gas is being used to charge accumulators.
NOTE: Remove "Dyna-seal" or O-ring (if equipped)
prior to attaching connector to accumulator gas
valve. Refer to Figure 3-24.
2. Attach swivel connector of hose assembly to
gas valve. Hand tighten sufficiently to compress
gasket swivel connector in order to prevent gas
leakage.
NOTE: If leakage is still present, replacement of the
small copper washer in the swivel connector may be
necessary.
FIGURE 3-23. LOCKNUT INSTALLATION

17. Insert pipe plug into plug and poppet assembly.
18. Install accumulator on truck and charge according to Charging Procedure.
3. Precharge bladder slowly to about 10 psi (69

kPa) before completely tightening the valve
stem nut. With wrench on valve stem flats,
tighten valve stem nut.
4. Proceed to inflate accumulator to 1400 50 psi
(9653 345 kPa) pressure by slowly opening
the pressure regulator valve on nitrogen cylinder, closing it occasionally to allow needle on
pressure gauge to stabilize (thus giving accurate reading of precharge pressure). When correct precharge has been reached, close
pressure regulator valve on nitrogen cylinder
securely.
5. Bleeder valve can be used to release any gas
pressure in excess of desired precharge.
6. Replace "Dyna-seal" and valve guard over
valve stem.
NOTE: For recharging only:
FIGURE 3-24. INSTALLATION/REMOVAL OF

DYNA-SEAL
1. "Dyna-Seal"
3. Accumulator
2. Accumulator Charging
Valve
J03025 06/03
Bleed all hydraulic pressure from the system using

the bleed valves on the brake manifold. Remove
valve guard and "Dyna-seal". Then, follow Charging
Procedure, Steps 1 thru 6.
J3-27
ACCUMULATORS - FRAME MOUNTED

Figure 3-26 illustrates the (RH) frame mounted brake
circuit accumulators which provide additional oil storage for the front and rear brake circuits.
Removal
1. Place the selector switch in NEUTRAL, turn the
rest switch ON. Turn key switch OFF to shut
down engine and allow at least 90 seconds to
allow steering accumulator oil to drain to tank.
2. Open needle valves (6 & 7, Figure 3-1) on
brake manifold (5) and allow the four brake system accumulators to bleed completely.
3. Remove charging valve guard (2, Figure 3-25)
and loosen small hex on charging valve (3)
three complete turns. Depress the valve core
until all nitrogen pressure has been relieved.
FIGURE 3-25. CHARGING VALVES

1. Accumulator
2. Charging Valve
Guard
3. Charging Valve
Make certain only the small swivel hex nut turns.

Turning the complete charging valve assembly
may result in the valve assembly being forced
out of the accumulator by the nitrogen pressure
inside. Wear protective face mask when discharging nitrogen gas.
4. Remove oil line (5, Figure 3-26) from bottom of
the accumulator. Plug all hoses and openings to
prevent possible contamination of the system.
5. Attach a lifting device to the accumulator.
6. Remove the mounting band capscrews, washers, and nuts (3) and remove the mounting
bands (4).
7. Raise the accumulator until clear of mounting
bracket and move to a clean work area for disassembly.
Installation
1. Lift accumulator into position on the mounting
bracket. Accumulator should be positioned with
the anti-rotation block positioned between the
two stop blocks on the lower mounting bracket.
2. Secure the accumulator to the mounting
bracket using mounting bands (4, Figure 3-26),
and corresponding hardware. Do not overtighten nuts, as this could distort the accumulator.
3. Reconnect oil line to the bottom of the accumulator.
4. Precharge both accumulators with pure dry
nitrogen as outlined in Frame Mounted Brake
Accumulator Charging Procedure.
J3-28
FIGURE 3-26. BRAKE ACCUMULATOR

INSTALLATION
1. Rear Brake Circuit
Accumulator
2. Front Brake Circuit
Accumulator
3. Capscrews, Washers
& Nuts
4. Mounting Bands
5. Oil Line
06/03 J03025
Disassembly
1. Remove charging valve (3, Figure 3-27).
2. Remove gland (4).
Note: Figure 3-28 illustrates a tool that can be
fabricated locally to aid in removing the gland.
3. Remove plugs and/or adaptor (10 & 11). Using
a round rod, push piston (6) out of accumulator.
4. Remove piston rings (7) and seal (8).
1. Clean parts using fresh cleaning solvent, lint
free wiping cloth and filtered compressed air.
All parts must be absolutely free of any foreign
matter larger than 3 microns.
2. Inspect piston for damage. If scored or otherwise damaged, replace with a new part.
3. Minor defects in the housing bore may be corrected by honing.
a. Measure the bore at several places along
the length of the housing. Make two measurements, 90 apart at each point to verify
tube is not out-of-round.
FIGURE 3-27. ACCUMULATOR ASSEMBLY

7. Bearing
1. Capscrew
8. "T" Ring Seal
2. Cover
9. Housing
3. Charging Valve
10. Plug
4. Gland
5. O-ring & Backup Ring 11. Plug
6. Piston
J03025 06/03
FIGURE 3-28. GLAND REMOVAL TOOL

(Fabricate Tool Locally)
J3-29
b. Verify housing I.D. does not exceed 8.002 in.

(203.25 mm).
c. Check dimensions frequently during honing
operation to prevent removal of too much
material. Do not hone gland seal area.
4. If housing defects can not be removed within
the above limits, replace the housing.
Repair of the housing by welding, machining or

plating to salvage a worn area is NOT approved.
These procedures may weaken the housing and
result in serious injury to personnel when pressurized.
5. Clean parts thoroughly to remove abrasive residue after honing.
Assembly
Testing
To carry out the testing required, it will be necessary
to check for internal and external leaks at high pressure. A source of 5000 psi (35 MPa) hydraulic pressure and nitrogen pressure of 1400 psi (9.65 MPa)
will be required. A small water tank with the necessary safety guards in place will be necessary for a
portion of the test.
Do not stand near gland during test procedure. A

box enclosure made of heavy steel plate is recommended to contain the accumulator during oil
pressurization test.
1. Fill each end of the accumulator with approximately 3.75 gallons (14.2 Liters) of clean type
C-4 hydraulic oil. Install an adaptor on the oil
end to connect to hydraulic power source. Plug
remaining ports.
a. Apply 5000 psi (35 MPa) oil pressure.
b. Verify no external leakage exists.
Assemble the accumulators in a dust and lint free

area. Maintain complete cleanliness during
assembly to prevent possible contamination.
1. Install a new seal (8, Figure 3-27) on piston.
Install new bearings (7). Coat seal and bearings with a small amount of petroleum jelly.
2. Install the piston with the concave side toward
gas end (gland end) of accumulator cylinder
housing (9). Push the piston to the center of the
housing.
3. Install new O-rings and backup rings (5) on
gland (4). Coat seals with a small quantity of
type C-4 hydraulic oil.
4. Install gland and tighten to 850 ft. lbs. (1152
N.m) torque using tool as shown in Figure 6-5.
5. Install charging valve (3) with new O-ring.
Tighten charging valve large hex nut to 16.5
6. Install pressure switch. Install pressure test fittings in bottom of housing. (Refer to Testing.)
J3-30
c. Verify no structural damage exists.

2. Release pressure and remove oil side fitting.
3. Drain oil. Leave port open.
4. Pressurize gas end of accumulator with approximately 100 psi (690 kPa) nitrogen pressure to
move piston to bottom of housing.
5. Submerge oil end of assembly in water.
6. Apply 1400 psi (9.65 MPa) nitrogen pressure to
gas end and observe for 20 minutes. No leakage (bubbles) is permitted.
7. Release nitrogen pressure and remove assembly from water.
8. Drain any remaining oil or water.
9. If the accumulator is to be placed in storage,
add 3 pints (1.5 L) of rust preventive oil in the
nitrogen side of the accumulator. Add 1 pint (0.5
L) in the oil side. If the accumulator will be used
immediately, type C-4 hydraulic oil may be used
instead of rust preventive oil. Plug all open
ports.
10. Verify all warning and caution labels are
attached and legible (Refer to parts book if
replacements are required).
06/03 J03025
ACCUMULATOR CHARGING
PROCEDURE
(Frame Mounted Brake Accumulators)
Do not loosen or disconnect any hydraulic line or

component until engine is stopped and key
switch has been OFF for at least 90 seconds and
brake accumulators have been manually bled
down.
use in the brake accumulators. The accidental
charging of oxygen or any other gas in this compartment may cause an explosion. Be sure pure
dry nitrogen gas is being used to charge the
accumulators.
When charging or discharging the nitrogen gas
in the accumulators, be sure the warning labels
are observed and the instructions regarding the
charging valve are carefully read and understood.
1. With engine shut down, the rest switch ON and
key switch in the OFF position, allow at least 90
seconds for steering accumulators to bleed
down. Turn steering wheel to be certain no oil
remains in accumulators.
2. Open the bleed valves (6 & 7, Figure 3-1)
located on the brake manifold in the hydraulic
components cabinet to completely bleed the
pressure from all brake system accumulators.
3. Remove charging valve guards.
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
5. Rubber Washer
6. Valve Body
7. O-ring
8. Valve Stem
9. O-ring

7. Connect the charging kit to the charging valves.
Open the regulator and charge the accumulators simultaneously to 1400 psi (9.8 MPa).
NOTE: When charging the accumulators, allow
adequate time for the system to fully charge. Insure
all oil has returned from the accumulators to the
hydraulic tank.
8. Shut off charging kit and check pressure gauge
reading. If gauge does not maintain 1400 psi
(9.7 MPa) continue charging procedure until
pressure is stabilized.
9. Remove the charging kit and tighten small hex
nut on charging valve to 4 ft.lbs. (5.4 N.m)
torque.
NOTE: If a new charging valve was installed, the
valve stem must be seated as follows:
a. Tighten small hex swivel nut to 10.5 ft.lbs.
(14.2 N.m) torque.
If nitrogen pressure is present in the accumulators, make certain only the small swivel hex nut
is turned during the next step. Turning the complete valve assembly may result in the valve
assembly being forced out of the accumulator by
the nitrogen pressure inside.
4. Remove charging valve cap (1, Figure 3-28).
Turn small swivel hex nut (4) three complete
turns counterclockwise.
5. Depress the valve stem and hold down until all
nitrogen has been released.
6. If a loss in nitrogen pressure is the reason for
recharging, inspect the charging valve and
accumulator for damage. Replace or repair
items, as necessary, before charging.
J03025 06/03
b. Loosen swivel nut.

c. Retighten swivel nut to 10.5 ft.lbs. (14.2
N.m) torque.
d. Again, loosen swivel nut.
e. Finally, tighten swivel nut to 4 ft.lbs. (5.4
N.m) torque.
10. Install charging valve cap (1) and tighten finger
tight. Install charging valve guard and tighten
capscrews to 25 ft.lbs. (33.9 N.m) torque.
11. Close brake accumulator bleed valves.
12. If necessary, recharge the smaller brake accumulators. Refer to Accumulators, Hydraulic
Components Cabinet, Charging Procedure.
13. Operate truck and check the brake system.
J3-31
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)

Due to frequent use and wear, retarder control lever
(4, Figure 3-30) may occasionally require adjustment
or repair.
Disassembly and Adjustment

1. Remove capscrews (6, Figure 3-30) and lockwashers (7) from retarder control lever (4).
Removal
2. Remove potentiometer (8).
Adjustment of the retarder control lever or replacement of the potentiometer requires removal of the
assembly from the steering column.
3. Bend tangs on washer (10) away from slots in

locknut (9).
1. Tilt the steering wheel downward, and telescope the wheel towards the operator seat.
Remove the top cover from the steering column.
a. Lever Disassembly:
If the retarder control lever is to be completely disassembled, loosen and remove
locknut (9). Remove tang washer (10),
spring (11), and washer (12).
1. Remove capscrews (1, Figure 3-30) and lockwashers (2) from steering column (3).
Remove set screw (14).
2. Disconnect the wiring harness from harness

connector (5) on retarder control lever (4).
Remove the lever and shaft assembly. If necessary, unscrew lever (16) from shaft (15)
and handle (17).
3. Remove the retarder control lever.
Wash the mechanical parts in clean solvent

and inspect for excessive wear, burrs, or
scratches. Replace any defective parts.
Installation
b. Lever Adjustments:
1. Connect the wiring harness to harness connector (5, Figure 3-30) on retarder control lever (4).
2. Place the retarder control lever into position on
steering column (3).
3. Install capscrews (1) and lockwashers (2).
Tighten the capscrews to 36 in. lbs. (4.1 N.m)
torque.
4. Place the cover on the top of the steering column and return the steering wheel to its original
position.
Rotational Friction Adjustment: The lever

assembly should be adjusted such that the
frictional forces will hold the lever firmly in
the position selected by the operator. At the
same time, the adjustment should not be so
tight as to cause the operator to use undue
force to move the lever. Loosen or tighten
locknut (9) to attain the proper frictional force
(2 - 3 in.lbs (0.23 - 0.34 Nm) at the handle.
The position of the lever should remain stationary without moving from its own weight or
due to machine vibrations during truck operation.
When the desired adjustment is obtained,
bend the tang on washer (10) into the slots
on locknut (9).
Detent Adjustment: The detent that holds the
lever in the OFF position can be adjusted, as
well. Loosen or tighten set screw (13) to
adjust the detent. The breakout force of the
detent must be between 17 - 20 in.lbs (1.92
- 2.26 Nm).
J3-32
06/03 J03025
FIGURE 3-30. COLUMN-MOUNTED RETARDER LEVER ASSEMBLY

1. Capscrew
2. Lockwasher
3. Steering Column Assembly
4. Retarder Control Lever
5. Harness Connector
6. Capscrew
J03025 06/03
7. Lockwasher
8. Potentiometer
9. Locknut
10. Tanged Washer
11. Disc Spring
12. Internal Tang Washer
13. Set Screw

14. Housing
15. Shaft
16. Lever
17. Handle
J3-33
Assembly
Potentiometer Check
Potentiometer (8, Figure 3-30) is spring-loaded to the
OFF position. With the switch assembly removed
from the retarder control lever, make the following
checks:
1. Inspect the shaft bore and interior friction faces

in housing (14). Remove any scratches or
burrs, or replace the housing. Lightly lubricate
the surfaces with a Multi-Purpose EP NLGI
Consistency #2 grease.
2. If handle (17, Figure 3-30) or lever (16) has
been removed from shaft (15), assemble as follows:
a. Apply Loctite #271 to the threads on each
end of lever (16).
b. Install the lever onto shaft (15). Hand
tighten, only!
FIGURE 3-31. POTENTIOMETER CONNECTOR

1. Obtain a 10 volt power supply for testing the
potentiometer.
2. Connect the positive lead to the supply terminal
on the potentiometer connector in Figure 3-31.
3. Connect the negative lead to the ground terminal on the connector.
4. Connect a voltmeter to the signal and ground
connections.
5. Measure and record the OFF position signal
voltage.
6. Rotate the potentiometer clockwise to the full
ON position. Measure and record the signal
voltage.
7. Determine whether the potentiometer falls
within the specifications. When the potentiometer is in the OFF position, the signal voltage
must be within 5 - 15% of input voltage. When
the potentiometer is in the full ON position, the
signal voltage must be within 75 - 95% of input
voltage.
% of input voltage =
signal voltage
input voltage
c. Install handle (17) onto the lever. Hand

tighten, only!
3. Insert the lever, handle, and shaft assembly into
housing (14).
4. Install washer (12), new spring (11) [with the
outer spring diameter against washer (12)],
tang washer (10), and locknut (9) onto shaft
(14).
5. Tighten and secure locknut (9) as described in
Step 3.b. of Disassembly and Adjustment.
6. Move the lever to the full OFF (up) position.
Align the slot in potentiometer (8) with the key
on shaft (15) and rotate the potentiometer until
the capscrew holes line up with the housing.
Install washers (7) and capscrews (6) to secure
the potentiometer to the housing. Tighten the
socket head capscrews to 12 - 15 in. lbs. (1.36
- 1.69 N.m) torque.
7. Install set screw (13). Refer to Step 3.b. of Disassembly and Adjustment for adjustment procedures.
8. Install the retarder control lever on the steering
column. Refer to Installation.
) x 100
NOTE: With a 10 volt power supply, the

potentiometer voltage specifications are as follows:
OFF position . . . . . . . . . . . . . . . . . . . . 0.5 - 1.5 volts
Full ON position . . . . . . . . . . . . . . . . . . 7.5 - 9.5 volts
8. Replace the potentiometer if it does not meet
these specifications.
J3-34
06/03 J03025
SECTION J4
BRAKE CIRCUIT CHECK-OUT PROCEDURE
INDEX
BRAKE CIRCUIT CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-3

EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-5
INITIAL SYSTEM SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-6
BRAKE SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J4-7
Failure Modes Check-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-8
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-11
CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-15
J04026 07/03
Brake Circuit Checkout
J4-1
NOTES
J4-2
07/03 J04026
BRAKE CIRCUIT CHECK-OUT PROCEDURE

The brake circuit hydraulic pressure is supplied from
the steering circuit at the bleed down manifold. Some
brake system problems, such as spongy brakes, slow
brake release, or abnormal operation of the overhead
display panel mounted low brake pressure warning
light can sometimes be traced to internal leakage of
brake components. If internal leakage is suspected,
refer to Brake Circuit Component Leakage Test.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
NOTE: If internal leakage within the steering circuit is

excessive, this also may contribute to problems within
the brake circuit. Be certain that steering circuit
leakage is not excessive before troubleshooting brake
circuit. For Steering Circuit Test Procedure, refer to
Section L, Hydraulic System.
FIGURE 4-1. HYDRAULICS COMPONENTS CABINET

Rear Brake Accumulator
11. Brake Lock Shuttle Valve
21. Park Brake Pressure Switch
Charging Valve
12. Brake Manifold
22. Stop Light Pressure Switch
Front Brake Accumulator
13. Pressure Reducing Valve (PR)
23. Brake Lock Degradation Switch
Charging Valve
14. Brake Lock Solenoid (SV1)
24. Rear Brake Pressure Test Port (BR)
25. Front Brake Pressure Test Port (BF)
Relief Valve (Hoist-Power Down)
15. Park Brake Solenoid (SV2)
Hoist Pilot Valve
16. Front Brake Accum. Bleed (NVF) 26. Manifold
27. Brake Warning Delay Timer
Dual Relay Valve
28. Brake Warning Relay
Differential Pressure Switch
18. Low Accum. Test Port (LAP1)
Park Brake Release (Plug Port)
19. Rear Brake Accum. Bleed (NVR) 29. Supply Pressure Test Port
30. Brake Lock Pressure Test Port
Brake Cabinet
20. Low Brake Pressure Switch
J04026 07/03
J4-3
The steering circuit can be isolated from the brake

circuit by removing the brake supply line from the
bleeddown manifold. Plug the brake supply line and
cap the port in the bleeddown manifold. (see
WARNING below)

components in the hydraulic circuits, or installing test gauges, ALWAYS bleed down hydraulic
steering and brake accumulators. Hydraulic
fluid escaping under pressure can have sufficient force to enter a person's body by penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
The steering accumulator can be bled down with

engine shut down, turning key switch OFF, and waiting 90 seconds. Confirm the steering pressure is
wheel movement should occur. Open both bleed
down valves on brake manifold to bleed down all
four brake accumulators.

wheels are blocked to prevent possible rollaway.
FIGURE 4-2. BRAKE MANIFOLD
J4-4
07/03 J04026
EQUIPMENT REQUIRED
BRAKE CIRCUIT ABBREVIATIONS

AA
Automatic Apply Pressure
AF2
Accumulator, Front Brake
AF1
Supply Pressure to Brake Valve for

Front Brakes
AF3
Plug Port
AR1
Supply Pressure to Brake Valve for

Rear Brakes
AR2
Accumulator, Rear Brake
AR3
Plug Port
BF (B2)
BL
BR (B1)
CV, CVR,
CVF
Included on the last page of this module is a data

sheet to record the information observed during the
hydraulic brake system check-out procedure. The
data sheet can be removed, copied, and used during
the check-out procedure.
* Steps indicated in this manner should be recorded
on the data sheet for reference.
The following equipment will be necessary to properly check-out the hydraulic brake circuit:
Brake Pressure, Front

Brake Lock Apply Pressure
Brake Pressure, Rear
Check Valve, Check Valve (Rear),
Check Valve (Front)
Hydraulic brake schematic, refer to Section "R"

this manual.
Calibrated pressure gauges:
HS1
High Pressure Shuttle Valve
> One 0-5000 psi (0-34,475 kPa) range.
LAP1
Low Accumulator Pressure, Pressure

Tap
> Three 0-3000 psi (0-20,685 kPa) range.
LAP2
Low Brake Pressure Switch

N.C. - 1850 75 psi (12.95 MPa)
LS1
Low Pressure Shuttle Valve
NVF
Front Accumulator Manual Drain Valve
NVR
Rear Accumulator Manual Drain Valve
PK1
Park Brake Release Pressure
PK2
Plug Port
PK3
Park Brake Pressure Switch

N.C., 1250 psi (8.75 MPa)
PP3
Brake Lock Pressure Tap
PR
Brake Lock Pressure Regulator

2000 psi (13.8 MPa)
PS1
Automatic Apply Valve

1650 psi (11.55 MPa)
SP1
Supply Oil Inlet
SP2
Plug Port
SP3
Supply Oil Pressure Tap
SP4
Plug Port
SV1
Brake Lock Solenoid
SV2
Park Brake Solenoid
T1
Return To Tank
T2
Plug Port
T3
Plug Port
J04026 07/03
One PB6039 female quick disconnect and hose

long enough to reach from brake cabinet to the
inside of the operator's cab for each gauge.
Accumulator charging kit (EB1759 or equivalent)
with gauges and dry nitrogen.
J4-5
INITIAL SYSTEM SET-UP

Prior to checking the brake system, the hydraulic
steering system must be operating properly, have
correct accumulator precharge and be up to normal
operating temperatures. Refer to Section L, Hydraulic System, for steering system operation troubleshooting procedures and specifications.
Be certain brakes have been properly bled to remove
trapped air. Refer to Wet Disc Brake Bleeding Procedure in this section. Also, prior to checking the brake
system, make certain the parking brake is functioning
properly. Refer to Parking Brake in this section.
1. Apply the parking brake, put selector switch in
NEUTRAL, place the rest switch in the ON
position, turn the key switch OFF to shut down
the engine, and allow approximately 90 seconds for the steering accumulators to bleed
down. Confirm the steering pressure is
released by turning the steering wheel - no
movement should occur. Block the truck
wheels.
NOTE: Leave rest switch in the ON position and the
GF cutout switch in the CUTOUT position throughout
brake tests. (See Figure 3-1, page E3-2, Propulsion
System, for GF switch location.)
2. Open each brake accumulator bleeddown valve
and precharge both brake manifold accumulators (1 & 3, Figure 4-1) to 1400 psi (9,652 kPa).
Move the charging kit to the frame mounted
accumulators (behind right front tire) and precharge both accumulators to 1400 psi (9,652
kPa). Allow gas temperature to approach ambient temperature before completing precharge
process.
* Record on data sheet.
NOTE: For best performance, charge accumulators
in the ambient conditions in which the machine will
be operating.
3. Close both accumulator bleeddown valves.
FIGURE 4-3. BRAKE CABINET PORT

IDENTIFICATION
(Viewed from the bottom of the cabinet.)
1. AR1: Rear Brake Oil Supply to Brake Valve
2. AA: Automatic Apply Oil Supply to Brake Valve
3. AF1: Front Brake Oil Supply to Brake Valve
4. PK1: Oil Supply to Park Brake
5. T1: Oil Return to Hydraulic Tank
6. SP1: Brake System Oil Supply from Bleeddown
Manifold and filter
7. To "B1" Port on Brake Valve
5. Set park brake. Release brake lock.
6. Start engine. Observe rising brake pressures as
system charges. Brakes should release at
approximately 1650 psi (11,375 kPa) both front
and rear.
7. Actuate brake lock. Turn parking brake switch
OFF. Rear brake pressure should not exceed
2000 100 psi (13,788 690 kPa). Release
brake lock.
4. Install pressure gauges at:

a. Front brake test port "BF" (25, Figure 4-1) 3000 psi (20,685 kPa) gauge.
b. Rear brake test port "BR" (24) - 3000 psi
(20,685 kPa) gauge.
c. Park brake release pressure "PK2" (9) 3000 psi (20,685 kPa) gauge.
d. Low accumulator pressure test port "LAP1"
(18) - 5000 psi (34,475 kPa) gauge.
8. Slowly depress brake pedal and note brake

valve pressures. If the rear brake circuit
exceeds 2400 psi (16,545 kPa) at the "BR" test
port or front brake circuit exceeds 2400 psi
(16,545 kPa) at the "BF" test port, correct the
problem before proceeding. This brake valve
may require adjustment or a dual relay valve
may be malfunctioning. Refer to repair procedures, this section.
J4-6
07/03 J04026
BRAKE SYSTEM CHECKOUT
Left front brake pressure reads 2400 75 psi

(16,545 517 kPa)
NOTE: Unless otherwise specified, perform the

following checks with engine running, rest switch in
the ON position, park brake on and brake lock
released.
Right front brake pressure reads 2400 75

psi (16,545 517 kPa).
9. Apply brake lock. Turn the parking brake switch

to the OFF position:
Verify park brake indicator lamp is off.
Verify park brake release pressure (gauge
installed in "PK2" port in hydraulic cabinet) is
2700 100 psi (18,615 690 kPa).
Both pressures must remain above their

minimum values for a minimum of 20
seconds.
19. Release pedal, assure that each circuit's pressure is zero.
20. Remove gauges from front brake test ports and
install at the "BR" and "BF" test ports in the
hydraulic cabinet.
10. Cycle park brake several times to assure crisp

application and release of oil pressure when
switch is OFF.
21. Disconnect circuit #52B wire on the coil of the

brake lock solenoid (SV1) (14, Figure 4-1).
Install a jumper wire between circuits #33 and
#33W at the brake warning delay timer (27, Figure 4-1).
11. Place parking brake switch in the ON position

and release the brake lock.
22. Apply the brake lock; the brake lock degradation

switch should close:
12. Install a 3000 psi (20,685 kPa) pressure gauge

at the "LBP" (9, Figure 4-5) and "RBP" (8) test
ports on the junction block at the left front corner of the rear axle housing.
13. Very slowly depress brake pedal. Force feedback of pedal on foot should be smooth with no
abnormal noise or mechanical roughness.
14. Slowly depress brake pedal:
Verify brake indicator lamp and stop lights
illuminate at 75 5 psi (517 34 kPa) rear
brake pressure.
15. Quickly and completely depress pedal. Verify
that within 1 second after brake is applied:
Left rear brake pressure ("LBP", 9) reads
2400 75 psi (16,545 517 kPa).
Right rear brake pressure ("RBP", 8) reads
2400 75 psi (16,545 517 kPa).
Both pressures must remain above their
minimum values for a minimum of 20
seconds.
16. Release pedal, assure that each circuit's pressure is zero.
17. Move the two 3000 psi (20,685 kPa) gauges to
the test ports on the front brake backplates.
18. Quickly and completely depress pedal. Verify
that within 1 second after brake is applied:
J04026 07/03
Verify the warning buzzer turns on.

Verify the low brake pressure warning lamp
illuminates.
23. Depress the brake pedal until the warning
stops.
24. Very slowly, release the brake pedal while
observing the "BR" pressure gauge:
Verify warning resumes when pressure drops
to 1000 25 psi (6,895 172 kPa).
* Record pressure reading when alarm resumes.
25. Reconnect #52B wire at brake lock solenoid
coil. Remove jumper between circuits #33 and
#33W.
26. Cycle brake lock several times to assure crisp
shift of solenoid valve and release of oil pressure. Verify stop lights illuminate when brake
lock is on.
27. Apply brake lock and read brake pressure at
"BR" gauge:
Pressure should be 2000 100 psi (13,788
690 kPa).
28. If above pressure is not correct, remove plug on
end of PR valve (13, Figure 4-1) and adjust to
obtain correct pressure. Reinstall plug after
adjustment.
J4-7
Failure Modes Check-Out

29. Start engine and allow low brake accumulator
pressure (LAP1 gauge) to stabilize at or above
2700 psi (18,613 kPa).
30. Turn the key switch OFF to shut down the
engine, and allow approximately 90 seconds for
the steering accumulators to bleed down.
31. Disable the steering pressure switch by unplugging the diode between circuits #33 and #33F
on diode board DB1 in the auxiliary control box
or by disconnecting the wires at the steering
pressure switch.
32. Turn the key switch ON. After 2 minutes, record
the low accumulator pressure (LAP1) gauge
reading.
If pressure decreases to less than 2100 psi
(14,480 kPa), internal system leakage is
excessive. The source of the leakage must be
identified and repaired.
33. Very slowly, open the front brake accumulator
bleeddown valve a small amount ([NVF] 16,
Figure 4-1) while observing LAP1 decreasing
pressure.
The low brake pressure lamp and buzzer
must activate when pressure drops to 1850
75 psi (12,755 517 kPa).
Verify the low pressure warning lamp and the

buzzer activate within 100 psi (690 kPa) of
the pressure recorded in step 33.
Verify the brake pressures "BR" and "BF"
begin to rise within 100 psi (690 kPa) of the
auto apply set point pressure recorded in step
33.
37. Reinstall diode on diode board DB1 or connect
wire harness at steering pressure switch.
2700 psi (18,613 kPa).
39. Shut down engine but do not turn key switch
OFF. (Do not allow steering accumulators to
bleed down.)
40. While observing pressure gauges, make
repeated, slow, brake applications until auto
apply comes on.
Auto apply must not actuate prior to the sixth
pedal application.
When the LAP1 pressure reaches 1650 psi

(11,375 kPa) brake pressures "BR" and "BF"
should begin to rise (auto apply).
34. Close the front brake accumulator bleeddown
valve. Start engine and allow low brake accumulator pressure (LAP1 gauge) to stabilize at or
above 2700 psi (18,613 kPa).
35. Turn key switch OFF to shut down engine and
allow the steering accumulators to bleed down
completely.
J4-8
36. Turn key switch ON. Very slowly, open the rear
brake accumulator bleeddown valve a small
amount ([NVR] 19, Figure 4-1) while observing
LAP1 decreasing pressure.
41. Turn the key switch OFF and allow the steering
accumulators to bleed down.
42. Open both accumulator bleeddown valves and
bleed down the entire brake system. Close
valves after all pressure is released.
43. Disconnect the hose (4, Figure 4-4) that supplies oil to the brake valve ("P2" port), front
brake circuit, by removing at the tee attached to
the bottom of the hydraulic cabinet (brake manifold port "AF1"). Cap the tee fitting, but hose
must be vented to atmosphere.
2700 psi (18,613 kPa).
07/03 J04026
45. Depress the brake pedal very slowly until the

brake differential pressure switch activates the
low brake pressure lamp and buzzer.
Verify fault indicators are activated at 600
50 psi (4 137 345 kPa).
* Record Pressure on data sheet.
46. Shut down the engine and turn key switch
OFF. Allow steering accumulators to bleed
down.
47. Open both accumulator bleeddown valves and
bleed entire brake system. Close valves after
all pressure is released.
48. Reconnect hose (4, Figure 4-4) to tee at "AF1"

port, bottom of hydraulic cabinet
49. Disconnect the hose (5, Figure 4-4) that supplies oil to the brake valve ("P1" port), rear
brake circuit, by removing at the tee attached
to the bottom of the hydraulic cabinet (brake
manifold port "AR1"). Cap the tee fitting, but
hose must be vented to atmosphere.
2700 psi (18,613 kPa).
FIGURE 4-4. HYDRAULIC COMPONENTS CABINET

1. Operator's Cab
2. Hoses to Brake Valve & Steering Control Valve
3. Hydraulic Components Cabinet
4. To Brake Valve, Port "P2"
5. To Brake Valve, Port "P1"
J04026 07/03
6. To Brake Valve, Port "B1"

7. To Rear, Frame Mounted Brake Accumulator
8. To Rear Axle Junction Block, Port "P1"
9. To Front, Frame Mounted Brake Accumulator
10. To Brake Valve, Port "B2"
J4-9
51. Depress the brake pedal very slowly until the

brake differential pressure switch activates the
low brake pressure lamp and buzzer.
Verify fault indicators are activated at 600
50 psi (4 137 345 kPa).
* Record Pressure on data sheet.
52. Shut down the engine and turn key switch OFF.
Allow steering accumulators to bleed down.
Open both accumulator bleeddown valves and
bleed entire brake system. Close valves after all
pressure is released.
53. Reconnect hose (5, Figure 4-4) to tee at "AR1"
port, bottom of hydraulic cabinet.
54. Remove all test equipment and verify all hoses
have been reconnected.
NOTE: If hoses (4, Figure 4-5) and (10) are switched,
the rear brakes will be slow to apply and slow to
release.
FIGURE 4-5. REAR BRAKE HOSES

1. BS - Left & Right Brake Cooling Oil Supply
2. LBR - Left Brake Cooling Return Line
3. T - Return To Tank
4. P1 - Pressure Inlet From Accumulator
5. Axle Housing
6. Wheel Motor
7. RBR - Right Brake Cooling Return Line
8. RBP - Right Brake Pressure Test Port
9. LBP - Left Brake Pressure Test Port
10. PX - Pilot Inlet/Brake Apply Line
11. PB - Parking Brake
J4-10
07/03 J04026
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING

POSSIBLE CAUSES
SUGGESTED CORRECTIVE ACTION
TROUBLE: The Brakes are Locked, Service and/or Parking

Parking brake solenoid is de-energized.
Check power to solenoid
Connections to tank and pressure ports reversed.
Correct the plumbing.
Parking brake solenoid coil defective.
Replace coil.
Parking brake solenoid valve defective.
Replace solenoid valve.
Tank line is plugged or restricted.
Remove restriction.
TROUBLE: Both Brake Circuits are Dragging

Tank line has back pressure.
Ensure tank line has no back pressure.
Pedal set screw out of adjustment; residual pressure.
Adjust pedal deadband with set screw.
TROUBLE: One Brake Circuit is Dragging

Obstruction in the brake valve subassembly.
Remove obstruction.
Brake valve is out of balance.
Adjust balance according to instructions.
Actuator piston defective.
Replace piston.
Brake valve is defective.
Rebuild or replace brake valve assembly.
A dual relay valve is defective
Rebuild or replace dual relay valve assembly.
TROUBLE: The Brakes are Not Going to Full Pressure

Supply pressure is low.
Check steering/brake pump system and accumulators.
Internal malfunction of modulating section of brake

valve.
Remove, disassemble, clean, and inspect brake

valve.
Improper collar adjustment on brake valve.
Adjust collars according to instructions.
TROUBLE: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system.
Check wiring.
Brake accumulator bleeding down.
Valve open; close valve.
Differential pressure switch defective.
Check switch on brake valve and dual relay valves;

replace defective switch assembly or adjust as necessary.
Brake warning relay defective.
Replace relay.
J04026 07/03
J4-11
POSSIBLE CAUSES
TROUBLE: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released
Brake valve out of balance (not tracking).
Differential pressure switch is defective or improperly adjusted.
Check the switch and replace if defective. Check differential pressure switch adjustment.
Accumulator precharge/leak.
Check accumulators and recharge if necessary.
Problem in brake valve subassembly.
Remove, disassemble, clean, and inspect brake

valve assembly or replace it.
Dual relay valve defective
Inspect and repair dual relay valve(s)
Air in one brake circuit.
Bleed brakes.
Small leak in one circuit.
Inspect brake system and repair leaks.
Brake warning delay timer defective
Replace timer.
TROUBLE: A Low Brake Pressure Warning Occurs When Brakes are Applied
Leak or other malfunction in one brake circuit.
Inspect brake system and repair leaks.
Brake valve balance is out of adjustment.
A dual relay valve is defective
TROUBLE: The Differential Pressure Warning Circuit is not Operating

Low brake pressure lamp is burned out.
Replace bulb.
Electrical problem.
Check switch circuit wiring.
Problem in brake valve assembly.
Remove, disassemble, clean, and inspect, or

replace brake valve.
Dual relay valve defective
Brake warning relay defective.
Replace relay.
J4-12
07/03 J04026
POSSIBLE CAUSES
TROUBLE: The Low Pressure Warning Circuit Not Operating Properly

The low brake pressure lamp is burned out.
Replace the bulb.
The electrical circuit is open.
Check switch circuit wiring.
Pressure switch defective.
Replace the pressure switch.
TROUBLE: Low Pressure Warning is On Even Though System Pressure is Proper

Short in electrical system.
Check wiring.
Pressure switch is defective.
Replace the switch.
TROUBLE: Low Pressure Warning Comes On and Pressure is Low

Steering circuit is malfunctioning.
Check steering circuit pressures.
The pump is worn.
Rebuild or replace pump.
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open.
Close valve, check precharge.
Accumulator precharge is low.
Recharge accumulator
Leak in one circuit.
Check plumbing.
Malfunction in brake valve.
Remove,
replace.
disassemble,
clean,
reassemble;
or
TROUBLE: A "Squeal" is Heard When Controller is Operated

Rapid operation of controller.
Normal
Brake valve assembly is damaged.
Replace the brake valve assembly.
Hydraulic oil is too hot.
Check entire hydraulic system for restriction etc.
TROUBLE: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected.
Check plumbing.
TROUBLE: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in brake valve assembly.
Remove,
replace.
Damage in brake valve assembly.
Repair or replace brake valve assembly.
Dual relay valve malfunctioning
Repair or replace dual relay valve assembly.
J04026 07/03
disassemble,
clean,
reassemble;
or
J4-13
POSSIBLE CAUSES
TROUBLE: Oil is Leaking Around the Pedal Base

Defective seal on top of brake valve.
Replace the seal.
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component.
Check all steering and brake system components.
Steering accumulator precharge too high or too low.
Check steering accumulator precharge.
Brake valve plumbed incorrectly.
Correct plumbing.
Internal leakage in brake valve assembly.
Replace brake valve assembly.
Internal leakage in dual relay valve assembly.
Rebuild or replace dual relay valve
Steering/brake pump is worn.
Rebuild or replace pump.
Pump unloader or compensator not adjusted correctly.
Adjust pump pressure controls.
J4-14
07/03 J04026
CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
MACHINE MODEL_______ UNIT NUMBER__________SERIAL NUMBER______________
I. INITIAL SYSTEM SET-UP
Operate hydraulic steering system to obtain proper operating temperature. Refer to Check-out
Procedures.
STEP 2
__________ All brake accumulators charged to 1400 psi (9.65 MPa).
STEP 7
__________ Maximum rear brake pressure (brake lock).
STEP 8
__________ Maximum rear brake pressure.

__________ Maximum front brake pressure.
II. SERVICE BRAKE SYSTEM CHECK-OUT

Refer to appropriate Service Manual procedures and bleed brakes; bleed park brakes.
STEP 9
__________ Park brake indicator light off.

__________ Park brake circuit pressure.
STEP 14 __________ Pressure at which brake indicator light comes on.

__________ Pressure at which stop lights come on.
STEP 15 __________ Left rear brake pressure within one second (LBP).
__________ Right rear brake pressure within one second (RBP).
__________ Brake pressures remain above 2375 psi (16,375 kPa) minimum for 20
seconds.
STEP 18 __________ Left front brake pressure within one second.
__________ Right front brake pressure within one second.
__________ Brake pressures remain above 2375 psi (16,375 kPa) minimum for 20
seconds.
J04026 07/03
J4-15
CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
STEP 24 __________ Brake lock degradation switch actuation pressure.
STEP 27 __________ Rear brake pressure with brake lock applied.
FAILURE MODES CHECK-OUT

STEP 32 __________ Low accumulator pressure after 2 minutes.
STEP 33 __________ Pressure when warning systems actuate (front brakes).
__________ Pressure at which auto apply actuates.
STEP 36 __________ Pressure when warning systems actuate (rear brakes).
__________ Pressure at which auto apply actuates.
STEP 40 __________ Number of brake applications before auto apply actuates.
STEP 45 __________ Front brake pressure at which differential switch actuates low brake
pressure buzzer and lamp.
STEP 51 __________ Rear brake pressure at which differential switch actuates low brake
pressure buzzer and lamp.
Name of technician or inspector performing Check-Out _____________________________
J4-16
07/03 J04026
SECTION J5
WET DISC BRAKE ASSEMBLY
INDEX
WET DISC BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-3

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
Brake Disc Wear Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
Removal/Installation - Wet Disc Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
BRAKE REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-10
Floating Ring Seal Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-13
WET DISC BRAKE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-16
J05018 03/01
Disc Brake Assembly
J5-1
NOTES
J5-2
Disc Brake Assemblyl
03/01 J05018
WET DISC BRAKE ASSEMBLY

The oil cooled, wet disc brake assemblies mounted
on the front and rear wheels are similar in design.
The rear wheel brakes differ from the front in their
mounting arrangement only. The rear brake assembly requires an adapter hub (1, Figure 5-1) for installation on the wheel motor wheel hub.
Each disc brake assembly consists of the following
basic components:
Ten friction discs
Nine separator plates
Two damper discs
Piston assembly
Stationary ring gear
Rotating inner gear
Floating ring oil seal assembly
OPERATION
The ring gear (4, Figure 5-1) is internally splined to
retain the dampers (8) and separator plates (12). The
separator plates are alternately placed between the
friction faced discs (7) which are splined to the inner
gear (6). The inner gear mounts directly to the wheel
hub on the front wheel brakes. On the rear, the inner
gear requires an adapter hub which mounts on the
wheel hub on the wheel motor.
The inboard side of the assembly contains the piston
(9) which is activated by hydraulic pressure supplied
by the dual relay valves (controlled by the brake
valve). As hydraulic pressure is applied, the piston
moves to compress the rotating friction faced discs
against the stationary steel discs. The friction forces
generated resist the rotation of the wheels. As
hydraulic pressure increases, friction forces are
increased and wheel rotation is slowed until maximum force is reached and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The low pressure cooling circuit is completely isolated from the high pressure, piston apply circuit.
Cooling oil flows from the hydraulic tank to the hoist
pump, through the hoist circuit high pressure filters,
through the hoist valve, and into the brake housings.
A parallel circuit from the hoist valve outlet is connected to relief valves at the hydraulic tank which
limit brake cooling circuit pressure to 35 psi (241
kPa). Oil routed to the front brakes passes through
the oil cooler before entering the front brake housings. In addition, the brake cooling oil provides lubrication for the front wheel bearings. Oil exiting the
brake housings returns to the hydraulic tank.
J05018 03/01
FIGURE 5-1. WET DISC BRAKE ASSEMBLIES

1. Hub Adapter
(Rear Only)
2. Capscrew & Lockwasher
3. Socket Head Screw
(Temporary)
4. Ring Gear
Disc Brake Assembly
5. Capscrew & Hardene

Washer
6. Inner Gear
7. Friction Disc
8. Damper
9. Piston Assembly
10. Seal Carrier
11. Back Plate
J5-3
MAINTENANCE
Brake disc wear should be checked every 1000 hrs.
using the wear indicator tool (Part Number EF9302),
included in the tool group shipped with the truck.
Brake Disc Wear Indicator

The brake disc wear indicator tool is inserted in a port
which is open to cooling oil. Removal of the inspection hole plug to insert the brake disc wear indicator
will cause the loss of some of this oil. Advance planning will help to minimize oil loss.
Consider scheduling front brake disc wear inspections along with the recommended 1000 hr. change
of hydraulic oil and filters. Rear brakes should be
inspected for wear whenever the rear tires are
removed. Also consider obtaining additional brake
disc wear indicator tools for permanent installation on
truck. If all brake assemblies are equipped with disc
wear indicators, future checks will not require installation and removal.
FIGURE 5-2. BRAKE WEAR INDICATOR

1. Cover
2. Indicator Pin
Face (Ref.)
3. Housing Face (Ref.)
4. O-Ring
5. O-Ring
6. Tool Housing
7. O-Ring
8. Indicator Pin
Removal/Installation - Wet Disc Brake Assembly
Before removing test port plugs, always bleed

down hydraulic steering and brake accumulators. The steering accumulators can be bled
down with engine shut down, turning the key
switch OFF and waiting 90 seconds. Confirm the
steering pressure is released by turning the
steering wheel - No front wheel movement
should occur.
Open bleed down valves located on the brake
manifold. This will allow both accumulators for
the rear brakes and both accumulators for the
front brakes to bleed down.
1. Place the selector switch in NEUTRAL, apply

the park brake, turn the rest switch ON, turn the
key switch OFF and allow the steering accumulators to bleed down completely. Block truck
wheels.
2. Open the bleeddown valves on the brake manifold (in the hydraulic components cabinet) and
bleed all pressure from the brake accumulators.
Close valves after pressure is released.
3. Thoroughly clean the brake assemblies, especially the area surrounding cooling oil lines.
4. Remove the hex head O-ring plug from the port
(5, Figure 5-3) next to the cooling line opposite
the cooling line (3) with the adjacent brake
apply line (2) port. Quickly insert the brake wear
indicator tool and tighten securely.
NOTE: The front wheel brakes have a diagnostic
connector installed for measuring brake apply
pressure. The rear brakes do not have a diagnostic
connector installed on the brake backplate, but
instead have an O-ring plug installed. Do not attempt
to install the brake wear indicator in this port.
5. Start the engine and allow the steering system
to stabilize and the brake accumulators to fill.
J5-4
03/01 J05018
6. While fully applying the service brake pedal,

check brake wear as follows:
a. Remove wear indicator cover (1, Figure 5-2).
b. Push pin (8) in until it stops against brake
piston.
c. Measure the distance from indicator pin end
face (2) to housing face (3).
If pin end face (2) is even with the housing
face (3) or below, disc pack is worn to
maximum safe wear limits. Brakes should be
scheduled for rebuild.
If pin end face (2) extends out beyond
housing face (3), brake disc wear is still within
allowable limits.
7. Pull pin (8) out until it stops against tool housing
(6) and install protective cover (1).
8. Release brakes. Shut down engine, allow steering accumulators to bleed down. Open brake
accumulator bleeddown valves to remove all
pressure from the brake system. Close valves
after all pressure is released.
9. Remove the brake disc wear indicator tool and
reinstall O-ring plug in port.
10. To check the remaining brake assemblies,
repeat Steps 4 through 9.
FIGURE 5-3. BRAKE WEAR INDICATOR

INSTALLATION
(Left Front Brake Shown)
1. Brake Assembly
2. Brake Apply Line
3. Brake Cooling Line
4. Diagnostic Coupler
5. Wear Indicator
Installation Port
NOTE: Checking disc wear in all brake assemblies is

recommended. Disc wear in one brake assembly
may be different from the other due to dissimilar
operation of parts and/or haul profiles which require
repeated braking while steering in one direction only.
11. Refill hydraulic tank as required.
12. If brake repairs are necessary, refer to Brake
Rebuild this section.
NOTE: If any leakage is observed around the brake
disc wear indicator tool, replace O-rings (4, 5 and 7
Figure 5-2).
J05018 03/01
Disc Brake Assembly
J5-5
BRAKE REBUILD
The brake assembly should be disassembled

and reassembled on a clean, dry work surface.
The surface should be wooden or if metal,
covered with padding to prevent damaged to
machined surfaces
Match mark individual parts for correct orientation

prior to disassembly.
If a rear wheel brake is to be disassembled, start

with step 1 below. If a front wheel brake is to be
disassembled, start the disassembly procedure
at step 5.
The front brake assembly weighs approximately

3210 lbs. (1460 kg) The rear brake assembly
weighs approximately 4000 lbs. (1820 Kg). Be
certain lifting devices are rated to handle the
load.
Disassembly
Rear Wheel Brake Only:
FIGURE 5-4. BRAKE ASSEMBLY
Refer to Wheel Motor Rebuild instructions for rear

wheel brake assembly removal.
1. Verify socket head capscrews (3, Figure 5-1)
are installed at each of the six locations on the
back plate (11). These capscrews are required
to retain the seal carrier (10) to the back plate
when the brake assembly is not installed on the
truck. Shipping bars (4, Figure 5-4) must be
installed.
2. Remove the 12-point capscrews and hardened
washers (5, Figure 5-1).
3. Remove capscrews and lockwashers (2) used
to retain the hub to the seal carrier.
4. Be certain hub and other parts are marked to
ensure proper orientation during reassembly.
Lift the hub adaptor (1) from brake assembly.
Be certain to note shim packs installed at six
locations on between seal carrier and hub.
Both Front and Rear Wheel Brakes:
Remove the front wheel/brake assembly according to
the instructions in Section G, Front Wheel Hub and
Spindle.
5. Position brake assembly on work surface with
ring gear retainer bars on bottom as shown in
Figure 5-5.
1. Ring Gear
2. Back Plate
3. Capscrew
4. Shipping/Storage
Bar
5. Inner Gear
6. Remove socket head capscrews (2, Figure 55). Lift seal retainer (1) off brake assembly.
NOTE: Socket head capscrews (2) are required to
retain and position seal carrier on brake back plate
when the brake assembly is not installed on the
wheel hub or during brake assembly shipping or
storage. Shipping bars (4, Figure 5-4) must be
installed to retain the inner gear inside the brake
assembly.
7. Remove capscrews (4, Figure 5-5) and hardened flatwashers (5) from backplate (3).
8. Insert a 7/8 UNC x 2.0 in. pusher bolt in each of
the three tapped holes in the back plate.
Tighten bolts evenly to lift back plate from ring
gear (7). Remove and discard O-ring (6).
9. Noting order of assembly of discs, remove the
damper (10) from top of stack. Remove friction
discs (11), separator plates (9) and remaining
damper at bottom of stack.
10. Rotate the brake assembly to position shipping
bars on top as shown in Figure 5-4.
11. Remove capscrews (3) retaining shipping bars
(4) to housing.
J5-6
03/01 J05018
FIGURE 5-5. INITIAL DISASSEMBLY

1. Seal Carrier
2. Capscrew
3. Back Plate
4. Capscrew
5. Hardened Washer
6. O-Ring
7. Ring Gear
8. Piston Housing
9. Separator Plate
10. Damper
11. Friction Disc
12. Inner Gear
FIGURE 5-6. PISTON/HOUSING ASSEMBLY REMOVAL

1. Piston Housing
2. Capscrew
J05018 03/01
3. Hardened Washer
4. O-Ring
Disc Brake Assembly
5. Ring Gear
J5-7
FIGURE 5-7. PISTON REMOVAL

1. Capscrew
2. Spring Guide
3. Piston Retract Spring

4. Piston Assembly
5. Piston Housing
12. Attach a lift strap through bars and lift inner gear
(5) out of brake assembly. Remove shipping
bars and spacers.
13. Remove capscrews (2, Figure 5-6) and hardened washers (3) from piston housing (1).
14. Insert a 7/8 UNC x 2.0 in. pusher bolt in each of
the three tapped holes in the piston housing.
Tighten bolts evenly to lift housing from ring
gear (5). Remove and discard O-ring (4).
J5-8
6. Seal Assembly
7. Seal Assembly
15. Position piston assembly with retract springs on

top as shown in Figure 5-7.
16. Remove capscrews (1, Figure 5-7), spring
guides (2), and piston retract springs (3).
NOTE: Capscrew (1) threads are coated with
Loctite during assembly. A small amount of heat
applied to the piston housing may be required for
easier removal.
17. Loosen or remove plugs installed in piston
housing ports. Carefully lift piston (4) out of
housing (5). Remove seal assemblies (6 & 7).
03/01 J05018
5. Inspect piston retract springs (3, Figure 5-7).

Check springs for free height and test for height
under load. Replace if not within approximately
10% of specification.
Free Height:
If the brake wear indicator test indicates internal
brake components are worn to the maximum
allowable limit, it is recommended that all friction
discs, separator plates and dampers should be
replaced with new parts. Always replace seal
assemblies and O-rings with new parts.
1. Clean all parts thoroughly prior to inspection.
2. Remove and discard toric rings from floating
ring oil seal assembly (6, Figure 5-1) in seal
retainer and back plate. Inspect seal ring polished (mating) surfaces for scratches or other
damage. Inspect the contact band of the mating
faces to determine amount of wear.
NOTE: A new seal will have a contact band
(dimension "A", Figure 5-8) approximately 0.06 in.
(1.6 mm) wide. As wear occurs, the contact band will
widen slightly (dimension "B") and migrate inward
until the inside diameter is reached and the entire
seal assembly must be replaced. Remaining seal life
can be estimated by the width of the contact band.
3. Inspect piston housing for nicks or scratches in
piston seal area. If nicks or scratches cannot be
removed by polishing, replace housing.
4. Inspect piston seal assembly grooves for damage.
. . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 in. (101.6 mm)

Height @ 225 lb. (1000 N) working load:
. . . . . . . . . . . . . . . . . . . . . . . . . 3.351 in. (85.12 mm)
Height @ 600 lb. (2669 N) working load:
. . . . . . . . . . . . . . . . . . . . . . . . . . 2.750 in. (69.9 mm)
6. Inspect friction disks for warping, tooth wear,
and excessive friction material wear. Replace if
wear exceeds minimum groove depth.
Disc thickness including friction material:
. . . . . . . . . . . . . . . . . . 0.30 0.01 in. (7.7 0.3 mm)
Friction material thickness (new)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 in. (1.1 mm)
Nominal friction material groove depth:
. . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 in. (0.63 mm)
Minimum allowable friction material groove
depth:
. . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 in. (0.25 mm)
Flatness over friction material (new)
. . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 in. (0.45 mm)
7. Inspect separator plates for warping and tooth
wear.
Disc thickness (new)
. . . . . . . . . . . . . . . . 0.146 0.004 in. (3.7 0.1 mm)
Flatness (new)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in. (0.5 mm)
8. Inspect damper plate for warping, tooth wear
and excessive facing material wear
Disc thickness, including facing material
(new)
. . . . . . . . . . . . . . . . 0.323 0.020 in. (8.2 0.5 mm)
Disc thickness, steel plate only (new)
. . . . . . . . . . . . . . . . 0.146 0.004 in. (3.7 0.1 mm)
Flatness, steel plate (new)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in. (0.5 mm)
9. Inspect ring gear for excessive tooth wear and
nicks and scratches in O-ring seal grooves.
FIGURE 5-8. SEAL WEAR PROGRESSION
J05018 03/01
10. Inspect inner gear for excessive tooth wear and

damage at capscrew holes.
Disc Brake Assembly
J5-9
8. After completion of piston leakage test, release

pressure, remove hydraulic source and drain oil
from piston apply cavity. Plug ports to prevent
contamination.
Assembly
The work area must be clean! Handle all parts

carefully to avoid damage to polished sealing
surfaces.
1. Check piston housing (5, Figure 5-7) bore for
nicks, scratches or dirt particles. Position housing on work surface with bore facing up.
2. Lubricate square section O-ring portion of piston seal assemblies (6 & 7) with type C-4
hydraulic oil and install in piston (4) grooves. Be
certain O-ring is not twisted.
3. Lubricate piston groove and outer piston seal
rings. Install in grooves over O-rings, using fingers or a smooth rounded object to push seal
into groove.
4. Install two equally spaced 1/2 UNC x 5.0 in.
guide studs in the housing at the piston retract
spring mount tapped holes.
5. Lubricate housing bore. Install lift eyes and
attach an overhead hoist to piston. Position piston over housing with retract spring cavity holes
aligned with studs installed in previous step.
Place a spring guide over each stud to aid alignment. Carefully lower straight into bore until
seated against housing. If necessary, seat piston by tapping with a soft mallet.
6. Assemble twelve capscrews (1), spring guides
(2) and retract springs (3). Apply Loctite to
capscrew threads and install assembled parts
through piston into tapped holes in housing.
torque.
Piston Pressure Test:
7. Test piston/housing assembly as follows:
a. Install a plug in one brake apply pressure
port (2, Figure 5-8).
b. Install a fitting into remaining port and attach
a hydraulic pressure test device.
c. Slowly apply pressure and loosen the apply
port plug to bleed air from piston cavity.
d. Cycle piston to full stroke ten times by applying 300 psi (2070 kPa) hydraulic pressure.
Observe piston for leakage.
NOTE: Minor oil seepage (non-measurable) is
permissible. If leakage is greater, disassemble piston
assembly and determine cause.
J5-10
9. Install O-ring (4, Figure 5-6) in groove of ring

gear (5).
10. Attach lifting eyes to piston/housing assembly
and lower into position over ring gear. Install
capscrews (2) and hardened washers (3). Alternately tighten capscrews to 575 ft. lbs. (780
N.m) torque.
11. Insert inner gear (5, Figure 5-9) into assembly.
Orient gear as shown.
12. Place shipping (retainer) bars over the piston
housing as shown in Figure 5-9. Attach bars
using 1/2 UNC x 1.75 in. capscrews and lockwashers (7) at outer ends of bars (4). Insert
spacers (9) and 1/2 UNC x 8.0 in. capscrews
and lockwashers (8) as shown to retain inner
gear in position.
13. Attach lift eyes to assembly, lift and rotate to
place piston housing on the bottom.
14. Install discs as follows:
a. Insert a damper disc (1, Figure 5-10) into the
ring gear and inner gear with the friction
material (down) facing the piston (5).
b. Insert a friction disc (2) on top of the damper.
c. Install a separator plate (3).
d. Continue installing the remaining friction
discs and separator discs, alternating each
type as installed.
NOTE: The disc pack contains a total of ten (10)
friction discs, nine (9) separator plates, and two (2)
damper discs.
e. Install the remaining damper on top of the
last friction disc with its facing material on
top. (Unfaced side toward top friction disc.)
15. Using a new O-ring (6, Figure 5-5), install back
plate (3) over ring gear. Be certain back plate is
oriented properly according to the match marks
made during disassembly.
NOTE: A seal carrier socket head capscrew hole on
the back plate should be aligned with the drain plug
on the piston housing.
16. Install capscrews (4) and hardened washers
(5). Alternately tighten capscrews to 575 ft. lbs.
(780 N.m) torque.
03/01 J05018
17. Follow procedures in Floating Ring Seal

Assembly/Installation to install seal assembly
in cavities in the back plate and seal carrier.
18. Install seal carrier on back plate. Secure in

place with six 1/2 UNC x 0.75 in. socket head
capscrews to retain seal carrier in position until
brake assembly is installed on the truck.
FIGURE 5-9. INNER GEAR INSTALLATION

9. Spacer
5. Inner Gear
1. Cooling Oil Port
10. Wear Indicator Installation
6. Drain Plug
2. Brake Apply Pressure Ports
Port
3. Piston Housing
11. Ring Gear
4. Shipping Bar
FIGURE 5-10. DISC PACK INSTALLATION

1. Damper
2. Friction Disc
J05018 03/01
3. Separator Plate
4. Piston Housing
Disc Brake Assembly
5. Piston
J5-11
NOTE: After a front wheel brake assembly is

installed, the seal must be setup for proper seal
compression. Refer to Seal Assembly Gap Check in
Section G, Front Wheel Hub and Spindle.
19. Assembly is now complete if the brake assembly is to be installed on a front wheel. If the
brake assembly is to be installed on a rear
wheel, follow the additional steps below.
Rear Wheel Brake Assembly Only:
20. Install a new O-ring (1, Figure 5-11) in hub
groove.
21. Position hub over seal carrier. Orient the hub
according to the marks made during disassembly. to align hub flange holes with seal retainer
tapped holes.
22. Insert the following shims between hub flange
and seal retainer at each pair of capscrews (3)
(six places):
Ten . . . . . . . . . . . . 0.020 in. (0.51 mm) thick
One . . . . . . . . . . . 0.010 in. (0.25 mm) thick
23. Install capscrews and lockwashers (3) and
tighten securely.
Seal Gap Adjustment:

24. Refer to Figure 5-12 and adjust seal gap:
a. Measure seal gap "A" at three equally
spaced locations. Add the three dimensions
and divide by 3 to determine an average
dimension.
b. Add 21.470 in. (545.34 mm) to the average
dimension determined in previous step.
c. Measure dimension "B" at three equally
spaced locations. Add the three dimensions
and divide by 3 to determine the average
dimension.
d. Subtract the dimension in step c. from the
dimension in step b. to determine change in
shim pack.
e. Add or remove equal quantities and thicknesses of shims to the original shim pack as
determined in step at the six shim locations.
The shim pack must provide a final dimension "B" within 0.005 in. (0.13 mm) of the
dimension calculated in step b.
Example
Step a: average gap "A" = . . . . . . . . . . .0.600 in.
Step b: add "A" + 21.470 = . . . . . . . . . 22.070 in.
Step c: average dimension "B" = . . . . .22.034 in.
Step d: ("A" + 21.391) - ("B") = . . . . . . .0.036 in.
Step e: In this example, adding two 0.020 in.
shims would result in a dimension "B" of
22.074 in., and is within the tolerance limit
of 0.005 in.
25. Final tighten capscrews (3, Figure 5-11) to 90 ft.
26. Install capscrews and hardened washers (8). It
will be necessary to remove the shipping bars
from the inner gear to access some capscrews.
Alternately tighten capscrews to 1995 ft. lbs.
(2705 N.m) torque. Replace shipping bars.
FIGURE 5-11. REAR BRAKE, HUB INSTALLATION

6. Socket Head Cap1. O-Ring
screws
2. Hub Adapter
3. Capscrews & Washers 7. Ring Gear
8. Capscrew & Hardened
4. Shims
Washer
5. Seal Carrier
9. Inner Gear
FIGURE 5-12. SEAL GAP ADJUSTMENT
J5-12
03/01 J05018
Floating Ring Seal Assembly/Installation

Failures are usually caused by combinations of factors rather than one single cause, but many failures
have one common denominator: Assembly Error!
Floating ring seals should always be installed in
matched pairs: that is, two new rings or two rings
that have previously run together. Never assemble
one new ring and one used ring; or two used rings
that have not previously run together.
ALWAYS USE NEW TORIC RINGS!
1. Inspect seal surfaces and mounting cavities for
rough tool marks or nicks that may damage
rubber seal rings. Hone smooth and clean, if
required. Remove any oil, dust, protective coating or other foreign matter from the metal seal
rings, the toric rings, and both the housing and
seal ring ramps. Use tri-chloroethane #111
which is a non-petroleum base, rapid drying
solvent leaving no film. Allow surfaces to dry
completely. Use clean, lint-free material such
as "Micro-Wipes # 05310" for cleaning and wiping.
When using tri-chloroethane or any solvent,

avoid prolonged skin contact. Use solvents only
in well ventilated areas and use approved respirators to avoid breathing fumes. Do not use near
open flame or welding operations or other heated
surfaces exceeding 900F (482C). Do not smoke
around solvents.
Both ramps must be dry. Use clean, lint-free cloths
or lint-free paper towels for wiping.
NOTE: Oil from adjacent bearing installations or seal
ring face lubrication must not get on the ramp or
toric until after both seal rings are together in
their final assembled position.
2. Install the rubber toric on the seal ring.
Make sure it is STRAIGHT! Make sure the toric

ring is not twisted and that it is seated against the
retaining lip of the seal ring ramp. Use the flash line
as a reference guide to eliminate twist.The flash line
should be straight and uniform around the toric.
NOTE: Handle seal carefully; nicks and scratches
on the seal ring face cause leaks.
FIGURE 5-13. SEAL TERMINOLOGY
1. Seal Ring
2. Rubber Toric
3. Housing Retainer Lip
4. Housing Ramp
5. Seal Ring Housing
J05018 03/01
6. Seal Ring Face

7. Seal Ring Ramp
8. Seal Ring Retainer
Lip
Disc Brake Assembly
J5-13
3. Place installation tool onto seal ring with toric.

Refer to Section M, Special Tools, for installation tool. Lower the rings into a container of trichloroethane until all surfaces of toric ring are
wet.
6. If small adjustments are necessary, DO NOT

push directly on the seal ring. Make any
required adjustments with installation tool.
ALTERNATE PROCEDURE:
After positioning the seal squarely over the retaining
lip, thoroughly lubricate the ring by spraying with trichloroethane #111.
DO NOT USE Stanosol or any other liquid that
leaves an oily film or does not evaporate quickly.
4. With all surfaces of toric ring wet, use installation tool to position seal ring and toric ring
squarely against the seal housing.
APPLY SUDDEN AND EVEN PRESSURE to pop
(push) toric under housing retaining lip.
7. Toric can twist if it is dry on one spot or if there

are burrs or fins on the housing retaining lip.
A bulging toric or cocked seal can contribute to eventual failure.
5. Check with site gauge. Check variation in seal

ring "assembled height" in four places, 90
apart. Height variation around the assembled
ring should not exceed 0.51 0.05 in. (1.30
0.01 mm) for brake assembly floating seal or
0.45 0.04 in. (1.14 0.01 mm) for the hub
seal.
J5-14
NOTE: Toric ring must not slip on ramps of either

seal ring or housing. To prevent slippage, - WAIT - at
least two minutes. Let all tri-chloroethane evaporate
before further assembly. Once correctly in place, the
toric ring must roll on the ramps only. If correct
installation is not obvious, repeat steps 3
through 6.
03/01 J05018
10. Be certain both housings are in correct alignment and are square and concentric. Move the
parts slowly and carefully toward each other.
8. Wipe the polished metal seal surfaces with
clean tri-chloroethane to remove any foreign
material or fingerprints. No foreign particles of
any kind should be on the seal ring faces.
Something as small as a paper towel raveling
will hold the seal faces apart and cause leakage.
Ensure seals are
square and concentric.
NOTE: Do not slam, bump or drop seals together.
High impact can damage the seal face and cause
leakage.
9. Apply a thin film of clean oil on the seal faces.

Use a lint-free applicator or a clean finger to distribute the oil evenly. Make sure no oil comes in
contact with the rubber toric rings or their mating surfaces.
Before assembling both seals & housing
together - WAIT - at least two minutes. Let all
tri-chloroethane evaporate. (Some may still be
trapped between toric and housing ramp.)
J05018 03/01
Disc Brake Assembly
J5-15
WET DISC BRAKE BLEEDING

PROCEDURE
NOTE: Rear wheel brakes must be bled prior to
rear tire installation.
1. Be certain the hydraulic brake supply (steering
circuit) is operating properly.
2. If necessary, charge the brake system accumulators. Refer to Section J, Brake Circuit Component Service - Hydraulic Brake Accumulators.
3. Be certain bleeddown valves on brake accumulator manifold are closed.
4. Check hydraulic tank oil level and correct if necessary.
5. With the wheels securely blocked, start the
engine and allow accumulators to fill.
6. Slowly depress the brake pedal until the service
brake is partially applied.
Rear Wheel Brakes:
7. Crack open the O-ring plug located next to the
cooling oil port and brake apply port on the
brake backplate. Close plug after oil runs clear
and free of bubbles. Repeat for remaining
wheel.
J5-16
NOTE: The other cooling line has a single hex plug

located adjacent. DO NOT use this plug for
bleeding brake.
Front Wheel Brakes:
NOTE: The front wheel brakes are equipped with a
diagnostic coupler on the brake backplate. A hose
with a mating fitting can be attached and used to
direct the oil into a container during the bleeding
process.
8. Attach a hose to the diagnostic coupler on the
brake backplate (brake apply pressure circuit).
9. Slowly depress the brake pedal until the service
brake is partially applied.
10. After oil stream is clear of air, remove hose from
coupler. Release brake pedal.
11. Repeat Steps 8 through 10 for the remaining
wheel.
12. Shut down engine, allow steering accumulators
to bleed down and check hydraulic tank oil
level.
03/01 J05018
SECTION J7
PARKING BRAKE
INDEX
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
Inspection - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J7-4
Removal - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
Installation - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J7-5
Disassembly - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
Cleaning and Inspection - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
Assembly - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
PARKING BRAKE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-8
J07010 12/98
Parking Brake
J7-1
NOTES
J7-2
Parking Brake
12/98 J07010
PARKING BRAKE
The Model 930E truck is equipped with a dry disc
type parking brake assembly mounted on each
wheel motor rotor shaft. The parking brake assemblies are inboard mounted and can be accessed
through the rear axle housing door.
The parking brake is intended to prevent truck movement after the vehicle has stopped, the engine is
shut down, and when the truck is left unattended.
The parking brake is not for use during truck loading
or dumping operations. Refer to the Operation and
Maintenance Manual for additional brake system
operation instructions.
OPERATION
The parking brake is a spring applied, hydraulically
released, multiple disc type brake, actuated by the
parking brake switch mounted on the instrument
panel in the operator's cab.
When the parking brake switch is placed in the ON

position, the parking brake solenoid valve (SV2)
located on the brake manifold in the hydraulic components cabinet is de-energized, removing hydraulic
pressure from the parking brake assemblies. Internal
belleville springs in the park brake assemblies act on
the piston to compress the disc pack, preventing
rotation of a gear (4, Figure 7-1) mounted on the
wheel motor rotor shaft.
When the parking brake is switched to the OFF position, pressurized oil is supplied to the brake assemblies through the (energized) parking brake solenoid
valve. Oil pressure applied to the parking brake piston compresses the belleville springs, releasing the
discs to allow the wheel motor rotor gear to rotate.
System interlocks prevent application of the parking
brake if the truck is in motion.
FIGURE 7-1. PARKING BRAKE

INSTALLATION
(RH Shown)
1. Wheel Motor Mounting Flange
2. Wheel Motor
3. Parking Brake Assembly
4. Gear (Motor Rotor Shaft)
5. Retainer Plate
6. Capscrew & Hardened
Washer
7. Park Brake Supply Hose
8. Cooling Air Duct Mount
9. Capscrew & Lockwasher
J07010 12/98
Parking Brake
J7-3
MAINTENANCE
Removal - Parking Brake
The parking brake system requires periodic inspection to determine the amount of wear incurred to
insure adequate brake torque is available. The following inspection should be made at 500 hour intervals.
Parking brake repairs should be performed when the

wheel motor is removed from the truck whenever
possible. If repairs are necessary when the wheel
motor is installed, it will be necessary to setup a lifting device inside the rear axle housing to support the
weight of the brake assembly when it is removed
from the wheel motor.
Inspection - Parking Brake

wheels.
2. Open brake accumulator bleeddown valves
located on brake manifold inside the hydraulic
components cabinet behind the cab. Allow adequate time for the accumulators to bleed down
completely.
If repairs are made when the wheel motor is

removed, follow the appropriate procedures below. If
repairs must be accomplished with the wheel motor
installed on the truck, follow all procedures listed
below.
The parking brake assembly weighs approximately 350 lbs. (159 kg). Be certain a lifting
device capable of supporting the weight is used
to support the brake assembly when removed.
wheels.
3. Open the rear axle housing access door and

remove wing nuts retaining duct inside door.
Remove duct tube and open access covers
inside axle housing.
4. Observe for signs of oil leakage or damage.
5. Measure amount of disc wear as follows:
a. With the parking brake applied, insert a
depth micrometer through one of the piston
position holes (18, Figure 7-2) and record
the dimension.
b. Repeat step a., measuring through the other
two holes and recording the dimensions.
c. Add the three measurements and divide the
total by 3 to determine the average.
d. If the resulting average of the three measurements is greater than 0.969 in. (24 mm),
the parking brake assembly must be
removed and rebuilt.
6. Repeat Step 5 for the other parking brake
assembly.
7. After inspection is complete, close duct access
covers and reinstall duct outlet tube.
2. Block wheels securely to prevent truck movement during parking brake repair.
3. Open brake accumulator bleeddown valves
located on brake manifold inside the hydraulic
components cabinet behind the cab. Allow adequate time for the accumulators to bleed down
completely.
4. Open the rear axle housing access door and
remove wing nuts retaining duct inside door.
Remove duct tube and open access covers
inside axle housing. Remove ducts as required
to setup a lifting device for brake removal.
5. Disconnect park brake apply supply hose (7,
Figure 7-1).
6. Remove capscrews and lockwashers (9). Install
guide studs in two of the mounting holes to support brake assembly when removed from wheel
motor frame.
7. Slide parking brake assembly out of wheel
motor frame and off inner gear (4). Remove
from axle housing.
J7-4
Parking Brake
12/98 J07010
Gear Removal:
Park Brake Installation:
If the rotor shaft gear (4, Figure 7-1) is worn, damaged or otherwise requires removal, follow the procedures below:
NOTE: Two oil supply ports are provided on the lower

half of the parking brake assembly. Install the O-ring
fitting for attaching the supply hose (7, Figure 7-1) to
the lowest port, depending on whether the brake is to
be installed on the right or left wheel motor. Install an
O-ring plug in the unused port.
NOTE: The gear is a shrink fit on the splined motor

shaft.
1. Remove capscrew and hardened washer (6,
Figure 7-1) from shaft. Remove retainer plate
(5).
2. Install a gear puller using tapped holes provided
in gear (4).
3. Apply heat around gear hub area while tightening puller until gear is removed from shaft.
1. Install two guide studs in wheel motor end

frame to guide brake assembly into position. Be
certain mating surfaces are clean and free of
burrs.
Gear Installation:
2. Lift parking brake into position for installation.

Note proper orientation depending on whether
brake is to be installed on a left or right wheel
motor. (Bleeder screw at top of brake will be
tilted toward front of truck.)
If the wheel motor rotor shaft gear was removed,

install gear prior to parking brake installation.
3. Slide assembly over guide studs and gear on

wheel motor rotor shaft.
1. Thoroughly clean gear (4, Figure 7-1) and

shaft. Inspect splines and remove burrs, etc.
that may interfere with installation.
4. Install capscrews and lockwashers (9, Figure 71) Tighten evenly to be certain brake housing is
properly seated on the wheel motor. Tighten to
220 ft. lbs. (298 N.m) final torque.
Installation - Parking Brake
2. Heat gear to 536F (280C). Install immediately

on shaft; gear must be fully seated against
shoulder on rotor shaft.
3. Install retainer plate (5), washer and capscrew
(6). Tighten capscrew to 440-495 ft. lbs. (595670 N.m) torque.
5. Install brake oil supply hose (7). Remove lifting

equipment.
6. Refer to Park Brake Bleeding Procedure in this
chapter and bleed air from brake apply line and
housing.
7. Reinstall all ducts removed.
J07010 12/98
Parking Brake
J7-5
Assembly - Parking Brake
Disassembly - Parking Brake
1. If dowel pins (2, Figure 7-2) have been

removed, press new dowel pins into holes in
housing until fully seated against shoulder.
1. Match mark housing (3, Figure 7-2), piston

housing (4), and cap structure (5).
2. Install a separator disc (12) over dowel pins.

Insert a spring (1) over each dowel pin. Insert a
friction disc (13). Insert springs (1) over dowels.
The following procedure is necessary to properly
relieve the pressure exerted by the belleville
springs on the cap structure. Failure to follow
this procedure could result in capscrew failure
and personal injury during disassembly!
2. Loosen the 12-point capscrews (10, Figure 7-2)
evenly, in 20 ft. lbs. (27 N.m) increments.
a. Alternate the loosening procedure by selecting successive capscrews located approximately 180 from the previous.
3. Install another separator disc, the 2nd friction

disc and the remaining separator disc.
NOTE: The internal teeth of the two friction discs
must be aligned and must be concentric with the pilot
diameter machined on the rear of the housing to
enable the completed assembly to be installed
properly. If available, a mating gear as installed on
the wheel motor rotor shaft (4, Figure 7-1) should be
used to simplify alignment.
4. Assemble the seals (8 & 9) on the piston.
b. Continue loosening procedure until spring

pressure is released and capscrews and
washers can be removed by hand.
a. Install O-ring seal in bottom of each groove.

Be certain O-rings are not twisted.
b. If available, use an expander to expand the
O.D. of each seal enough to allow it to slide
onto piston.
3. Remove cap structure (5). Lift belleville springs

(7) out of piston (6) counterbore.
4. Lift piston/housing assembly off housing (3)
dowels.
5. Remove springs (1), separator discs (12), and
friction discs (13).
6. Remove piston (6) from piston housing (4).
Remove piston seals (8 & 9) and discard.
NOTE: If an expander tool is not available, the seals

may be heated to 400F (204C) MAXIMUM. This
will allow ring to be manually expanded until it will fit
over piston.
c. When each seal is over the groove, re-size
by compressing the seal ring. Use a full circle clamp with any sharp edges or grooves
covered to prevent damage to the seal surfaces.
Cleaning and Inspection - Parking Brake

1. Clean all parts thoroughly.
2. Inspect dowel pins (2, Figure 7-2). If pins are
grooved from excessive wear or otherwise
damaged, press defective pin out of housing.
3. Inspect compression springs (1, Figure 7-2).
Check springs for free height and test for height
under load. Replace if not within approximately
10% of specification.
Free Height:
. . . . . . . . . . . . . . . . . . . . . . . . . 0.456 in. (11.58 mm)
Height @ 36.4 lb. (162N) working load:
0.350 in. (8.89 mm)
d. Install the quad ring in each seal.

5. Lubricate the piston seals and insert piston (6)
into piston housing (4).
6. Install piston/housing assembly over dowels on
housing (3).
7. Place belleville springs (7) in piston counterbore
as shown in Figure 7-2.
8. Place cap structure (5) on assembly and insert
capscrews (10) with hardened washer (11). Do
not tighten capscrews.
4. Inspect belleville springs for cracks or damage.

5. It is recommended the separator discs and friction discs be replaced if wear is indicated.
6. Check piston and piston housing bore for
scratches, nicks, pitting or other defects than
may cause seal leakage. Slight defects may be
repaired by polishing.
J7-6
The following procedure is necessary to properly

compress the belleville springs. Failure to follow
this procedure could result in capscrew failure
and personal injury during assembly!
Parking Brake
12/98 J07010
FIGURE 7-2. PARKING BRAKE ASSEMBLY

1. Compression Spring
2. Dowel Pin
3. Housing
4. Piston Housing
5. End Cap Structure
6. Piston
7. Belleville Springs
8. Piston Seal Assembly
10. Capscrew
11. Hardened Washer
12. Separator Disc
9. Select three capscrews 120 apart and mark

them.
a. Tighten the marked capscrews to 30 ft. lbs.
(41 N.m) torque. (Snug the remaining capscrews after each of the marked capscrews
are torqued in the following steps.)
Pressure Test:
10. Install the O-ring plug and bleeder (17). Install a
fitting in one of the pressure supply ports and
attach a hydraulic power source. Install an Oring plug in the remaining port.
b. Re-tighten the marked capscrews until the

gap between the cap structure and piston
housing is equalized.
c. Re-tighten the marked capscrews in 20 ft.
lbs. (27 N.m) increments until fully tight - 90
ft. lbs. (122 N.m) torque.
d. Tighten the remaining capscrews to 90 ft.
J07010 12/98
13. Friction Disc

14. Gear (Armature)
15. Plug
16. Oil Supply Port
17. Bleeder & O-Ring Plug
18. Piston Position Holes
Parking Brake
a. Slowly apply pressure and open the bleeder

valve to bleed air from the piston cavity.
Close the bleeder and apply 300 psi (2068
kPa) hydraulic pressure and hold for one (1)
minute.
b. Observe for oil leakage. NO leakage is permitted.
c. If leakage occurs, the brake assembly must
be disassembled and repaired.
J7-7
PARKING BRAKE BLEEDING

PROCEDURE
wheels.
6. Connect a clear plastic hose to the parking

brake bleeder screw. Place the other end of
hose in a container.
2. Block the truck wheels securely to prevent

movement when the parking brake is released.
10. Remove brake bleed equipment, close axle

housing cooling air ducts and reinstall duct tube
at door.
3. Open the rear axle housing access door,

remove the cooling air duct tube and open
access covers.
7. Slowly open bleeder valve and allow hydraulic

fluid to run until clear and free of bubbles. Close
bleeder screw securely.
8. Repeat Steps 6 & 7 for the other parking brake.
9. Shut down engine.
4. Be certain the brake accumulator bleeddown

valves are closed.
5. Start the engine and allow the steering system
to fully charge (pump unloads). Turn the parking
brake to the OFF position.
J7-8
Parking Brake
12/98 J07010
SECTION L
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-1
HYDRAULIC SYSTEM COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-1
STEERING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-1
STEERING CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-1
STEERING CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-1
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-1
HOIST CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
HIGH PRESSURE FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-1
HYDRAULIC CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-1
L01033
Index
L1-1
NOTES
L1-2
Index
L01033
SECTION L2
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-3

HYDRAULIC PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-3
HOIST CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-4
STEERING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-6
DISC BRAKE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-8
L02031
Hydraulic System
L2-1
NOTES
L2-2
Hydraulic System
L02031
HYDRAULIC SYSTEM
HYDRAULIC PUMP MODULE
The following is a general description of the model
930E hydraulic system. Additional information concerning individual component description and operation can be found under the different system
circuits such as the hoist circuit, steering circuit, and
hydraulic brake circuit.
Hydraulic pumps (16 & 18, Figure 2-1) are mounted

on a modular structure behind the traction alternator. The pump module also contains the pilot operated hoist valve (3), used to control operation of the
hoist cylinders during body dumping operations. An
overcenter manifold (10) contains internal valves (8
& 9) used to ensure smooth operation and maximum service life from the hoist cylinders.
The overcenter manifold also provides quick disconnect fittings (12) to allow operation of the hoist circuit by an external hydraulic source or to utilize the
hoist circuit of the truck to dump the load from a disabled truck.
FIGURE 2-1. HYDRAULIC PUMP MODULE

1. Hoist Valve Tank Return (To
Brake/Hoist Return Manifold)
2. Supply to Pilot Valve
3. Hoist Valve
4. From Pilot Valve
5. To Brake/Hoist Return Manifold
6. Work Port Outlet
L02031
7. Supply From Hoist Pump & Filter

8. Counterbalance Valve
9. Needle Valve
10. Overcenter Manifold
11. Hoist Cylinder Supply Tubes
12. Hoist Quick Disconnects
13. Pump Case Drain Line
Hydraulic System
14. Steering Pump Inlet Port

15. Unloader Valve
16. Steering/Brake Pump
17. Hoist Pump Inlet Hoses
18. Hoist Pump
19. Pump Driveshaft
L2-3
HOIST CIRCUIT OPERATION
Relieve pressure before disconnecting hydraulic

and other lines. Tighten all connections before
starting truck.
immediately.
Always maintain complete cleanliness when
opening any hydraulic connection. Insure that all
system lines are capped while the component is
removed from the truck.
NOTE: It is highly recommended that any hydraulic
oil to be used for filling or adding to the hydraulic
system is routed through a 3 micron filter device prior
to use.
The hoist, steering and brake circuits share a common hydraulic tank (7, Figure 2-2). The tank is
located on the left side of the frame, forward of the
rear wheels. Service capacity of the tank is 250 gal.
(947 l). Type C-4 hydraulic oil is recommended for
use in the hydraulic system. Oil used in the hoist,
steering and brake circuits flows from the bottom of
the tank through 100 mesh wire suction strainers.
Hydraulic oil from the tank is supplied to a gear type
hoist circuit pump (18, Figure 2-1), rated at 246 GPM
(931 l/min.) @ 1900 RPM and 2500 psi (17.2 MPa).
Oil from the pump outlet port is directed to high pressure filters (4, Figure 2-2) and then enters the hoist
valve (5).
The hoist pump (and steering/brake pump) is driven
by a driveshaft (6) off the rear of the traction alternator.
Hoist valve (5) directs oil flow to hoist cylinders (1)
when the operator moves the body dump control
lever. The body dump lever is connected to the hoist
pilot valve located in the hydraulic components cabinet by a flexible control cable. If the control lever is in
the float position, oil is returned to the hydraulic tank
through brake/hoist return oil manifold (2) and also
flows through the disc brake circuit to cool the wet
disc brake system. Heat generated during service
brake application is removed by an oil-to-water heat
exchanger (1, Figure 2-5).
Hoist system pressure is limited to 2500 psi (17.2
MPa) maximum pressure.
L2-4
Hydraulic System
L02031
FIGURE 2-2. HOIST PUMP PIPING (Top View)

1. Hoist Cylinders
2. Brake/Hoist Return Oil Manifold
4. Hoist Circuit Filters
L02031
5. Hoist Valve
6. Pump Drive Shaft
7. Hydraulic Tank
Hydraulic System
L2-5
STEERING CIRCUIT OPERATION

Hydraulic oil from the tank is supplied to a piston
type, pressure compensated steering and brake circuit pump (8, Figure 2-3), rated at 66 GPM (257 l/
min.) @ 1900 RPM. An unloader valve (15, Figure 21) maintains system pressure between 2750 psi
(18.9 MPa) and 3025 psi (20.9 MPa).
Oil from the pump is directed to a high pressure filter
(9, Figure 2-3) before entering the bleeddown manifold (5). The bleeddown manifold provides several
functions in the steering, brake, and hoist systems. It
is used to route oil flow to the steering system and
hydraulic brake system. (Refer to Section J for brake
system operation.)
L2-6
Steering system oil is directed to accumulators (3),

used to store pressurized oil in the event of loss of
pump pressure. Oil is also directed to flow amplifier
valve (4) for use by the cab mounted steering control
unit and steering cylinders (1).
A relatively small volume of oil is supplied from the
flow amplifier to the steering control unit, mounted on
the steering column in the cab. When the operator
moves the steering wheel, oil is routed from the
steering control unit back to the flow amplifier based
on the direction and rate of speed of rotation of the
steering wheel.
The flow amplifier provides a large volume of oil to
the steering cylinders to turn the front wheels determined by input from the steering control unit.
Hydraulic System
L02031
FIGURE 2-3. STEERING SYSTEM COMPONENTS (Bottom View)

1. Steering Cylinders
2. Manifold
3. Steering System Accumulators
4. Flow Amplifier Valve
5. Bleeddown Manifold
L02031
6. Hydraulic Tank
7. Pump Supply Shutoff Valve
8. Steering/Brake Circuit Pump
9. Steering/Brake Circuit Filter
10. Hoist Circuit Pump
Hydraulic System
L2-7
DISC BRAKE COOLING SYSTEM

When the hoist control valve is in the float or hold
position, oil is supplied by the hoist valve to the disc
brake assemblies located at each wheel to remove
heat generated during service brake application.
Oil supplied to the rear wheel brakes flows from the
hoist valve to the brake/hoist return oil manifold (11,
Figure 2-5), to the brake assemblies and is then
returned to the brake/hoist return oil manifold and the
hydraulic tank (12). Oil supplied to the front wheel
brakes is routed from the hoist valve to an oil/water
heat exchanger (1) before entering the brake assemblies. The front brake oil is then returned to the
brake/hoist return oil manifold and then the hydraulic
tank. In addition, the front brake cooling oil is used to
lubricate the front wheel hub bearings.
The brake cooling circuit pressure is limited by orificed regulator valves located in the brake/hoist
return oil manifold. Figure 2-4 shows the piping and
flow of oil through the brake/hoist return oil manifold.
The internal check valves crack open at 35 psi (241
kPa). Their opening pressure will be slightly higher
as flow through it increases.
Refer to Section J for information regarding operation
of the brake system.
FIGURE 2-4. BRAKE/HOIST RETURN OIL
MANIFOLD
1. Rear Brake Return
2. Rear Brake Supply
3. Rear Brake Supply Press.
4. Front Brake Supply Press.
5. Rear Brake Cooling Oil (From Hoist Valve)
6. Return From Hoist Valve
7. Return From Hoist Valve
8. Manifold
9. Front Brake Bypass
10. Rear Brake Return Pressure
11. Hoist Return Pressure
12. Front Brake Return Pressure
13. Rear Brake Oil Return
14. Rear Brake Oil Return
15. Hoist Return to Tank
16. Front Brake Oil Return
L2-8
Hydraulic System
L02031
FIGURE 2-4. DISC BRAKE COOLING CIRCUIT (Bottom View)

1. Heat Exchanger
2. Front Brake Cooling Oil Supply
From Hoist Valve
3. L. F. Brake Cooling Outlet Hose
4. R. F. Brake Cooling Inlet Hose
L02031
5. R. F. Brake Cooling Outlet Hose

6. L. F. Brake Cooling Inlet Hose
7. Hoist Pump
8. Filters
9. Rear Axle Housing
Hydraulic System
10. Rear Brake Cooling Supply &

Return Lines
12. Hydraulic Tank
L2-9
NOTES
L2-10
Hydraulic System
L02031
SECTION L3
HYDRAULIC SYSTEM COMPONENT REPAIR
INDEX
HYDRAULIC SYSTEM COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3

HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-5
INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-10
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-16
Filling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-17
HYDRAULIC TANK STRAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-17
Inspect and Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-17
HYDRAULIC TANK BREATHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-18
L03030
Hydraulic Component Repair
L3-1
NOTES
L3-2
L03030
HYDRAULIC SYSTEM COMPONENT REPAIR

HOIST PUMP
Removal
NOTE: The hoist pump can be removed without
removing the steering pump from the truck if
desired.
1. Turn keyswitch OFF and allow ample time
(approximately 90 seconds) for the accumulators to bleed down.
2. If necessary, drain the hydraulic tank by use of
the drain valve located on the rear side of the
tank.
NOTE: If oil in the hydraulic tank has not been
contaminated, the shut-off valves can be closed and
both pump inlet lines can be drained, eliminating the
need to completely drain the tank.
3. Remove the rear axle blower duct to allow the

hoist pump to be lowered from the pump module mounting bracket for removal. Remove
duct support bracket.
4. Close the pump supply shut-off valves.
Always maintain complete cleanliness when

opening any hydraulic connection. Insure that
all system lines and components are capped
while the component is removed from the truck.
FIGURE 3-1. HOIST AND STEERING PUMP PIPING (Top View)

1. Hoist Cylinders
L03030
5. Hoist Valve
6. Pump Drive Shaft
7. Hydraulic Tank
L3-3
5. Loosen the capscrews securing the inlet and

outlet hoses (1, Figure 3-2) on the hoist pump
and allow oil to drain. Remove inlet and outlet
hoses. Cap or cover all lines and pump inlets
and outlets to prevent contamination.
6. Remove the capscrews securing the hoist
pump drive flange to the drive shaft.
The hoist pump weighs approximately 310 lbs

(140 kg). The hoist and steering pump together
weigh approximately 560 lbs (254 kg). Use a
suitable lifting or support device that can handle
the load safely.
FIGURE 3-2. HYDRAULIC PUMP
4. Pump Mount
1. Pump Outlet Hoses
Capscrews
2. Pump Mount
Capscrews
6. Pump Mount Bracket
3. Hoist Pump
7. Outlet Hose
1. Hoist Pump
2. Nut & Washer
3. Dowel
4. O-ring
5. Capscrew
L3-4
FIGURE 3-3. STEERING/BRAKE PUMP REMOVAL

11. Steering & Brake Pump
6. Bearing Plate
12. Pump Case Return
7. O-ring
Fitting (Pump Drain)
8. Transition Plate
13. Inlet Port
9. Coupling
10. Capscrew
14. Compensator
Adju
ment
15. Unloader Adjustment
16. O-ring
17. Nut
L03030
7. Attach a suitable lifting or support device to the

hoist pump. Attach a support to the front end of
the steering pump to hold it in place during
removal of the hoist pump.
8. Remove four capscrews (2, Figure 3-2) securing the hoist pump to the front support bracket.
Remove the six capscrews holding support
bracket (6) to the pump module support.
Remove support bracket.
9. Make sure the lifting and support devices are in
place on both pumps. Loosen (but do not
remove) the rear support bracket capscrews
holding the steering pump. Lower the pumps
allowing hoist pump to come down further than
steering pump.
10. Remove four steering/brake pump mounting
capscrews (4). Slide hoist pump forward to disengage the splines of drive coupling (9, Figure
3-3) from the steering pump.
11. Move pump to a clean work area for disassembly.
Installation
NOTE: The following assumes the steering pump is
already in position on the truck.
1. Install O-ring (16, Figure 3-3) to steering pump
(11). Install coupler (9) to hoist pump.
The hoist pump weighs approximately 310 lbs

(140 kg). The hoist and steering pump together
weigh approximately 560 lbs (254 kg). Use a suitable lifting or support device that can handle the
load safely.
2. Attach a suitable lifting or support device to the
hoist pump. Move pump into position in truck.
3. Lubricate the steering pump spline shaft and
align with coupling (9). Install hoist pump to
steering pump and install capscrews (10) with
hardened washers and tighten to standard
torque. Raise pumps up into position.
4. Attach front support bracket to the pump module support structure and to the pump with capscrews, lockwashers and nuts. Tighten
5. Connect hoist pump drive flange to drive shaft
with capscrews, lockwashers and nuts. Tighten
to standard torque.
6. Tighten the capscrews for steering pump support bracket (6, Figure 3-2) to standard torque.
7. Uncap inlet and outlet hoses and install to
pumps using new O-rings. Tighten capscrews
securely.
8. Service the hydraulic tank with C-4 type hydraulic fluid. Refer to Hydraulic Tank this section for
filling instructions.
9. Open the three suction line shut-off valves.
Loosen capscrews (at the pump) on suction
hoses to bleed trapped air. Then loosen capscrews (at the pump) on pressure hoses to
bleed any trapped air. Tighten all capscrews
securely.
NOTE: If trapped air is not bled from steering pump,
possible pump damage and no output may result.
10. Reinstall blower duct and support bracket.
L03030
L3-5
Disassembly
NOTE: As parts are removed they should be laid out
in a group in the same order in which they are
removed.
1. Clean the exterior of the pump assembly thoroughly. If the steering pump is attached,
remove capscrews (10, Figure 3-3) and pull
the steering pump free of transition plate (8).
Remove O-ring (16).
2. Remove coupling (9). Inspect the coupling.
Remove and discard internal snap ring, if
installed. Remove dowels (3) if damaged, or if
replacement of the bearing plate is necessary.
3. The pump may be supported by placing on

wood blocks with the input drive shaft pointing
down. Mark each section nearest the input
drive gear to facilitate reassembly
4. Remove nuts (17, Figure 3-3). Remove bearing plate (20, Figure 3-4) with transition plate
(22) and O-ring (26). Remove capscrews
securing the bearing plate to the transition
plate and remove O-ring (23). Remove dowels
if damaged, or if replacement of the transition
plate is necessary.
FIGURE 3-4. HOIST PUMP

1. Drive Gear & Shaft
2. Seal
3. Idler Gear
4. Stud
5. Steel Ball
6. Flange
7. Dowel
8. Gear Plate
9. O-ring
L3-6
10. Connector Plate

11. O-ring
12. Bearing Plate
13. Gear Plate
14. Connector Plate
15. Washer
16. Nut
17. Stud
18. Idler Gear
19. Dowel
20. Bearing Plate
21. Dowel
22. Transition Plate
23. O-ring
24. (Not Used)
25. Coupler
26. O-ring
27. Drive Gear (Rear)
28. Snap Ring

29. Coupler
30. Steel Ring
31. Backup Ring
32. O-ring
33. Pressure Plate
34. Isolation Plate
35. Plug
36. Snap Ring
L03030
5. Remove connector plate (9, Figure 3-5).

Remove O-ring (8) and steel rings (10) and
(14). Remove dowels (6) if damaged, or if connector plate replacement is necessary.
8. Remove bearing plate (2, Figure 3-5). Remove

O-ring (23) and stud O-rings (1). Remove dowels (20) if damaged or replacement of the
bearing plate is necessary.
NOTE: If the connector plate is stuck, tap lightly with

a plastic hammer to loosen.
9. Remove coupling (21). Remove snap ring (22)

if damaged or replacement is necessary.
6. Remove backup ring (15), O-ring and retainer

(16) and isolation plate (17). Grasp the drive
gear (12) and idler gear (11) and pull straight
up and out of the gear plate (5) bore. Remove
pressure plate (18) from gears.
NOTE: Disassembly of the rear pump section is now

complete. Do not remove thru studs at this time as
the studs serve as guides for disassembly.
7. Remove gear plate (5) and pressure plate

(19). Remove steel rings, backup ring, O-ring
and retainer and isolation plate. Remove Oring (3) and stud O-ring (4).
FIGURE 3-5. HOIST PUMP DISASSEMBLY (Rear Section)

1. O-ring
2. Bearing Plate
3. O-ring
4. O-ring
5. Gear Plate
6. Dowel
L03030
7. Stud
8. O-ring
9. Connector Plate
10. Steel Ring
11. Idler Gear
13. Bearings
14. Steel Ring
15. Backup Ring
16. O-ring & retainer
17. Isolation plate
18. Pressure Plate
19. Pressure Plate

20. Dowels
21. Coupling
22. Snap Ring
23. O-ring
L3-7
10. Remove bearing plate (10, Figure 3-6). If the

bearing plate is stuck, tap lightly with a plastic
hammer to loosen it. Remove O-rings (9) and
(11).
11. Remove steel rings (13), backup ring (14), Oring and retainer (15) and isolation plate (17).
Remove dowels (16) if damaged or if replacement of the bearing plate (10) is necessary.
12. Unscrew thru studs (12) and remove. Remove

flange (5). If stuck, tap the flange lightly with a
plastic hammer to loosen. Remove O-ring (8).
Remove dowels (6) if damaged, or if replacement of the flange (5) or gear plate (7) is necessary.
13. Remove steel rings, backup ring, O-ring and
retainer. Remove drive gear (1) and idler (3)
from gear plate (7). Remove both pressure
plates (18).
FIGURE 3-6. HOIST PUMP DISASSEMBLY (Front Section)

2. Seal
3. Idler Gear
4. Steel Ball
5. Flange
6. Dowel
7. Gear Plate
L3-8
8. O-ring
9. O-ring
10. Bearing Plate
11. O-ring
12. Thru Studs
13. Steel Rings
14. Backup Ring
15. O-ring & Retainer

16. Dowel
17. Isolation Plate
18. Pressure Plate
19. Plug
20. Seal
21. Snap Ring
L03030
FIGURE 3-7. PREPARATION FOR SEAL

REMOVAL
1. Flange
3. Wooden Blocks
2. Bearings
14. Remove outboard shaft seal (2), snap ring (21)

and inboard shaft seal (20).
NOTE: To aid in shaft seal removal place the flange
on two small wooden blocks as shown in Figure 3-7.
FIGURE 3-8. SHAFT SEAL REMOVAL
1. Flange
2. Punch
3. Bearings
15. Use a punch and hammer and tap the outboard

shaft seal out of the flange bore. (Refer to Figure 3-8.) Use care not to mar, scratch or damage the seal bore surface, or bearings.
16. After the seals and snap ring have been
removed, clean the bore thoroughly. If necessary, the bore may be smoothed with number
400 emery paper (only).
L03030
L3-9
INSPECTION OF PARTS
1. Examine the gear bores in both gear plates; reference Figure 3-9. During the initial break-in,
the gears cut into the aluminum gear plates.
The nominal depth of this cut is 0.008 in (0.203
mm) and should not exceed 0.015 in (0.381
mm). As the gear teeth cut into the gear plates,
metal is rolled against the pressure plates.
Using a knife or sharp pointed scraper, remove
the metal that was rolled against the pressure
plates. Remove all metal chips that were broken
loose.
NOTE: Replacing new bearing in the flange,

connector plates or bearing plate is not
recommended due to close tolerances and special
tooling required for crimping the bearing in place to
prevent bearing spin.
6. Inspect the flange seal bore for scratches or
gouges which may interfere with shaft seal
installation.
7. For additional pump and system inspection
refer to the Troubleshooting Guide.
Assembly
1. A suitable seal press ring or plug and two small
wood blocks should be available.
When removing the rolled up metal, do not

attempt to remove the gear track-in grooves.
2. Examine the pressure plates. They should not
show excessive wear on the bronzed side. If
deep curved wear marks are visible, discard
and replace with new.
3. Examine the gears. If excessive wear is visible
on the journals, sides, or face of the gears, or at
the point where the drive gear rotates in the lip
seal, discard and replace with new.
4. If any of the internal parts show excessive wear,
replace with new. Replace all O-rings and seals
with new.
2. The following seal installation procedures are

outlined for use with a vise, but they can be
adapted for use with a press if one is available.
3. Open the vise jaws wide enough to accept the
combined thickness of the flange, wood blocks
and press ring.
4. Place the wood blocks flat against the fixed jaw
of the vise. Place the flange plate against the
blocks in such a position that the bearing projections are between the blocks and clear of the
vise jaw, refer to Figure 3-10.
5. Lubricate the seals with hydraulic oil. Position
inboard shaft seal (3, Figure 3-11) with the
metal face toward the outboard end of the
flange.
5. Inspect the bearings, if they are worn beyond

the gray teflon into the bronze material, the
complete flange connector plates or bearing
plate should be replaced.
FIGURE 3-9. GEAR BORE INSPECTION

1. Gear Track-In
L3-10
2. Gear Plate
FIGURE 3-10. SHAFT SEAL INSTALLATION

1. Flange
2. Wood Blocks
3. Bearing Projection
L03030
7. Install snap ring (2, Figure 3-11) with the snap

ring opening over weep hole (10).
12. With the bronze side up and the milled slot facing toward the discharge side, slide pressure
plate (2, Figure 3-13) down into the gear bores
until it rests on the backup ring and O-ring. Do
not force the plate down the gear bores. If it
hangs up on the way down, work it back and
forth until it slides freely into place.
8. Install the outboard seal (metal face out), until it

just contacts the snap ring.
13. Coat the inside of the gear plate and the gears
with clean hydraulic oil.
9. Lubricate thru stud threads (14, Figure 3-11)

with hydraulic oil. Thread the studs into flange
until snug. There are 4 long studs and 4 short
studs. Reference Figure 3-12 for proper stud
location. Lubricate and install O-ring (7). Install
dowel pins (12), if removed. Install gear plate
(13). Make sure the recess in the gear plate will
be toward the connector plate, or facing up
when the gear plate is installed.
NOTE: To ensure the gear pump is correctly timed

during reassembly, place a mark on the end of the
input shaft to indicate the location of the valley
between any two gear teeth. Refer to Figure 3-16
which illustrates gear timing.
6. Position the press ring over the seal. Make sure

the seal stays centered and true with the bore,
and start applying pressure with the vise. Continue pressing the seal until it just clears the
snap ring groove in the bore.
10. Install steel rings (5, Figure 3-12). Lubricate and

install backup ring (8), O-ring (7) and ring
retainer (6) as shown in Figure 3-12.
11. Install isolation plate (9) on the suction side of
the gear plate. The isolation plate has a relief
area milled on one side; turn that side up or
toward the pressure plate.
FIGURE 3-11. SHAFT SEAL INSTALLATION

1. Outboard Shaft Seal
2. Snap Ring
3. Inboard Shaft Seal
4. Seal, Metal Face
5. Flange
6. Steel Ball
7. O-ring
L03030
8. Bearing
9. Bearing
10. Weep Hole
11. Plug
12. Dowel
13. Gear Plate
14. Thru Studs
14. With the extension end of the drive gear facing

toward the shaft seals, install the drive gear. Do
not drop the gear in the bore as damage to the
bronze face of the pressure plate could result.
Use care when pushing the drive gear extension thru the shaft seals. Install the idler gear.
FIGURE 3-12. PUMP REASSEMBLY

1. Gear Plate
2. Drive Gear
3. Idler Gear
4. Bearing
5. Steel Ring
6. Retainer
7. O-ring
8. Backup Ring
9. Isolation Plate
10. Relief Area
11. Thru Studs
L3-11
15. Install the opposite pressure plate with the

bronze side down and the milled slot facing
toward the discharge side.
16. Install steel rings (11, Figure 3-14), backup ring
(12), O-ring and retainer (13). Install isolation
plate with its relief toward the pressure plate.
17. Lubricate and install thru stud O-rings (5) and
connector plate O-ring (7). Install dowel (14) if
removed. Lubricate the I.D. of the bearings
(17) and install connector plate (6). Install snap
ring (8) and coupling (9).
FIGURE 3-13. PRESSURE PLATE INSTALLATION

1. Gear Plate
2. Pressure Plate
3. Slot
FIGURE 3-14. HOIST PUMP REASSEMBLY

2. Idler Gear
3. Gear Plate
4. Relief
5. O-ring
6. Connector Plate
L3-12
7. O-ring
8. Snap Ring
9. Coupling
10. Thru Studs
11. Steel Ring
12. Backup Ring
13. O-ring & Retainer

14. Dowel
15. Isolation Plate
16. Pressure Plate
17. Bearings
L03030
18. Lubricate O-ring (3, Figure 3-15) and install in

bearing plate (7). Lubricate O-rings (4) and
install over studs (12). Replace dowel (2) if
removed. Install bearing plate (7).
20. Lubricate the I.D. of bearings (26). Install Orings (8 & 9) and dowel (25), if removed. Install
gear plate (10). Ensure the relief in gear plate
is toward bearing plate (7).
19. Repeat Steps 10, 11 and 12 for installation of

the steel rings, backup ring, O-ring, retainer,
isolation plate and pressure plate.
FIGURE 3-15. HOIST PUMP REASSEMBLY

2. Dowel
3. O-ring
4. O-ring
5. Coupling
6. Connector Plate
7. Bearing Plate
L03030
8. O-ring
9. O-ring
10. Gear Plate
11. Connector Plate
12. Stud
13. Idler Gear
14. Capscrew
15. Bearing Plate

16. Transition Plate
17. O-ring
18. (Not Used)
19. Coupling
20. Nut
21. O-ring
22. Dowel
23. Dowel
24. O-ring
25. Dowel
26. Bearings
L3-13
21. Install rear drive gear (1) and idler gear (13).
The rear drive gear must be timed with the front
drive gear. This is accomplished by lining up a
tooth on the rear drive gear with the valley of
two teeth on the front drive gear, as shown in
Figure 3-16.
FIGURE 3-17.
FIGURE 3-16. PUMP GEAR TIMING
1. Wrench
2. Input Shaft
22. Repeat Steps 15 and 16 for installation of the

remaining pressure plate, steel rings, backup
ring, O-ring, and retainer and isolation plate.
23. Lubricate and install O-ring (24, Figure 3-15) in
connector plate (11). Install dowel (23) if
removed. Lubricate the I.D. of the bearing in
connector plate (11). Install connector plate (11)
with flat washers and nuts.
24. Install dowel (22), if removed. Lubricate and
position O-ring (17) in transition plate (16).
Assemble bearing plate (15) to transition plate
and install capscrews (14). Tighten the capscrews to standard torque.
25. Lubricate O-ring (21) and position on bearing
plate (15). Install the assembled bearing plate
and transition plate (15 & 16) to connector plate
(11) and secure in place with nuts (20). Tighten
the nuts to standard torque.
3. Pump
27. Lubricate the thru stud threads and install two

opposite stud nuts and hardened washers.
Tighten the nuts to 240 to 250 ft. lbs. (325 to
339 N.m) torque.
28. Using an 18 inch (45 cm) adjustable wrench,
check pump drive shaft rotation. The drive shaft
will be tight but should turn freely with a maximum of 5 to 10 ft. lbs. (7 to 14 N.m) torque,
after the initial surge. (Figure 3-17.)
29. If the shaft will not turn properly, disassemble
the pump and examine the parts for burrs or foreign material causing buildup or interference
between parts.
30. When the input shaft turns properly install the
remaining hardened washers and nuts. Tighten
nuts to 240 to 250 ft. lbs. (325 to 339 N.m)
torque.
31. Install a new O-ring on steering pump flange
and install steering pump to the transition plate
(16, Figure 3-15). Install the capscrews and
tighten to standard torque.
26. Install coupling (19).
A snap ring may have been installed previously

inside of coupling (19). This snap ring is not necessary, and must not be used. In some cases,
depending on tolerance stack-up, the snap ring
can cause excessive axial loading, leading to
premature pump failure.
L3-14
L03030
TROUBLESHOOTING GUIDE
(Hoist Pump)
TROUBLE
1. Sandblasted band around pressure
plate bores
2. Angle groove on face of pressure
plate
POSSIBLE CAUSE
1. Abrasive wear caused by
fine particles.
a. Dirt (fine contaminants,
not visible to the eye)
SUGGESTED CORRECTIVE
ACTION
1. Was clean oil used?
2. Was filter element change period
correct?
3. Were correct filter elements used?
3. Lube groove enlarged and edges

rounded
4. Hoist cylinder rod wiper and seals

in good condition?
4. Dull area on shaft at root of tooth
5. Cylinder rods dented or scored?
5. Dull finish on shaft in bearing area
6. Was system flushed properly after

previous failure?
6. Sandblasted gear bore in housing

1. Scored pressure plates.
2. Scored shafts
3. Scored gear bore
2. Abrasive wear caused by

metal particles
a. Metal (coarse) contaminants, visible to the eye
1. Was system flushed properly after

previous failure?
2. Contaminants generated elsewhere in hydraulic system?
3. Contaminants generated by wearing pump components?
1. Any external damage to pump
3. Incorrect installation
2. Any interference between pump

and machine?
2. Damage on rear of drive gear and

rear pressure plate only
1. Eroded pump housing
2. Eroded pressure plates
1. Did shaft bottom in mating part?
4. Aeration-Cavitation
a. Restricted oil flow to
pump inlet
b. Aerated Oil
1. Tank oil level correct?

2. Oil viscosity as recommended?
3. Restriction in pump inlet line?
4. Air leak in pump inlet line?
5. Loose hose or tube connection?
1. Heavy wear on pressure plate
5. Lack of oil
2. Heavy wear on end of gear

1. Housing scored heavily
2. Inlet peened and battered
2. Any leaks in piping inside tank?

6. Damage caused by metal
object
1. Metal object left in system during

initial assembly or previous repair?
2. Metal object generated by another
failure in system?
3. Foreign object caught in gear teeth

1. Pressure plate black
1. Was oil level correct?
7. Excessive Heat
2. O-rings and seals brittle
1. Metal object left in system during

initial assembly or previous repair?
3. Gear and journals black
2. Was relief valve setting too low?

3. Was oil viscosity correct?
4. Was oil level correct?
1. Broken shaft
8. Over Pressure
2. Broken housing or flange
L03030
1. Relief valve setting correct?

2. Did relief valve function?
L3-15
HYDRAULIC TANK
Filling Instructions
NOTE: If filling is required, use only type C-4
hydraulic oil as specified on the truck Lubrication
Chart. Filtering of oil with a 3 micron filtering system
is recommended.
5. Continue to repeat Steps 1 thru 4 until the oil

level is maintained in the top sight gauge with
the engine stopped, key switch OFF, and body
down.
NOTE: With the engine running and oil at operating
temperature, the oil should be visible in the lower
sight glass. If not, shut down engine and add oil per
Filling Instructions.
NOTE: Minor adjustments to the oil level can be
made by using drain cocks (5) next to the filler neck.
Prior to opening the hydraulic tank, allow at least

90 seconds for the accumulator to bleed down
after engine shutdown and keyswitch OFF.
1. With the engine stopped, body down, and the
key switch OFF, wait for at least 90 seconds.
2. Remove fill cap (1, Figure 3-18) and add clean
type C-4 hydraulic oil until oil is visible at the top
sight gauge.
Should a component fail in the hydraulic system,

an oil analysis should be made before replacing
any component. If foreign particles are evident,
system must be flushed. Refer to Hydraulic System Flushing instructions.
3. Install the fill cap.

4. Start the engine, and raise and lower the dump
body three times.
Removal
1. Turn the keyswitch OFF and allow at least 90
seconds for the steering accumulators to bleed
down.
NOTE: Be prepared to contain approximately 250
gal. (947 L) of hydraulic oil. If the oil is to be reused,
clean containers must be used with a filtering (3
micron) system available for refill.
2. Thoroughly clean the outside of the hydraulic
tank and attached equipment.
3. Drain the hydraulic tank by use of the drain
valve located on the rear side of the tank.
4. Disconnect hydraulic lines. Plug lines to prevent
possible contamination to the system. Tag each
line at removal for proper identification during
installation.
Use care to avoid contact with hot oil if truck has

been operating. Avoid spillage and contamination.
FIGURE 3-18. HYDRAULIC TANK
1. Fill Cap
2. Sight Gauges
3. Breather Filters (2)
L3-16
4. Drain Valve
5. Drain Cocks
5. Attach a suitable lifting device to the hydraulic

tank. The weight of the hydraulic tank is
approximately 1300 lbs (590 kg).
6. Remove the capscrews and lockwashers
securing the hydraulic tank to the frame.
7. Move hydraulic tank to a clean work area for
disassembly or repair.
L03030
Installation
1. Lift the hydraulic tank into position and secure
with capscrews and lockwashers. Tighten to
459 ft. lbs. (622 N.m) torque.
2. Uncap the hydraulic lines and attach to the
proper connections.
3. Replace breather filters if required.
4. Fill the hydraulic tank with clean, filtered C-4
hydraulic oil. Refer to Filling Instructions.
5. Bleed all air from the hydraulic lines.
6. Bleed trapped air inside steering pump. Refer to
Pump Pressure Setting, Section L for air bleeding procedure.
HYDRAULIC TANK STRAINERS
NOTE: If the oil is to be reused, clean containers

must be used with a filtering (3-micron) system
available for refill.
2. Be prepared to contain approximately 250 gal.
(947 l) of hydraulic oil. Drain hydraulic oil from
tank.
3. Disconnect pump suction hoses. (5, Figure 319).
4. Remove capscrews and lockwashers (3) securing cover (2) to the hydraulic tank. Remove and
discard gasket.
5. Remove capscrews and lockwashers securing
suction strainers. Remove suction strainers.
Inspect and Clean
NOTE: Inspect the strainers thoroughly for metallic
particles and varnish build up (if oil has been
overheated). The quantity and size of any particles
may be an indication of excessive wear of
components in the hydraulic system.
Removal
1. Clean the strainers with fresh cleaning solvent
from the inside out.
Prior to opening the hydraulic tank, allow at least
90 seconds for the accumulators to bleed down
after engine shutdown with the key switch OFF.
1. Shut down the engine and the key switch OFF
for at least 90 seconds.
2. Inspect the strainers for cracks or wear.

Replace, if necessary.
3. Clean any sediment from the bottom of the
hydraulic tank.
Installation
1. Install suction strainers and secure in place with
capscrews and lockwashers. Tighten capscrews to standard torque.
2. Using new cover gasket, move cover (2, Figure
3-19) into position and install capscrews and
lockwashers (3). Tighten the capscrews to standard torque.
3. Install the pump suction hoses.
4. Fill the hydraulic tank; refer to Hydraulic Tank
Filling Instructions. Open both suction line shutoff valves (4).
5. Loosen suction line connections at both pumps
to bleed any trapped air. Tighten the hose connections.
6. Bleed trapped air inside steering pump. Refer to
Steering and Brake Pump Installation, this Section, for air bleeding procedure.
FIGURE 3-19. STRAINER REMOVAL

1. Hydraulic Tank
3. Capscrews & Lock2. Cover
washers
4. Shutoff Valve
5. Pump Suction Hoses
L03030

L3-17
HYDRAULIC TANK BREATHERS

There are two breather filters located on top of the
hydraulic tank to allow air in and out of the tank. The
filters should be replaced at the interval specified on
the lubrication chart.
Keep the area around the breather filters clean and
free of debris build up. If there is any sign that the
breather filters are oil soaked, replace the filters as
soon as possible and check for proper oil level. Once
the breather filters become oil soaked, they will plug
very quickly.
L3-18
Plugged breather filters can cause pressure build

up inside the hydraulic tank and can cause the
service brakes to drag.
L03030
SECTION L4
STEERING CIRCUIT
INDEX
STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-3

COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-4
Steering Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-4
Bleeddown Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-5
Bleeddown Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-5
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
Hoist Limit Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
Low Precharge Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
High Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
Quick Disconnect Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-8
FLOW AMPLIFIER SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-10
No Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-10
Steering Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-12
Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-14
No Steer, External Shock Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-16
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-18
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-20
Full Pump Volume: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-20
Half Pump Volume: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-20
Neutral Position: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-20
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-21
L04038
Steering Circuit
L4-1
NOTES
L4-2
Steering Circuit
L04038
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
The pump (8, Figure 4-1) supplies oil to the bleeddown manifold (5) after passing through a high
pressure filter (9). This oil supply is then distributed
to the brake system and steering system.
System pressure is regulated to between 2750 psi

(19.0 MPa) and 3025 psi (20.9 MPa) by an unloader
valve located on the bottom of the steering pump
case.
FIGURE 4-1. STEERING SYSTEM COMPONENTS (Bottom View)

1. Steering Cylinders
2. Manifold
3. Steering Accumulators
L04038

6. Hydraulic Tank
7. Shut-off Valve
Steering Circuit
9. Steering/Brake Circuit
Filter
10.Hoist Circuit Pump
L4-3
Oil pressure from the bleeddown manifold is routed

back to the pump and sensed by the ACC port on
the unloader valve. A steering pressure switch,
mounted on the bleeddown manifold is connected
electrically to a Low Steering Pressure warning
lamp mounted in the cab and warns the operator if
system pressure drops below 2300 psi (15.9 MPa).
COMPONENT DESCRIPTION
The bleeddown manifold performs many functions,

including distribution of the steering circuit oil supply
to the steering system accumulators (3) and the flow
amplifier valve (4). Oil is also provided to the service
brake apply system, the automatic lubrication system
grease pump motor, and the optional radiator shutters if installed.
Two accumulators, pre-charged with nitrogen, are
mounted on the left frame rail behind the front tire.
They provide a sufficient oil supply to allow the operator to steer the truck off the haul road and park in a
safe area if a loss of steering circuit oil occurs. A
steering circuit bleeddown solenoid mounted on the
bleeddown manifold is electrically activated when the
key switch is turned OFF. This action bleeds the
hydraulic oil back to the tank to release the pressurized oil when the truck is parked.
If a loss of steering pressure occurs during operation,
the truck must be stopped immediately. The pressure
in the accumulators allow the operator to steer the
truck for a short period. Do not attempt further operation until the problem is located and corrected.
The bleeddown manifold and accumulators supply oil
to the flow amplifier valve. The flow amplifier directs
oil flow to the appropriate ports on the steering cylinders as determined by inputs from the steering control unit as the operator steers the truck (see Figure
4-2).
Oil entering the steering control unit is blocked until
the steering wheel is turned in a desired direction.
The valve then directs oil to the flow amplifier which
in turn, provides a high volume of oil to the steering
cylinders. Hydraulic oil at the opposite ends of the
steering cylinders flows back through the flow amplifier, and bleeddown manifold to the hydraulic tank.
FIGURE 4-2. STEERING CONTROL UNIT

T: Tank Port
L: Left Steer Port
P: Pressure (Supply)
Port
R: Right Steer Port
LS: Load Sense Port

1. Valve Assembly
Steering Control Unit

The steering control unit (Figure 4-2) is mounted
inside the cab and is directly coupled to the lower
end of the steering column.
Operation of the steering control unit is both manual
and hydraulic in effect. This component incorporates
a hydraulic control valve; steering effort applied to
the steering wheel by the operator actuates the
valve, which in turn directs hydraulic oil through the
flow amplifier valve to the steering cylinders to provide the operator with power steering.
Oil flow to the brake apply system flows through a

check valve which will prevent loss of oil in the brake
circuit if a loss of oil occurs in the steering circuit.
(Refer to Section J for a detailed description of the
brake apply system hydraulic circuit and components.)
L4-4
Steering Circuit
L04038
Bleeddown Manifold Valve

Bleeddown manifold valve (5, Figure 4-1) is located
on the outside of the left hand frame rail just behind
the flow amplifier. The bleeddown manifold is
equipped with the following major circuit components
as shown in Figure 4-3:
Steering Pressure Switch (7)
Steering accumulator bleeddown solenoid valve
(6)
600 psi (4.1 MPa) Relief Valve (12)
4000 psi (28.0 MPa) relief valve (13)
Body-Up Solenoid Valve (15)
Pilot operated check valves (see Figure 4-4)
The bleeddown manifold receives oil from the steering/brake pump through a high pressure filter and
directs oil to the accumulators, brake circuit, flow
amplifier and autolube system hydraulic pump. Oil
supply for the steering control unit and steering cylinders is supplied via the flow amplifier. The manifold
also provides hoist circuit control when the body is
raised.
The relief valves, accumulator bleed down solenoid,
and body-up limit solenoid are factory preset and
cannot be individually rebuilt.
Bleeddown Solenoid
Each time the keyswitch is turned OFF, with the truck
stopped, it energizes the steering system bleed down
solenoid (6, Figure 4-3 & 27, Figure 4-4). When the
bleed down solenoid is energized, all hydraulic steering pressure, including the accumulators, is bled
back to the hydraulic tank. Brake pressure however,
will not bleed down due to internal check valves in
the brake manifold and bleeddown manifold check
valve (see schematic).
After approximately 90 seconds, the solenoid will deenergize to close the return port to tank. By this time
all the oil in the accumulators should be returned to
tank. At start-up, the steering circuit will be charged,
including the brake circuit. The low steering pressure
light and buzzer will turn on until steering pressure
reaches 2300 psi (15.9 MPa). This is controlled by
the steering pressure switch (7, Figure 4-3).
During operation, if steering pressure falls below
2300 psi (15.9 MPa), the low steering pressure warning light will illuminate until pressure returns to normal.
L04038
Steering Circuit
FIGURE 4-3. BLEEDDOWN MANIFOLD

1. To Hoist Valve, Power Up
2. To Hoist Valve, Power Down
3. Spare Pressure Port
4. Test Port
5. To Brake System
6. Steering Accumulator Bleed Solenoid
7. Steering System Pressure Switch
8. Supply To Flow Amp
9. Return From Flow Amp
10. To Front Steering Accumulator
11. To Rear Steering Accumulator
12. Relief Valve, 600 psi (4.1 MPa)
14. Autolube Pump Supply Port
15. Hoist Up Solenoid Valve
16. Return From Hoist Pilot Valve
17. Hoist Pilot Valve, Power Down
18. Hoist Pilot Valve, Power Up
19. Return to Tank
20. Feedback Pressure to Unloader valve
21. Supply From Pump
L4-5
FIGURE 4-4. BLEEDDOWN MANIFOLD SCHEMATIC

1. Steering/Brake Pump Inlet
2. Steering Pump Pressure Test Port
3. Steering Accumulator
4. APU Port
5. Pressure Feedback (to Steering Pump)
6. Steering Pressure Switch
7. (Not Used)
8. Radiator Shutters (If installed)
10. Brake Circuit Supply
11. Steering Accumulator
12. Steering Circuit Supply to Flow Amplifier
13. Quick Disconnect, Supply Port
14. Steering Circuit Return From Flow
Amplifier
15. Quick Disconnect, Return Port
L4-6
Steering Circuit
16. Spare Return Port

17. Autolube Pump Supply
18. Hoist Pilot Return
19. Hoist Pilot Power Down
20. Hoist Pilot Power Up
21. Tank Return Port
22. Hoist Power Up
23. Hoist Power Down
24. Hoist Up Limit Solenoid
26. Cavity Plug
27. Steering Accumulator Bleeddown Solenoid
29. Pilot Operated Check Valve
L04038
Relief Valves
The 4000 psi (28.0 MPa) relief valve limits maximum
steering circuit pressure by returning oil to the
hydraulic tank through internal passages in the
bleeddown manifold.
The 600 psi (4.1 MPa) relief valve provides maximum
pressure protection for the oil returning to the hydraulic tank.
Hoist Limit Solenoid
The body-up limit solenoid is a 3-way valve, activated
by the hoist limit switch (refer to Section D for additional information) when the hoist cylinders approach
the maximum extension limit. When activated, the
solenoid will close the power up pilot line to the hoist
valve from the hoist pilot valve mounted in the
hydraulic cabinet.
Pilot operated check valve (30, Figure 4-4) is opened
by the power down pilot pressure line (19) to allow oil
in the raise port to bypass the body-up limit solenoid
(24) for the initial power down operation while the
solenoid is activated by the hoist limit switch.
Refer to Section D, Electrical System (24VDC) for
adjustment procedure of the hoist limit switches.
Accumulators
The steering accumulators (5, Figure 4-1) are a floating piston type. The top side of the accumulators are
charged to 1400 psi (9.7 MPa) with pure dry nitrogen
with the piston at the bottom.
Oil entering the accumulators pushes the piston
upward compressing the nitrogen on the top side of
the piston. The nitrogen pressure increases directly
with steering circuit pressure. When steering circuit
pressure reaches 3025 psi (20.9 MPa) the unloader
valve will unload the pump. The accumulators will
contain a quantity of oil under pressure and held by
check valves in the bleeddown manifold, available for
steering the truck. When system pressure drops to
2750 psi (19.0 MPa) the pump output will again
increase, to refill the accumulators and increase
steering system pressure. The accumulators also
provide oil, for a limited period of time, to be used in
case the pump becomes inoperative.
Low Precharge Warning Switch

Pressure switches located in the top of each accumulator monitor nitrogen pressure and are used to
activate the accumulator precharge warning light if
the nitrogen pressure drops below 1100 psi (7.6
MPa).
The switches monitor nitrogen pressure when the
key switch is turned ON and before the engine is
started. If nitrogen pressure is too low, the warning
lamp turns on - a latching circuit prevents the warning lamp from turning off when the engine is started
and steering system pressure compresses the nitrogen remaining in the accumulator.
Do not operate the truck with less than 1100 psi

(7.6 MPa) nitrogen precharge in the accumulator.
Low nitrogen pressure may not provide an adequate supply of steering system oil in some
emergency conditions. If the low precharge warning light remains on, check accumulator precharge pressure and recharge if necessary.
High Pressure Filter

The high pressure filter (9, Figure 4-1) filters oil for
the steering and brake circuits.
If the filter element becomes restricted, a warning
indicator is activated at 40 psi (276 kPa) and oil will
bypass the element at 50 psi (345 kPa).
Refer to Section L9 for further information regarding
hydraulic system filters and maintenance procedures.
Quick Disconnect Ports
Ports on the bleeddown manifold allow service personnel to connect an external hydraulic supply to
allow operation of the truck steering and service
brake systems if the steering/brake pump, engine
etc. is not operational.
The external supply is connected to port 13, Figure
4-4 and the return is connected to port 15. This feature should only be used for emergency use to allow
operation of the truck to return to the shop for service
or move the truck out of haul road traffic.
L04038
Steering Circuit
L4-7
Flow Amplifier
Flow amplifier (4, Figure 4-1, & Figure 4-5) is located
on the left frame rail forward of the bleed down manifold valve and is used in the steering circuit to provide the high volume of oil required for the steering
cylinders.
L4-8
The flow amplifier uses the amount of flow from the

steering control unit to determine a proportional
amount of flow to send from the bleed down manifold
to the steering cylinders.
Steering Circuit
L04038
FIGURE 4-5. FLOW AMPLIFIER VALVE
L04038
Steering Circuit
L4-9
FLOW AMPLIFIER SYSTEM OPERATION

Refer to figures 4-6 through 4-9 for oil flow paths during the following conditions:
Neutral
Steering Left
Steering Right
External shock load
No Steer
(Refer to Figure 4-6):
High pressure oil from the steering pump and steering accumulators is available through the steering
bleeddown manifold to the HP port on the flow
amplifier assembly.
Upon entering the priority valve, it goes past the
spool to the closed amplifier valve and also out port
P through a hose to port P on the steering control
unit. In the steering control unit, it goes to a closed
area in the control.
As pressure builds up in these two areas, oil passes
through orifices in the end of the priority valve and
builds pressure on the end of the valve and port PP.
When pressure reaches approximately 500 psi (3.5
MPa), the spool moves, compressing its spring and
closes off oil supply through area A resulting in high
pressure at PP, but only 500 psi (3.5 MPa) at the
amplifier spool and steering control unit.
L4-10
Steering Circuit
L04038
FIGURE 4-6. FLOW AMPLIFIER - NO STEER
L04038
Steering Circuit
L4-11
Steering Left
When the operator turns the steering wheel left, the
steering control unit is opened to allow oil coming in
port P to pass to the gerotor section of the control
unit to turn the rotor. Oil in the other side of the gerotor flows through other passages in the control unit
valve and out steering control unit port L. This oil
enters port L of the flow amplifier assembly and
goes to a closed area B in the directional valve.
As pressure in this area builds, it also passes into the
spool through orifice C to the spring area on the
end of the directional valve. The pressure then
moves the spool compressing the springs on the
opposite end. This movement allows the oil entering
area B to pass through the directional valve to area
D of the amplifier valve through sleeve E holes to
a passage between sleeve E and valve F, through
hole G in sleeve E where it initially is blocked by
the valve body.
As pressure builds up in this area, oil also flows from
area D, around the outside of sleeve E, around
pin H, through orifice J to build pressure on the
end of the amplifier valve and opens hole G only
enough to allow the flow of oil coming from the steering control unit to pass to the control area of the
directional valve.
At the steering control unit, when the operator turned

the steering wheel, supply oil from port P was also
delivered through the control unit valve to port LS.
This oil enters the flow amplifier assembly through its
LS port and builds pressure in the spring area of the
priority valve. This additional force on the spring end
of the priority valve causes area A to open and
allow the necessary flow and pressure to pass
through the amplifier valve to operate the steering
cylinders.
The flow amplifier valve includes a relief valve in the
priority valve spring area that is used to control maximum steering working pressure to 2750 psi (19.0
MPa) even though supply pressure coming in to port
HP is higher. When 2750 psi (19.0 MPa) is
obtained, the relief valve prevents the LS pressure
from increasing and thereby allows the priority valve
to compress the spring enough to close off the area
A when 2750 psi (19.0 MPa) is present.
At the same time, the movement of sleeve E

opened the holes near the spring end to allow the oil
from the priority valve to flow into the center of sleeve
E.
This oil now inside sleeve E pushes valve F
against its spring to give the oil access to a series of
holes K, that are in the same plane as hole G. The
passage of oil through holes K past the valve body
is metered by holes K being opened the same proportion as is hole G. The number of holes K (7) in
sleeve E determine the amount of additional oil that
is added to the steering control unit oil passing
through hole G.
This combined oil going to the center area Q of the
directional valve passes out port CL of the flow
amplifier assembly and travels to the steering cylinders to steer the front wheels to the left. As the cylinders move, oil is forced to return out the opposite
ends, enter port CR of the flow amplifier assembly,
pass through the directional valve to area M,
passes through the return check valve N, and exit
port HT to the hydraulic reservoir.
L4-12
Steering Circuit
L04038
FIGURE 4-7. FLOW AMPLIFIER - LEFT STEER
L04038
Steering Circuit
L4-13
Steering Right
Only a few differences occur between steer left and
steer right. When the operator turns the steering
wheel right, oil is supplied out ports R and LS of
the steering control unit.
The oil enters the flow amplifier assembly at port R

and shifts the directional valve the opposite direction.
The oils flow through the amplifier valve exactly the
same. The combined oil from the amplifier valve
passes through the center area Q of the directional
valve to port CR where it goes to the opposite ends
of the steering cylinders to turn the wheels right.
The returning oil comes back through port CL to go
to the tank. The LS oil operates exactly the same as
steer left.
L4-14
Steering Circuit
L04038
FIGURE 4-8. FLOW AMPLIFIER - RIGHT STEER
L04038
Steering Circuit
L4-15
No Steer, External Shock Load

When the operator is not turning the steering wheel,
the steering control unit valve supply is closed. The
directional valve remains centered by its springs thus
closing the passages to ports CL and CR. This
creates a hydraulic lock on the steering cylinders to
prevent their movement.
If the tires hit an obstruction to cause a large shock
load to force the wheels to the left, increased pressure will occur in the ends of the cylinders connected
to port CR. The shock and suction relief valve
inside the flow amplifier assembly at port CR will
open at its adjusted setting (3100 psi (21.4 MPa) and
allow oil to escape from the pressurized ends of the
cylinders, preventing a higher pressure.
L4-16
As the cylinders are allowed to move, the other ends

will have less than atmospheric pressure on port
CL. This low pressure permits oil that is escaping
through the CR port relief valve to flow through the
check valve portion of the shock and suction relief
valve connected to port CL. The oil then flows to the
low pressure ends of the cylinders to keep the cylinders full of oil and prevent cavitation. A shock load in
the opposite direction merely reverses the above
procedure.
Steering Circuit
L04038
FIGURE 4-9. FLOW AMPLIFIER - NO STEER, EXTERNAL SHOCK LOAD
L04038
Steering Circuit
L4-17
STEERING PUMP
Operation
The steering/brake pump is mounted on the rear of

the hoist system pump. The drive shaft mates with an
internally splined coupling inside the hoist pump
when the pump is bolted in place.
Driveshaft (35, Figure 4-10) runs through the centerline of pump housing (37) and valve plate (48). Cylinder barrel (45) is splined to the drive shaft.
The pump is a pressure compensated piston type

with system operating pressure controlled by an
unloader valve. The pressure compensator is
adjusted to 3325 psi (22.9 MPa). The pump mounted
unloader valve maintains system pressure between
2750 psi (19.0 MPa) and 3025 psi (20.9 MPa).
Oil flow from the pump is routed through a high pressure filter then to the bleeddown manifold valve
where the flow is directed to the steering circuit
(accumulators, flow amplifier, etc.) and to the brake
apply system components mounted in the hydraulic
components cabinet behind the cab.
Ball bearing (33) supports the outboard end of the

driveshaft and a bushing type bearing (47) supports
the inboard end. The pump cylinder barrel is carried
in a polymerous (journal type) bearing (41).
The valve plate has two crescent shaped ports (inlet
and outlet). Pumping pistons (44) in the cylinder barrel are held against swashblock (28) by shoe retainer
(17). The shoe retainer is held in position by the fulcrum ball (40) which is forced outward by retainer
springs (13). The springs act against the pump cylinder barrel (45) forcing it against the valve plate while
also forcing the piston shoes against the swashblock.
The semi-cylindrical shaped swashblock limits the
piston stroke and can be swiveled in arc shaped saddle bearings (21). The cradle is swiveled by the control piston (14).
High Altitude Operation

The steering pump on later model trucks incorporates an adjustable stroke control device (25, Figure
4-10). If the truck is operating at high altitude locations (10, 000 feet (3,050 meters) above sea level or
greater), it may be necessary to adjust the pump
stroke to reduce oil flow to eliminate pump cavitation
problems.
L4-18
Steering Circuit
L04038
1. Plug
2. O-ring
3. Spring
4. Back-Up Ring
5. O-Ring
6. Back-Up Ring
7. O-Ring
8. O-Ring
9. O-Ring
10. Back-Up Ring
11. Spring
12. Control Piston Sleeve
13. Spring
14. Piston
15. Pin
16. Control Piston Stop
Pin
17. Shoe Retainer
18. Pin
19. Retainer Ring
20. Washer
21. Saddle Bearing
22. Roll Pin
23. Link
24. O-Ring
25. Stroke Adjuster
26. Retainer Ring
27. Pin
28. Swashblock
29. Dowel Pin
30. Saddle
31. Roll Pin
32. Retainer Ring
33. Bearing
34. Shaft Retainer Ring
35. Shaft
36. Seal Retainer
37. Pump Housing
38. Shaft Seal
39. O-Ring
40. Fulcrum Ball
41. Cylinder Bearing
42. O-Ring
43. Elbow Fitting
44. Piston/Shoe Assy.
45. Cylinder Barrel
46. Gasket
47. Bearing
48. Valve Plate
49. Capscrew
50. O-Ring
51. Cover
52. Seal
53. Cap
L04038
FIGURE 4-10. STEERING PUMP
Steering Circuit
L4-19
PRINCIPLE OF OPERATION
Full Pump Volume:
Control piston (1, Figure 4-11) controls the angle of
the swashblock (4). When control piston moves to
the full right position, the pump is at maximum pumping capacity.
The driveshaft turns the splined housing (2) which
contains the pumping pistons (3). When the housing
is rotated, the pistons move in and out of their bores
and the piston shoes ride against the angled
swashblock (4).
As the cylinder rotates, the individual piston bores
are connected, alternately to the left (port A) and
right (port B) crescent shaped ports in the valve
plate. While connected to left side (suction) port A,
each piston moves outward, drawing fluid from port
A into the piston bore until its outermost stoke is
reached. At that point the piston bore passes from
the left crescent port to the right crescent port.
FIGURE 4-11. PUMP AT FULL VOLUME
While rotating across the right side crescent, each

piston moves downward on the angled swashblock
face. Thus, each piston is forced inward. Each piston
displaces fluid through the right side crescent to port
B until it's innermost stroke is reached. At that point,
the piston bore again passes from the right to the left
side crescent and the operating cycle is repeated.
Half Pump Volume:

Figure 4-12 shows that the position of the control piston (1) is near the center of its travel. The swashblock is not angled as steep as before, and therefore
the pistons have a shorter stroke. As the piston
stroke gets shorter, the pump output also decreases.
FIGURE 4-12. PUMP AT HALF VOLUME
Neutral Position:
Neutral position (Figure 4-13) results when the control piston (1) centers the swashblock (4). The
swashblock angle is now zero and swashblock face
is now parallel to cylinder face. Therefore, no inward
or outward motion of the pump pistons exists as piston shoes rotate around the swashblock face. The
lack of inward and outward motion results in no fluid
being displaced from the piston bores to the crescents in the valve plate and subsequently no delivery
from pump ports.
FIGURE 4-13. PUMP IN NEUTRAL POSITION
L4-20
Steering Circuit
L04038
Steering Pump
Figure 4-14 shows the steering pump and the location of the pressure control adjustments and stroke
(flow) adjuster.
Note: Stroke adjuster (3, Figure 4-14) is set at the
factory to provide maximum pump flow and
adjustment is not normally required. If the truck is
operated at high elevations, 10,000 ft. (3,050 meters)
above sea level or more, it may be necessary to
readjust the stroke control to reduce pump flow to
prevent pump cavitation under certain conditions. If
the truck is operating at high altitude and problems
are experienced, consult your Komatsu service
representative for adjustment procedures.
Figure 4-15 shows the schematic of the pump and
the pressure control valves.
FIGURE 4-14. PUMP ASSEMBLY

5. Compensator Press.
1. Outlet Port
Adjust
2. Case Drain
6. 4-Way Valve
3. Stroke Adjuster
7. GPA Port
4. Unloader Valve
8. GP2 Port
Press. Adjust
FIGURE 4-15. STEERING PUMP PRESSURE CONTROL SCHEMATIC

1. 4-Way Valve
2. Unloader Control Block
3. ACC Port
L04038
4. Pressure Compensator
Control Block
5. Case Drain
Steering Circuit
6. GP2 Port
7. GP4 Port
8. GPA Port
L4-21
NOTES
L4-22
Steering Circuit
L04038
SECTION L5
STEERING CONTROL UNIT
INDEX
STEERING CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
STEERING CONTROL UNIT REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-4
Cleaning and Inspection - Steering Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-5
Assembly - Steering Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-7
L05027
L5-1
NOTES
L5-2
L05027
STEERING CONTROL UNIT

Removal
NOTE: Clean steering control unit and surrounding
area carefully to help avoid contamination of
hydraulic oil when lines are opened.
1. Shut off engine and bleed down steering circuit.
NOTE: To insure the hydraulic oil has completely
drained from the accumulators, turn the steering
wheel. If the wheels do not turn, all the hydraulic
pressure has been drained from accumulators.
2. Disconnect hydraulic lines. Plug lines securely
to prevent spillage and possible contamination
to the system. Tag each line as removed for
proper identification during installation.
Use care to avoid contact with hot oil. Avoid spillage and contamination.
3. Remove capscrews (10, Figure 5-1) from steering unit mounting bracket and remove sterring
control unit (7).

5. "T" Port Hose
1. Brake valve
6. "P" Port Hose
2. Steering Control Unit
7. "R" Port Hose
3. "LS" Port Hose
4. "L" Port Hose
Installation
1. Lubricate the male splines on the end of the
steering column shaft.
Note: There is no lower end bearing in this new
steering column assembly, therefore the male end of
the shaft will have to be guided into the mating
female part of the steering control unit (7).
2. Move the steering control unit (7) into place and
start each of the capscrews (10) without removing them from the holes in either the steering
column four bolt flange or the brackets.
3. Tighten the four capscrews (10) to standard
torque.

INSTALLATION
1. Steering Wheel
2. Button Horn
3. Steering Column
4. Capscrew
5. Flat Washer
6. Lock Washer
L05027
7. Steering Control Unit

8. Bracket L.H.
9. Bracket R.H.
10. Capscrew
11. Lock Washer
4. Remove plugs from the hydraulic lines. Be certain that the previously tagged hydraulic lines
are connected to their respective ports according to the markings on the steering control unit.
L5-3
STEERING CONTROL UNIT REBUILD

Disassembly
Serious personal injury to the operator or to anyone positioned near the front wheels may occur if
a truck is operated with the hydraulic steering
lines improperly installed. Improperly installed
lines can result in uncontrolled steering and/or
SUDDEN AND RAPID rotation of the steering
wheel as soon as the steering wheel is moved. It
will turn rapidly and cannot be stopped manually.
After servicing the steering control unit, hydraulic steering lines should be checked for correct
hook-up before starting the engine.
The steering control unit is a precision unit

manufactured to close tolerances, therefore
complete cleanliness is a must when handling the
valve assembly. Work in a clean area and use lint
free wiping materials or dry compressed air. Clean
type C-4 hydraulic oil should be used during
reassembly to insure initial lubrication.
1. Allow oil to drain from valve ports.
2. Match mark gear wheel set and end cover to
insure proper relocation during reassembly.
FIGURE 5-3. VALVE PORT IDENTIFICATION

1. Steering Control
Valve
"T" - Return to Tank
"P" - Supply from Pump
"L" - Left Steering

"R" - Right Steering
"LS" - Load Sensing
5. Check for proper steering wheel rotation without

binding. Be certain wheel returns to neutral after
rotating 1/4 turn left and right.
L5-4
FIGURE 5-4. MARKING VALVE COMPONENTS

1. Valve Assembly
3. Capscrew With
2. Match Marks
Rolled Pin
4. End Cover
3. Remove end cover capscrews and washers.

Remove capscrew with rolled pin (3, Figure 54). Mark hole location of capscrew with rolled
pin on end cover to facilitate reassembly.
L05027
4. Remove end cover (4) and O-ring (2, Figure 55).
13. Remove the dust seal (2, Figure 5-6) using a

screwdriver. Take care not to scratch or damage
the dust seal bore.
FIGURE 5-5. END COVER REMOVAL

1. Gear Wheel Set
FIGURE 5-6. DUST SEAL REMOVAL
2. O-Ring
1. Screwdriver
2. Dust Seal
3. Housing
5. Remove outer gear of gear wheel set (1) and Oring between gear set and distribution plate.
6. Lift inner gear off cardan shaft.
7. Remove cardan shaft (11, Figure 5-7), distribution plate (15) and O-ring (14).
8. Remove threaded bushing (4) and ball (3).
9. With valve housing positioned with the spool
and sleeve vertical, carefully lift spool assembly
out of housing bore.
Cleaning and Inspection - Steering Control Unit
1. Clean all parts carefully with fresh cleaning solvent.
If housing is not vertical when spool and sleeve
are removed, pin (9) may slip out of position and
trap spools inside housing bore.
10. Remove O-ring (5), kin ring (6) and bearing
assembly (7).
2. Inspect all parts carefully and make any

replacements necessary.
NOTE: All O-rings, seals and neutral position springs
should be replaced with new. Prior to reassembly
thoroughly lubricate all parts with clean type C-4
hydraulic oil.
11. Remove ring (8) and pin (9) and carefully push
inner spool out of outer sleeve.
12. Press the neutral position springs (10) out of
their slot in the inner spool.
L05027
L5-5
FIGURE 5-7. STEERING CONTROL VALVE

1. Dust Seal
2. Housing & Spools
3. Ball
4. Threaded Bushing
5. O-ring
6. Kin Ring
L5-6
7. Bearing Assembly
8. Ring
9. Pin
10. Neutral Position
Springs
11. Cardan Shaft
12. Spacer
13. Tube
14. O- ring
15. Distribution Plate
16. Gear Wheel Set
17. O-ring
18. O-ring
19. End Cover
20. Washers
21. Rolled Pin
22. Capscrew With Pin
23. Capscrews
L05027
Assembly - Steering Control Unit

NOTE: When assembling the spool and sleeve, only
one of the two possible matching positions of the
spring slots can be used. The reason is that in the
other end of the sleeve and spool (opposite end of
the spring slots) there are three slots in the spool
and three holes in the sleeve. These must be
opposite each other on assembly so that the holes
are partly visible through the slots in the spool, refer
to Figure 5-8.
1. To install the neutral position springs, place a
screwdriver in the spool slot as shown in Figure 5-9.
2. Place one flat neutral position spring on each
side of the screwdriver blade. Do not remove
screwdriver.
FIGURE 5-8. SPOOL AND SLEEVE ASSEMBLY
3. Push two curved neutral position springs in

between one side of the screwdriver blade and
a flat spring. Repeat for the opposite side.
Remove the screwdriver.
1. Slots
2. Hole
3. Spool
4. Sleeve
4. Slide the inner spool in the sleeve. Compress

the ends of the neutral position springs and
push the neutral position springs in place in the
sleeve.
5. Install the cross pin (9, Figure 5-7).
FIGURE 5-9. NEUTRAL POSITION SPRING INSTALLATION
L05027
L5-7
6. With neutral position springs (7, Figure 5-10)

centered in spool and sleeve, install ring (3),
rear bearing race (4), thrust bearing (5) and
front bearing race (6) in that order. The chamfer
on the rear bearing must be facing away from
the bearing.
FIGURE 5-11. SPOOL INSTALLATION

1. Housing
2. Spool Assembly
FIGURE 5-10. BEARING INSTALLATION

1. Sleeve
2. Cross Pin
3. Ring
4. Bearing Race (with
chamfer)
5. Thrust Bearing
6. Bearing race
7. Neutral Position
Springs
Cross pin must remain horizontal when spool

and sleeve are pushed into bore to prevent pin
from dropping out of spool.
7. Place the dust seal (1, Figure 5-7) in position.

Using a flat iron block over the seal, tap into
position.
8. Position the O-ring and kin ring on the spool.
9. Position the steering unit with the housing horizontal. Slowly guide the (lubricated) spool and
sleeve with fitted parts, into the bore using light
turning movements. Refer to Figure 5-11.
L5-8
L05027
10. Install the check ball in the hole shown in Figure

5-12. Install threaded bushing and lightly
tighten.
11. Grease the housing O-ring (3) with Vaseline and

install in the housing groove.
12. Install the distribution plate (15, Figure 5-7) with
plate holes matching the corresponding holes in
the housing.
13. Guide the cardan shaft (11) down into the bore
with the slot in the cardan shaft aligned with the
cross pin (9).
14. Position inner gear wheel onto cardan shaft. It
may be necessary to rotate the gear slightly to
find the matching splines on the cardan shaft.
(Splines are machined to insure proper alignment of cardan shaft and inner gear wheel.)
15. Grease the O-rings (17 & 18) on both sides of
the outer gear wheel with Vaseline and install.
16. Align outer gear wheel bolt holes with tapped
holes in housing and match marks.
17. Align cover (19) using match marks as a reference and install using capscrews (23) and
washers (20).
18. Install capscrew with pin (22) into proper hole.
FIGURE 5-12. CHECK BALL INSTALLATION

1. Check Ball hole
2. Check Ball
L05027
3. O-Ring
4. Housing
19. Tighten cover capscrews in a criss-cross pattern to 2 0.4 ft. lbs. (3 0.5 N.m) torque.
L5-9
NOTES
L5-10
L05027
SECTION L6
STEERING CIRCUIT COMPONENT REPAIR
INDEX
STEERING CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3

BLEEDDOWN MANIFOLD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
FLOW AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-4
FLOW AMPLIFIER REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-7
STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
Piston Seal & Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
STEERING AND BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-10
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-12
Control Piston Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-12

Valve Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-12
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-15
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-15
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-15
J06027
Steering Circuit Component Repair
J6-1
Control Piston Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-15

Valve Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-15
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-15
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-17
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-18
Compensator Block and Unloader Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-18
Stroke Adjuster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-18
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-18
Driveshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-19
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-19
Valve Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-20
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
Disassembly - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-22
Cleaning and Inspection - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-22
Assembly - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-23
Testing - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-23
Charging Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-24
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-25
L6-2
L06027
STEERING CIRCUIT COMPONENT REPAIR

BLEEDDOWN MANIFOLD VALVE

component connection until engine is stopped
and keyswitch has been off for at least 90 seconds. Hydraulic fluid escaping under pressure
can have sufficient force to enter a person's body
by penetrating the skin and cause serious injury
and possibly death if proper medical treatment
by a physician familiar with this injury is not
Removal
NOTE: It may not be necessary to remove the
bleeddown manifold from the truck for component
replacement. If the problem area has been isolated,
remove the inoperative component and replace with
a new one.
1. Perform normal truck shutdown procedures.
Turn keyswitch OFF and allow 90 seconds for
the accumulators to bleed down. Manually
bleed brake system accumulators using the
needle valves located in the hydraulic components cabinet.
2. Remove the protective cover from the manifold.
Disconnect wires at solenoids (6 & 15, Figure 61) and pressure switch (7).
3. Disconnect, identify and plug each hydraulic
line to prevent contamination.
4. Remove mounting capscrews and remove the
bleed down manifold. Clean exterior of manifold
before starting disassembly. The weight of the
valve is 375 lbs (170 kg).
Installation
1. Position the bleeddown manifold on the truck.
The weight of the valve is 375 lbs (170 kg).
Tighten the capscrews to standard torque.
2. Unplug lines and attach. Tighten connections
securely. Install new O-rings at flange fittings.
3. Attach electrical leads to solenoids and pressure switch. If check valves or relief valves were
removed, replace using new O-ring seals.
4. Start the engine and check for proper operation
and leaks. Check steering and brakes systems.
5. Reinstall protective cover.
NOTE: Relief valves are factory preset. Do not
attempt to reset or repair if relief valves are defective.
Replace as a unit. The check valves are also
replaced only as units.
J06027

4. Test Port
5. To Brake System
6. Steering Accumulator Bleed Solenoid
8. Supply To Flow Amp
9. Return From Flow Amp
14. Auto Lube Pump Supply Port
15. Hoist Up Solenoid Valve
16. Return From Hoist Pilot Valve
17. Hoist Pilot Valve, Power Down
18. Hoist Pilot Valve, Power Up
19. Return to Tank
21. Supply From Pump
J6-3
FLOW AMPLIFIER
Removal

applying pressure.
immediately.
1. Perform normal truck shutdown procedures.
Turn key switch OFF and allow 90 seconds for
the accumulators to bleed down.
2. Remove the protective cover from over the flow
amplifier. Disconnect, plug, identify, and tag
each hydraulic line.
3. Support the flow amplifier valve and remove the
mounting capscrews. Remove the valve. The
weight of the valve is 64 lbs. (29 kg).
4. Move the valve to a clean work area for disassembly.
Installation
1. Support the flow amplifier and move into position. The weight of the valve is 64 lbs. (29 kg).
2. Install mounting capscrews and tighten to standard torque.
3. Identify hydraulic line location, unplug lines and
connect at proper location. Tighten fittings
securely. Use new O-rings on the flange fittings.
4. Reinstall protective cover.
FLOW AMPLIFIER REBUILD

The flow amplifier valve is a precision unit manufactured to close tolerances. Therefore complete cleanliness is a must when handling the valve. Work in a
clean area and use lint free wiping materials or dry
compressed air. Use a wire brush to remove foreign
material and debris from around the exterior of the
valve before disassembly. Clean solvent and type C4 hydraulic oil should be used to insure cleanliness
and initial lubrication
L6-4
1. Capscrew
2. Lockwasher
3. Capscrews
4. Lockwasher
5. Cover
6. O-ring
7. O-ring
8. O-ring
9. (Not Used)
10. O-ring
11. O-ring
12. Shock/Suction Valve (Complete)
13. Orifice Screw
14. Valve Housing
15. Counterpressure Valve (Complete)
16. O-ring
17. Plug
18. Plug
19. Seal
20. Stop
21. Spring
22. Spring
23. Spring Control
24. Orifice Screw
25. O-ring
26. Shock/Suction Valve (Complete)
27. Main Spool
28. O-ring
29. Spring Control
30. Spring
31. Spring
32. Spring Stop
33. Orifice Screw
34. Capscrews
35. Capscrew
36. Lockwasher
37. Lockwasher
38. O-rings
39. Cover
40. O-rings
41. (Not Used)
42. Stop
43. Spring
44. Spool
45. Orifice Screw
46. Name Plate
47. Check Valve
48. Orifice Plug
49. Spring
50. Pins
51. O-ring
52. Spring
53. Amplifier Spool Assembly (Complete)
54. Relief Valve Assembly
55. Seal
L06027
J06027
J6-5
Disassembly
1. Remove counterpressure valve plug (17, Figure
6-2), and O-ring (16). Remove counterpressure
valve assembly (15).
2. Remove plug (18) and seal (19). Using an 8
mm hex allen head wrench, remove the relief
valve assembly (54). Remove steel seal (55).
3. Remove capscrew (35) and capscrews (34)
using a 10 mm and 13 mm hex head allen
wrench. Remove lockwashers (36 & 37).
Remove end cover (39).
4. Remove spring stop (42) and spring (43).
Remove spring stop (32) and springs (30 & 31).
Remove O-rings (38 & 40).
5. Remove spring control (29) and main spool
(27). Remove priority valve spool (44). Remove
spring control (23), springs (21 & 22) and spring
stop (20).
6. Remove amplifier valve spool assembly (53).
Set amplifier valve spool assembly aside for further disassembly, if required.
7. Remove shock and suction valve (26). Set
shock and suction valve aside for further disassembly, if required.
8. Remove capscrews (1 & 3) using a 10 mm and
13 mm hex head allen wrench. Remove lockwashers (2 & 4). Remove end cover (5).
9. Remove O-rings (6, 7 & 8). Remove spring (52).
10. Remove shock and suction valve assembly
(12). Set the shock and suction valve aside for
further disassembly, if required. Remove orifice
screw (13).
11. Remove orifice screw (45). Remove check valve
(47).
FIGURE 6-2. SHOCK & SUCTION VALVE

ASSEMBLY
1. O-Ring
2. Pilot Section
3. O-Ring
NOTE: Disassembly of the amplifier spool assembly

is only necessary should O-ring (2, Figure 6-4),
spring (9) or orifice plug (11) require replacement.
Otherwise, replace the amplifier spool assembly as a
complete unit. For complete disassembly refer to
Steps 12 & 13.
12. Remove retaining ring (7, Figure 6-4), remove
pin (5). Remove plug (10) and spring (9).
Remove retaining ring (6) and pin (4) and
remove inner spool (8).
13. Unscrew check valve (1) and remove. Remove
O-ring (2). Remove orifice screw (11) from plug
(10).
14. Clean and inspect all parts carefully. Make any
replacements necessary.
NOTE: If further disassembly is required for the

shock and suction valves refer to Figure 6-3.
NOTE: The flow amplifier valve is equipped with two,
identical shock and suction valves. The shock and
suction valves are only serviced as complete valve
assemblies. O-rings 1 & 3, Figure 6-3 are
replaceable. Check valve (47) and counterpressure
valve (15) are also serviced only as assemblies.
L6-6
L06027
10. Install spring control (29), springs (30 & 31) and
spring stop (32).
11. Lubricate O-rings (6, 7 & 8) with molycote
grease and position on cover (5). Install end
cover (5). Install capscrews (3) with lockwashers (4). Tighten capscrews to 2 ft. lbs. (2.7
N.m) torque. Install capscrew (1) and lockwasher (2). Tighten capscrew to 6 ft. lbs. (8
N.m) torque.
12. Lubricate O-rings (38 & 40) with molycote
grease and install on cover (39). Install end
cover (39). Install capscrews (34) with lockwashers (37). Tighten capscrews to 2 ft. lbs.
(2.7 N.m) torque. Install capscrew (35) with
lockwasher (36). Tighten capscrew to 6 ft. lbs.
(8 N.m) torque.
FIGURE 6-3. AMPLIFIER SPOOL ASSEMBLY
1. Check Valve
2. O-Ring
3. Spool
4. Pin
5. Pin
6. Retaining Ring
7. Retaining Ring
8. Inner Spool
9. Spring
10. Plug
11. Orifice Plug
13. To prevent contamination, fit plastic plugs to

each open valve port.
Assembly
1. Thoroughly lubricate each part prior to installation using clean, type C-4 hydraulic oil.
2. Reassemble the Amplifier spool assembly in
reverse order. Refer to Steps 12 & 13, and Figure 6-4 under disassembly.
3. Install orifice screw (13, Figure 6-2). Tighten orifice screw to 4 in. lbs. (.5 N.m) torque.
4. Install check valve (47). Tighten check valve to
8 in. lbs. (1 N.m) torque.
5. Install orifice screw (45). Tighten orifice screw
to 8 in. lbs. (1 N.m) torque.
6. Install seal (55) and relief valve assembly (54).
Install seal (19), and plug (18). Tighten plug to
22 in. lbs. (2.5 N.m) torque.
7. Install counterpressure valve assembly (15).
Install plug (17) using new O-ring (16).
8. Install both shock and suction valves (12 & 26)
as complete units. Install spring stop (20)
springs (21 & 22) and spring control (23). Install
orifice screws (24 & 33) if removed from main
spool (27). Install main spool (27).
9. Install amplifier spool assembly (53). Install priority valve spool (44) and spring (43). Install
spring (52).
J06027
J6-7
STEERING CYLINDERS
Figure 6-5 illustrates details of the steering cylinder
mounting. Refer to Section G for removal and installation instructions.
Relieve pressure before disconnecting hydraulic and other lines. Tighten all connections
before applying pressure.
penetrating the skin and cause serious injury
by a physician familiar with this injury is not
FIGURE 6-4. STEERING CYLINDER MOUNTING

1. Steering Cylinder
2. Tie Rod
3. Capscrew
4. Locknut
L6-8
5. Bearing Retainer
6. Capscrew
7. Lockwashers
8. Retainer
9. Mount Bracket
(Frame)
10. Bearing Spacer
11. Bearing
12. Pin
13. Hardened Washer
L06027
1. Housing
2. Locknut
3. Piston
FIGURE 6-5. STEERING CYLINDER ASSEMBLY

4. Piston Bearing
7. Backup Ring
8. Gland
6. O-Ring
9. Capscrew
10. Rod Structure

11. Rod Wiper
12. Rod Seal
13. Bearing
Cylinder Assembly
Disassembly
1. Remove capscrews (9, Figure 6-6) and pull rod
(10) and gland (8) out of cylinder housing (1).
2. Remove locknut (2) and piston (3). Remove piston bearing (4) and piston seal (5) from piston.
3. Pull rod (10) free of gland (8). Remove O-ring
(6) and backup ring (7). Remove rod seal (12)
and rod wiper (11). Remove Bearing (13).
4. Inspect cylinder housing, gland, piston and rod
for signs of pitting, scoring or excessive wear.
Clean all parts with fresh cleaning solvent and
lubricate with clean Type C-4 hydraulic oil.
1. Install new bearing (13, Figure 6-6), rod seal

(12), rod wiper (11), backup ring (7) and O-ring
(6) in gland (8).
2. Push rod (10) through top of gland, slowly
advancing rod over rod seal and rod wiper.
3. Install piston assembly (3) on rod. Secure piston to rod with locknut (2). Tighten locknut to
4. Carefully install rod and gland assembly into
cylinder (1). Insure backup ring and O-ring are
not damaged during installation of gland.
5. Install capscrews (9). Tighten capscrews evenly
Piston Seal & Bearing Installation

1. Install new piston seal (5, Figure 6-6) on piston
(3) as follows:
Test
a. Heat piston seal assembly (5) in boiling

water for 3 to 4 minutes.
After cylinder assembly rebuild, perform the following

tests to verify performance is within acceptable limits.
b. Remove piston seal from water and assemble on piston. DO NOT take longer than 5
seconds to complete as seal will take a permanent set. The piston bearing (4) may be
used to position seal assembly in groove.
Apply pressure evenly to avoid cocking seal.
1. Piston leakage must not exceed 1 in3/min. (1.6

cm3/min.) at 2500 psi (17.5 MPa), port to port.
c. If the seal has taken a slightly larger set

(loose on piston) a belt type wrench or similar tool can be used to compress the O.D. of
the seal until it fits tightly on the piston.
2. Rod seal leakage must not exceed 1 drop in 8

cycles of operation.
3. Piston break-away force should not exceed 100
psi. (69 kPa).
2. Install bearing (4) in the piston groove.
J06027
J6-9
STEERING AND BRAKE PUMP

Removal
NOTE: Clean the steering pump and surrounding
area carefully to help avoid contamination of
hydraulic oil when lines are opened.

applying pressure.
immediately.
1. Perform normal truck shutdown procedure.
Turn keyswitch Off and allow 90 seconds for
the accumulators to bleed down. Turn the steering wheel to be sure no oil remains under pressure.
NOTE: If oil in the hydraulic tank has not been
contaminated, the shut-off valve between the tank
and steering pump can be closed, eliminating the
need to completely drain the tank.
2. Drain the hydraulic tank by use of the drain

located on the bottom side of the tank.
NOTE: Be prepared to contain approximately 250
gal. (947 L) of hydraulic oil.If the oil is to be reused,
clean containers must be used with a 3 micron
filtering system available for refill.
3. Disconnect the suction line and outlet (7, Figure
6-7) at the steering pump (5). Disconnect and
cap pump case drain line from fitting at top of
pump housing. Plug all lines to prevent oil contamination.
The steering pump weighs approximately 250 lbs

(113 kg). Use a suitable lifting device capable of
handling the load safely.
4. Support the steering pump and the rear section
of the hoist pump. Remove mounting capscrews and rear support bracket (6). Remove
the four pump mounting capscrews (4).
5. Move the steering pump rearward to disengage
the drive coupler splines from the hoist pump
(3) and remove pump.
6. Clean exterior of steering pump.
7. Move the steering pump to a clean work area
for disassembly.
Installation
1. Install a new O-ring on pump mounting flange.
2. Make certain the steering pump splined coupler
is in place (inside hoist pump) prior to steering
pump installation.
The steering pump weighs approximately 250 lbs

(113 kg). Use a suitable lifting device capable of
handling the load safely.
FIGURE 6-6. STEERING PUMP REMOVAL

5. Steering/Brake
1. Hoist Pump Outlet
Pump
Hoses
6. Pump Mount Bracket
2. Pump Mount
7. Outlet To Filter
Capscrews
3. Hoist Pump
4. Pump Mount
Capscrews
L6-10
L06027
3. Move the steering pump into position. Engage

steering pump shaft with hoist pump spline coupler.
4. Install rear support bracket (6, Figure 6-7) with
capscrews. Do not tighten capscrews at this
time.
5. Align capscrew holes and install steering pump
mounting capscrews (4). Tighten mounting capscrews to standard torque. Tighten rear support
6. Remove plugs from pump inlet and outlet ports.
Remove caps from inlet and outlet lines and
install to steering pump using new O-rings.
Tighten capscrews securely. Do not connect
steering pump drain hose to the steering pump,
at this time (see Step 7).
7. Remove case drain fitting from top of pump
housing and add clean C-4 oil to pump through
opening until steering pump housing is full. This
may require 2 - 3 qt. (2 - 3 L) of oil.
8. Uncap the case drain line, connect to steering
pump fitting and tighten case drain line.
9. Replace hydraulic filter elements. Refer to
Hydraulic Filters, Section L9.
NOTE: Use only Komatsu filter elements, or elements that meet the Komatsu hydraulic filtration
specification of Beta 12 = 200.
10. Open shut-off valve in steering pump suction
line completely.
11. With the body down and the engine shut-off, fill
the hydraulic tank with clean C-4 hydraulic fluid
(as specified on the truck Lubrication Chart) to
the upper sight glass level.
12. With suction line shut-off valve open, loosen
suction (inlet) hose capscrews (at the pump) to
bleed any trapped air. Tighten hose connection
13. If required, top-off the oil level in the hydraulic

tank, to the level of the upper sight glass.
14. In the hydraulic components cabinet, open both
brake accumulator needle valves completely to
allow the steering pump to start under a
reduced load.
15. Move the hoist pilot control valve to the Float
position.
16. Start the truck engine and operate at low idle for
one (1) to two (2) minutes.
Do not allow the engine to run with the needle

valves in the open position for longer than this
recommendation: excessive hydraulic system
heating will occur.
DO NOT start any hydraulic pump for the first
time after an oil change, or pump replacement,
with the truck dump body raised. Oil level in the
hydraulic tank may be below the level of the
pump(s) causing extreme pump wear during this
initial pump start-up.
17. Shutdown the engine. Fully close both brake
accumulator needle valves in the hydraulic
components cabinet.
18. Verify that the oil level in the hydraulic tank is at
the upper sight glass when the engine is off and
the body is resting on the frame. If the hydraulic
oil level is not at the upper sight glass, follow
service manual instructions for filling/adding oil.
19. Start engine and check for proper pump operation. If necessary, refer to Steering Circuit
Checkout Procedure in Section L10, or Trouble
Shooting Chart at the end of this section.
If trapped air is not bled from steering pump,

possible pump damage and no output may
result.
J06027
J6-11
Disassembly
When disassembling or assembling pump,

choose a work area where no traces of dust,
sand or other abrasive particles which could
damage the unit are in the air. Do not work near
welding, sand-blasting, grinding benches and the
like. Place all parts on a CLEAN surface. To clean
parts which have been disassembled, it is important CLEAN solvents are used. All tools and
gauges should be clean prior to working with
these units and new, CLEAN and threadless rags
used to handle and dry parts.
1. Drain off excess hydraulic oil from pump inlet
and discharge ports. It may be necessary to
loosen the four valve plate capscrews (8, Figure
6-10) pull back on valve plate to allow fluid to
seep out of the case.
2. Thoroughly clean and dry the outside surface of
the pump housing.
NOTE: Depending upon what part or parts are to be
inspected, it may not be necessary to completely
disassemble all components.
Control Piston Group

3. Remove the two large plugs (24, Figure 6-8)
with O-rings (25) from both sides of pump.
4. Control piston (11, Figure 6-9) must be in the
neutral position. Control link pin (16) should be
centered in the plug opening.
5. Using appropriate snap ring pliers, remove
retaining rings (14) from both sides of the pin
and remove control link washers (15).
6. For handling purposes, insert a 1/4-20 UNC
capscrew into the threaded end of the control
link pin (16).
7. Using a brass rod and hammer, tap on end
opposite the capscrew to remove control link
pin.
Stroke adjuster assembly (items 12, 13, 14, 15

and 16, Figure 6-8) MUST be removed BEFORE
further disassembly of control piston.
8. Without disturbing jam nut (16), unscrew gland
(15) and remove stroke adjuster as a complete
assembly.
9. Back out capscrews (1, Figure 6-10), then
remove cap (4).
10. Remove bias control spring (1, Figure 6-9).
Valve Plate Group
NOTE: Valve plate (11, Figure 6-10) is a slight press
fit in the pump housing.
11. Support valve plate (11) from an overhead hoist
(lifting lug holes are provided) and remove four
capscrews (8) from valve plate.
12. Remove valve plate from pump housing by tapping away from the housing with a mallet until
valve plate pilot diameter disengages from the
case 0.25 in (6.35 mm).
13. With the weight of the valve plate still suspended from the overhead hoist, slide valve
plate back until it disengages from driveshaft
and set valve plate aside. Care must be taken
not to damage the wear face of the valve
plate.
14. To further disassemble control piston assembly,
move control piston (11, Figure 6-9) into sleeve
(4) until control piston maximum stop pin (8)
contacts the sleeve. Use a large mallet to drive
piston and sleeve assembly outward from the
valve plate.
15. When all sleeve seals (5, 6, & 7, Figure 6-9) are
clear of the valve plate, re-extend control piston.
While tipping the assembly enough to clear the
hole, pull the assembly from the valve plate.
16. Remove pin (18) from control piston by pressing
or tapping it out through the hole on opposite
side. Control stop pin (8) can be removed and
control piston (11) slipped out of sleeve (4).
17. Remove capscrews (12, Figure 6-11) and
remove compensator block (10).
18. Remove capscrews (7, Figure 6-10) and cover
plate (9).
L6-12
L06027
FIGURE 6-7. PUMP, FRONT HOUSING

1. Shaft
2. Bearing
3. Snap Ring
4. Retainer Ring
5. Lifting Eyes
6. Name Plate
7. Screw, Drive
J06027
8. Name Plate
9. Plug
10. O-Ring
11. Plate
12. O-Ring
13. Stem
14. O-Ring
15. Gland
16. Jam Nut
17. Pin
18. O-Ring
19. Pin
20. O-Ring
21. Housing
22. Seal Retainer

23. Elbow Fitting
24. Plug
25. O-Ring
26. Seal
J6-13
FIGURE 6-8. PUMP, ROTATING GROUP

1. Spring
2. Seal
3. Piston Ring
4. Sleeve
5. Back-Up Ring
6. O-Ring
7. O-Ring
L6-14
8. Pin
9. Back-Up Ring
10. Cylinder Barrel
11. Control Piston
12. Ball
13. Piston Shoe Assembly
14. Retainer Ring
15. Washer
16. Pin
17. Link
18. Pin
19. Dowel Pin
20. Saddle
21. O-Ring
22. Roll Pin

23. Roll Pin
24. Saddle Bearing
25. Swash Block
26. Cylinder Bearing
27. Retainer
28. Spring
L06027
Driveshaft Group
Rotating Group
28. Remove bearing retaining ring (3, Figure 6-8).

Use a mallet on the tail shaft and tap driveshaft
(1) out from the front of the pump housing.
The rotating group weighs approximately 30 lbs.
Extreme care must be taken not to damage cylinder wear face or cylinder wear plate face, bearing
diameters or piston shoes. Assistance from others and use of proper lifting techniques is
strongly recommended to prevent personal
injury.
19. To remove rotating group, firmly grasp the cylinder barrel (10, Figure 6-9) and pull assembly
outward until cylinder spline disengages from
driveshaft spline about 2.5 in. (63.5 mm). Once
clear, rotate cylinder barrel a revolution or two
to break any contact between piston/shoe
assemblies (13) and swashblock (25) wear
face.
20. Slide rotating group off the driveshaft and out of
the pump housing and place it on a clean, protective surface with piston shoes facing upward.
21. Mark each piston, its cylinder bore and location
in shoe retainer for ease of inspection and
assembly.
22. Piston/shoe assemblies can be removed individually or as a group by pulling upward on
shoe retainer (27).
23. Remove fulcrum ball (12).
24. If shoe retainer springs (28) are removed, mark
which spring came from which bore as they
must be returned to that individual bore on
assembly.
25. Remove the two pins (14, Figure 6-8) and pull
the cylinder bearing (26, Figure 6-9) straight out
of the pump housing.
Swashblock Group
26. Remove the two swashblock retaining pins (19,
Figure 6-8), tilt the bottom of the swashblock
(25, Figure 6-9) outward and remove the
swashblock from the pump case.
27. Saddle bearings (24) can be removed by using
a very short screwdriver or back hammer to pry
them loose; or continue to the next step for further disassembly which will make their removal
easier.
29. Remove seal retainer (22) from pump housing.

Use a mallet and tap saddle (20, Figure 6-9) out
from the inside of the pump housing. Saddle
bearings (24) can then be easily removed and
saddle O-ring (21) may also be removed at this
time.
Inspection
Always wear safety goggles when using solvents

or compressed air. Failure to wear safety goggles
could result in serious personal injury.
1. Clean all parts thoroughly.
2. Replace all seals and O-rings with new parts.
3. Check all locating pins for damage and all
springs for cracking or signs of fatigue.
4. Control piston (11, Figure 6-9) must slide
smoothly in sleeve (4).
5. Linkage to cradle should operate smoothly but
not loosely (with slop). Check piston and bore in
sleeve for signs of scratching or galling. Polish
with fine emery if needed.
Valve Plate Group
6. Closely examine mating faces of valve plate
(11, Figure 6-10) and cylinder barrel (10, Figure
6-9) for flatness, scratches or grooves. If faces
are not flat and smooth, the cylinder side will lift
off from the port plate (valve plate) resulting in
delivery loss and damage to the pump. Replace
if necessary.
Rotating Group
7. Check all pump piston assemblies (13, figure 69) for smooth action in their bores.
8. Check piston walls and bores for scratches or
other signs of excessive wear (pistons should
not have more than a few thousandths clearance). Replace if necessary.
9. Piston shoes must pivot smoothly, but end play
must not exceed 0.003 in (0.076 mm).
J06027
J6-15
10. Check end play as follows:

a. Place square end of piston on bench and
hold down firmly. Pull on end of shoe with
other hand and note end play. A good piston/shoe fit will have no end play, but the
shoe may rotate and pivot on the piston
ball. Inspect each shoe face for nicks or
scratches.
b. Measure shoe thickness (the part held

between retainer (27, Figure 6-9) and cradle. All shoes must be equal within 0.0001
in. (0.003 mm). If one or more piston/shoe
assemblies (13) needs to be replaced, all
piston/shoes assemblies must be replaced.
c. Inspect cylinder bearing (26) and matching
cylinder barrel bearing mating surface for
galling, pitting or roughness. Replace if necessary.
FIGURE 6-9. PUMP, REAR HOUSING

1. Capscrew
2. O-Ring
3. Plug
4. Cap
5. Back-Up Ring
L6-16
6. O-Ring
7. Capscrew
8. Capscrew
9. Cover Plate
10. O-Ring
11. Valve Plate

12. Gasket
13. Bearing
L06027
Swashblock Group
11. Inspect swashblock (25, Figure 6-9) for
scratches, grooves, cracks or uneven surface.
Replace if defective.
NOTE: The wear face is coated with a gray colored
epoxy based dry film lubricant for break-in
purposes. Scratching or wear of this coating is not
detrimental as long as the metal surface underneath
the coating is not scored or picked-up.
12. Compare saddle bearing (24) thickness in

wear area to thickness in a non-wear area.
Replace the saddle bearings if the difference is
greater than 0.004 in (0.102 mm).
13. Check mating surface of swashblock for cracks
or excessive wear. Replace if necessary.
14. Swashblock movement in the saddle and saddle bearing must be smooth.
FIGURE 6-10. UNLOADER & COMPENSATOR CONTROLS

1. Valve Plate
2. O-Ring
3. O-Ring
4. O-Ring
5. Plug
6. O-Ring
7. Plug
J06027
8. O-Ring
9. Orifice (0.062 in.)
10. Compensator Control Block
11. 4-Way Valve
12. Screw
13. Plug
14. O-Ring
15. Orifice (0.032 in.)

16. Compensator
17. Screw
18. Unloader Module
19. O-Ring
J6-17
Assembly
Driveshaft Group
15. Remove shaft seal (26, Figure 6-8).
16. Check shaft bearing (2) for galling, pitting, binding or roughness. Replace if necessary.
17. Check shaft and its splines for wear. Replace
any parts necessary.
Compensator Block and Unloader Module
18. Remove screws (17, Figure 6-11) and separate
unloader module (18) from compensator block
(10).
19. Remove 4-way valve (11) and compensator (16)
from compensator block. Remove all plugs and
orifices (9 & 15). Clean block in solvent; inspect
all passages and orifices for obstructions.
20. Remove unloader valve from block (18).
Remove plugs and clean block passages. If
unloader is inoperative, replace entire module.
Stroke Adjuster Assembly
21. Measure and record dimension A on stroke
adjuster assembly as shown in Figure 6-12.
The procedures for assembling the pump are basically the reverse order of disassembly procedures.
During assembly, install new gaskets, seals, and Orings.
1. Apply a thin film of CLEAN grease or hydraulic
fluid to sealing components to ease assembly. If
a new rotating group is used, lubricate thoroughly with CLEAN hydraulic fluid. Apply fluid
generously to all wear surfaces.
Swashblock Group
2. Press or tap roll pin (22, Figure 6-9) into pump
housing (18, Figure 6-8).
3. Press new shaft seal (26) into saddle (20, Figure 6-9) using an arbor press. Install O-ring (21)
into the groove in the saddle.
4. Press four roll pins (23) into saddle (20) until
they bottom, then press saddle bearing (24)
onto the pins to locate the bearing in the saddle.
22. Loosen jam nut (4). Separate stem (1) from

gland (3). Remove and discard O-ring (2).
23. Inspect parts for damage or excessive wear.
24. Install new O-ring on stem and reassemble to
gland. Adjust stem to gland to dimension A
recorded in Step 21. Tighten jam nut.
Extreme care should be used not to damage saddle bearing surfaces while installing the saddle
into the pump housing.
5. Use a long brass bar and a mallet (or an arbor
press), to install saddle and bearing assembly
into pump housing. Tap or press ONLY on the
area of the saddle that is exposed between the
saddle bearings (DO NOT tap on bearing surfaces). Saddle is fully seated when a distinct
metallic sound is heard when installing saddle
into pump housing.
6. Fasten control link (17, Figure 6-9) to swashblock (25) using link pin (16) and two retaining
rings (14).
7. Be sure the two dowel pins (19), are pressed
into swashblock (25).
8. Insert swashblock into pump housing until it
engages in saddle bearing and allow swashblock to settle to its lowest natural position.
FIGURE 6-11. STROKE ADJUSTER ASSEMBLY

1. Stem
2. O-Ring
L6-18
9. Retain by installing two swashblock retaining

pins (19, Figure 6-8) and O-rings (20). Once
pinned, make certain swashblock strokes
smoothly in the saddle by pulling firmly on the
free end of control link.
3. Gland
4. Jam Nut
L06027
Driveshaft Group
NOTE: Be sure punch marks on cylinder bearing (26,
Figure 6-9) will face toward shaft end of pump.
10. Insert cylinder bearing (26) straight into pump

housing. Be sure bearing is positioned so bearing retainer pins (14, Figure 6-8) can be
inserted in the case and into the bearing.
11. Install O-rings (18) on pins (17) and install pins.
12. An arbor press is required to install shaft bearing (2, Figure 6-8) onto driveshaft (1). IMPORTANT - press ONLY on the inner race of the
bearing. Press bearing until it contacts the
shoulder on driveshaft.
13. Use a long 6 in (153 mm) sleeve with an I.D.
slightly larger than the retaining ring I.D. and
press retaining ring (4) towards bearing until it
seats in the groove.
14. Place seal retainer (22) over seal (26) inside the
pump housing (21). Lubricate shaft seal with
clean hydraulic oil.
15. Install entire driveshaft assembly through front
of pump housing. A mallet will be required to
install the driveshaft through shaft seal.
16. Once the driveshaft assembly is fully seated in
the pump housing, install snap ring (3).
The assembled rotating group weighs approximately (30 lbs.). Assistance from others and use
of proper lifting techniques is strongly recommended to prevent personal injury.
21. The rotating group can now be carefully
installed over the end of the driveshaft and into
the pump housing.
22. When installing the rotating group, support the
weight of the cylinder barrel (10, Figure 6-9) as
cylinder spline is passed over the end of driveshaft to avoid scratching or damage.
23. Push cylinder barrel forward until the cylinder
spline reaches the driveshaft spline. Rotate the
cylinder slightly to engage shaft splines.
24. Continue to slide cylinder barrel forward until it
encounters the cylinder bearing (26). Lifting the
driveshaft slightly helps cylinder barrel and cylinder bearing engagement. Continue pushing
cylinder forward until the piston shoes contact
swashblock (25).
25. At this point, the back of the cylinder barrel
should be located approximately 0.25 in (6.3
mm) inside the back of the pump housing.

Rotating Group
17. Mating surfaces should be greased. Place cylinder assembly on clean table with the valve plate
side down.
18. During disassembly, shoe retainer springs were
referenced to individual bores. Assemble rotating group by inserting shoe retainer springs (28,
Figure 6-9) into the same spring bores located
in cylinder barrel (10) that they came from.
19. Slide fulcrum ball (12) over the nose of the cylinder barrel (10).
20. Place shoe retainer (27) over fulcrum ball and
align holes in retainer with corresponding holes
(marked during disassembly) in the cylinder
barrel. Once aligned, insert piston/shoe assemblies (13) into corresponding (marked during
disassembly) holes completing the rotating
group.
J06027
26. Install seal and piston ring (2 & 3, Figure 6-9)

into their respective grooves on control piston
(11) using care to assure they are in proper
location.
27. Insert control piston assembly into sleeve (4).
28. While supporting the control piston, press or slip
in pin (8) and secure with cotter or roll pin (18).
29. Order of piston sleeve seal installation starts at
widest end of sleeve.
30. Install backup ring (1, Figure 6-13) and O-ring
(2) and back-up ring (3) in rear most groove on
piston sleeve. Install O-ring (4) and back-up ring
(5) in remaining groove.
NOTE: Be certain that the grooves in Sleeve (4,
Figure 6-9) are at the 12:00 and 6:00 O-clock
positions when inserted into the valve plate.
31. Insert piston and sleeve assembly into valve
plate (11, Figure 6-10). Install O-ring (6) with
back-up ring (5) in seal groove of control cover
cap (4).
J6-19
40. With hole in control piston lined up with hole in

the link, carefully insert control link pin (16).
Care should be taken during this next step to prevent the washer and retaining ring from falling
into pump housing.
41. Install second control link washer (15) and control link retaining ring (14) onto pin.
42. Once assembled, remove capscrew from pin.
FIGURE 6-12. O-RING LOCATION ON PISTON
SLEEVE
1. Back-Up Ring
2. O-Ring
3. Back-Up Ring
4. O-Ring
5. Back-Up Ring
32. Insert bias control piston springs (1, Figure 6-9)

into control piston (11). Use four capscrews (1,
Figure 6-10) to fasten control cover cap to back
of valve plate. Tighten capscrews evenly to 138
ft.lbs. (187 N.m) torque.
33. Install O-ring (10) in rear of valve plate. Use four
capscrews (7) to fasten cover plate (9) over
opening in valve plate.
34. Pull free end of control link (17, Figure 6-9)
toward back of pump housing until the open
hole in the link lines up with open ports on sides
of pump case.
35. Install stroke adjuster assembly (Figure 6-12) to
hold swashblock in place.
Valve Plate Group
NOTE: The valve plate is a slight press fit into pump

housing. Make sure pilot diameter on valve plate is
aligned with mating diameter on the pump housing
prior to assembly.
43. Insert four capscrews (8, Figure 6-10) and alternately tighten until valve plate is drawn up to the
pump housing. Tighten capscrews evenly to
244 ft.lbs. (330 N.m) torque.
44. Install cover plate (9) with new O-ring (10) and
capscrews (7).
45. Install O-rings (2, 3 and 4, Figure 6-11) in proper
location on top of valve plate. Install block (10)
to valve plate with socket head capscrews (12)
and tighten to 183 in lbs (20.7 N.m) torque.
46. Install 4-way valve (11), and compensator valve
(16).
47. Install 0.062 in (1.575 mm) diameter orifice (9)
and plug (7) with new O-ring (8) in side of compensator block as shown in Figure 6-10. Install
0.032 in (0.813 mm) diameter orifice (15), plug
(7) and O-ring (8) in top of block.
48. Install remaining plugs with new O-rings.
36. Be sure driveshaft bearing (13, Figure 6-10) is

in place. Using assembly grease (to hold
desired position), place valve plate gasket (12)
in position on valve plate (11).
49. Install unloader module (18) on compensator

block with new O-rings (19) and socket head
capscrews (17). Tighten capscrews to 87 in.
lbs. (9.8 N.m) torque.
37. Support valve plate assembly from an overhead

hoist (lifting lug holes are provided) in preparation for mating to the pump housing.
50. Install plugs (9 & 24, Figure 6-8) and O-rings

(10 & 25) in pump housing.
38. Assemble one control link retainer ring (14, Figure 6-9) and one control link washer (15) onto
the threaded hole side of the control link pin
(16). Then thread a 1/4 in - 20 UNC capscrew
into pin to ease holding.
51. Measure pump rotation torque. Rotation torque

should be approximately 15 ft. lbs. (20.4 N.m).
39. Carefully maneuver valve plate assembly, supported by overhead hoist, over driveshaft and
into pump housing so slot on control piston (11)
engages control link (17).
L6-20
L06027
ACCUMULATORS
Removal
1. Insure key switch has been OFF for at least 90
seconds to allow accumulator oil to drain back
to tank. Move steering wheel to be certain all
pressurized oil is released.
2. Remove charging valve guard (3, Figure 6-2)
and loosen small hex on charging valve (4)
three complete turns. Depress the valve core
until all nitrogen pressure has been relieved.
Make certain only the small swivel hex nut turns.

Turning the complete charging valve assembly
may result in the valve assembly being forced
out of the accumulator by the nitrogen pressure
inside. Wear protective face mask when discharging nitrogen gas.
FIGURE 6-13. CHARGING VALVES

1. Accumulator
3. Charging Valve
2. Pressure Switch
Guard
Cover
4. Charging Valve
3. Remove oil line from bottom of the accumulator.

Plug all hoses and openings to prevent possible
contamination of the system. Disconnect and
mark electrical wiring to pressure switch.
4. Attach a lifting device to the accumulator to be
removed.
5. Loosen the mounting band (3, Figure 6-3) capscrews and remove the mounting bands.
6. Raise the accumulator until clear of mounting
bracket and move to a clean work area for disassembly.
Installation
1. Lift accumulator into position on the mounting
bracket. Accumulator should be positioned with
the anti-rotation block positioned between the
two stop blocks on the lower mounting bracket.
2. Secure the accumulator to the mounting
bracket using mounting bands (3, Figure 6-3),
capscrews, lockwashers and nuts. Do not overtighten nuts, as this could distort the accumulator.
3. If pressure switches were removed, install at
this time. Connect electrical wiring to pressure
switches and reconnect oil line to the bottom of
the accumulator.
4. Precharge both accumulators with pure dry
nitrogen as outlined in Steering Accumulator
Charging Procedure in this section.
J06027
FIGURE 6-14. ACCUMULATOR INSTALLATION

1. Accumulator
2. Pressure Switch
3. Mounting Band
J6-21
Disassembly - Accumulators
1. Remove charging valve (3, Figure 6-4).
2. Remove gland (4).
Note: Figure 6-5 illustrates a tool that can be
fabricated locally to aid in removing the gland.
3. Remove plugs and/or adaptor (10 & 11). Using
a round rod, push piston (6) out of accumulator.
4. Remove piston rings (7) and seal (8).
Cleaning and Inspection - Accumulators
1. Clean parts using fresh cleaning solvent, lint
free wiping cloth and filtered compressed air.
All parts must be absolutely free of any foreign
matter larger than 3 microns.
2. Inspect piston for damage. If scored or otherwise damaged, replace with a new part.
3. Minor defects in the housing bore may be corrected by honing.
a. Measure the bore at several places along
the length of the housing. Make two measurements, 90 apart at each point to verify
tube is not out-of-round.
FIGURE 6-15. ACCUMULATOR ASSEMBLY

7. Bearing
1. Capscrew
8. "T" Ring Seal
2. Cover
9. Housing
3. Charging Valve
10. Plug (or Adaptor)
4. Gland
5. O-ring & Backup Ring 10. Plug
6. Piston
L6-22
FIGURE 6-16. GLAND REMOVAL TOOL

(Fabricate Locally)
L06027
b. Verify housing I.D. does not exceed 8.002 in.

(203.25 mm).
c. Check dimensions frequently during honing
operation to prevent removal of too much
material. Do not hone gland seal area.
4. If housing defects can not be removed within
the above limits, replace the housing.
Repair of the housing by welding, machining or

plating to salvage a worn area is NOT
APPROVED. These procedures may weaken the
housing and result in serious injury to personnel
when pressurized.
5. Clean parts thoroughly to remove abrasive residue after honing.
Assembly - Accumulators
Testing - Accumulators
To carry out the testing required, it will be necessary
to check for internal and external leaks at high pressure. A source of 5000 psi (35 MPa) hydraulic pressure and nitrogen pressure of 1400 psi (9.65 MPa)
will be required. A small water tank with the necessary safety guards in place will be necessary for a
portion of the test.
Do not stand near gland during test procedure. A

box enclosure made of heavy steel plate is recommended to contain the accumulator during oil
pressurization test.
1. Fill each end of the accumulator with approximately 8.5 gallons (32.2 Liters) of clean type C4 hydraulic oil. Install an adaptor on the oil end
to connect to hydraulic power source. Plug
remaining ports.
a. Apply 5000 psi (35 MPa) oil pressure.
b. Verify no external leakage exists.
c. Verify no structural damage exists.
2. Release pressure and remove oil side fitting.
Assemble the accumulators in a dust and lint free

area. Maintain complete cleanliness during
assembly to prevent possible contamination.
1. Install a new seal (8, Figure 6-4) on piston.
Install new bearings (7). Coat seal and bearings with a small amount of petroleum jelly.
2. Install the piston with the concave side toward
gas end (gland end) of accumulator cylinder
housing (9). Push the piston to the center of the
housing.
3. Install new O-rings and backup rings (5) on
gland (4). Coat seals with a small quantity of
type C-4 hydraulic oil.
4. Install gland and tighten to 850 ft. lbs. (1152
N.m) torque using tool as shown in Figure 6-5.
5. Install charging valve (3) with new O-ring.
Tighten charging valve large hex nut to 16.5
6. Install pressure switch. Install pressure test fittings in bottom of housing. (See "Testing"
below.)
J06027
3. Drain oil. Leave port open.

4. Pressurize gas end of accumulator with approximately 100 psi (690 kPa) nitrogen pressure to
move piston to bottom of housing.
5. Submerge oil end of assembly in water.
6. Apply 1400 psi (9.65 MPa) nitrogen pressure to
gas end and observe for 20 minutes. No leakage (bubbles) is permitted.
7. Release nitrogen pressure and remove assembly from water.
8. Drain any remaining oil or water.
9. If the accumulator is to be placed in storage,
add 3 pints (1.5 L) of rust preventive oil in the
nitrogen side of the accumulator. Add 1 pint (0.5
L) in the oil side. If the accumulator will be used
immediately, type C-4 hydraulic oil may be used
instead of rust preventive oil. Plug all open
ports.
10. Verify all warning and caution labels are
attached and legible (Refer to parts book if
replacements are required).
J6-23
nitrogen charging procedure by turning the steering

wheel back and forth or by actuating the bleed down
solenoid by turning the key switch ON and then OFF.
Charging Procedure

component until engine is stopped and key
switch has been OFF for at least 90 seconds.
use in the steering accumulators. The accidental
charging of oxygen or any other gas in this compartment may cause an explosion. Be sure pure
dry nitrogen gas is being used to charge the
accumulators.
When charging or discharging the nitrogen gas
in the accumulators, be sure the warning labels
are observed and the instructions regarding the
charging valve are carefully read and understood.
1. With engine shut down and key switch in the
OFF position, allow at least 90 seconds for
accumulators to bleed down. Turn steering
wheel to be certain no oil remains in accumulators.
2. Remove charging valve guards.
If nitrogen pressure is present in the accumulators, make certain only the small swivel hex nut
is turned during the next step. Turning the complete valve assembly may result in the valve
assembly being forced out of the accumulator by
the nitrogen pressure inside.
3. Remove charging valve cap (1, Figure 6-6).
Turn small swivel hex nut (4) three complete
turns counterclockwise.
4. Depress the valve stem and hold down until all
nitrogen has been released.
5. If a loss in nitrogen pressure is the reason for
recharging, inspect the charging valve and
accumulator for damage. Replace or repair
items, as necessary, before charging procedure.
6. Connect the nitrogen charging kit to the charging valves. Open the regulator and charge the
accumulators simultaneously to 1400 psi (9.65
MPa).
NOTE: If a loss in nitrogen pressure occurred during
operation, oil may still be present in the accumulator
below the piston. This oil can be bled off during the
L6-24

6. Valve Body
1. Valve Cap
7. O-ring
2. Seal
8. Valve Stem
3. Valve Core
9. O-ring
4. Swivel Nut
5. Rubber Washer
NOTE: When charging the accumulators, allow
adequate time for the system to fully charge. Insure
all oil has returned from the accumulators to the
hydraulic tank.
7. Shut off charging kit and check pressure gauge
reading. If gauge does not maintain 1400 psi
(9.65 MPa) continue charging procedure until
pressure is stabilized.
8. Remove the charging kit and tighten small hex
nut on charging valve to 4 ft.lbs. (5.4 N.m)
torque.
NOTE: If a new charging valve was installed, the
valve stem must be seated as follows:
a. Tighten small hex swivel nut to 10.5 ft.lbs.
(14.2 N.m) torque.
b. Loosen swivel nut.
c. Retighten swivel nut to 10.5 ft.lbs. (14.2
N.m) torque.
d. Again, loosen swivel nut.
e. Finally, tighten swivel nut to 4 ft.lbs. (5.4
N.m) torque.
9. Install charging valve cap (1) and tighten finger
tight. Install charging valve guard and tighten
capscrews to 25 ft.lbs. (33.9 N.m) torque.
10. Operate truck and check steering.
L06027
TROUBLESHOOTING CHART
TROUBLE
POSSIBLE CAUSE
ACTION
STEERING CIRCUIT
Slow steering, hard steering or loss of power assist
Drift - truck veers slowly in

one direction.
Wander - truck will not stay

in straight line
Slip - a slow movement of

steering wheel fails to steer
front wheels
Spongy or soft steering
Erratic steering
1. Overloaded Steering Axle
1. Reduce Axle Loading
2. Malfunctioning relief valve preventing

adequate system pressure build-up
2. Check system pressure. Adjust

or replace relief valve
3. Worn or malfunctioning pump
3. Replace pump
4. Restricted high pressure filter or suction

strainer
4. Replace filter element or clean

strainer
1. Rod end of cylinder slowly extends

without turning the steering wheel
1. A small rate of extension may be

normal on a closed center system
2. Worn or damaged steering linkage
2. Inspect and replace linkage if

necessary. Check alignment or
toe-in of the front wheels.
1. Air in system due to low oil level, pump

cavitation, leaking fitting, pinched
hoses, etc.
1. Correct oil supply problem or

bleed air
2. Loose cylinder piston
2. Repair or replace steering cylinder
3. Broken centering springs (spool valve,

steering valve)
3. Repair or replace steering control

unit
4. Worn mechanical linkage
4. Repair or replace
5. Bent linkage or cylinder rod
5. Repair or replace defective components
6. Severe wear in steering control unit

unit
1. Leakage of steering cylinder piston

seals
1. Repair or replace steering cylinder
2. Worn steering control unit meter
2. Replace steering control unit
1. Low oil level
1. Service hydraulic tank and check

for leakage
2. Air in hydraulic system. Probably air

trapped in cylinders or lines.
2. Bleed air from system
1. Air in system due to low oil level, cavitating pump, leaky fittings, pinched
hose, etc.
1. Correct condition and add oil as

necessary
2. Loose steering cylinder piston
Free wheeling - steering

wheel turns freely with no
back pressure. Front
wheels do not steer.
J06027
2. Repair or Replace steering cylinder
1. Splines of steering column/steering

control unit coupling may be disengaged or damaged
1. Repair or replace steering column or coupling.
2. No flow to steering control unit;
2. Repair as required:
a. Low oil level

b. Ruptured hose
c. Broken steering control unit gerotor
drive pin
a. Add oil and check for leakage

b. Replace hose
c. Repair or replace steering control
unit
J6-25
TROUBLE
POSSIBLE CAUSE
1. Broken or worn linkage between steering cylinder and steered wheels
1. Check for loose fitting bearings at

anchor points in steering linkage
between cylinder and steered
wheels
2. Leaky steering cylinder seals
2. Repair or Replace steering cylinder
1. Binding or misalignment in steering column or splined coupling and steering

control unit
1. Align column to steering control

unit
2. High back pressure in tank can cause

slow return to center. Should not
exceed 300 psi (2068 kPa)
2. Remove restriction in the lines or

circuit. Check for obstruction or
pinched lines, etc.
3. Large particles can cause binding

between the spool and sleeve in the
steering control unit
3. Clean the steering control unit

and filter the oil. If another component has malfunctioned generating contaminating materials,
flush the entire hydraulic system.
1. Large particles in meter section
1. Clean the steering control unit.
2. Insufficient hydraulic power
2. Check hydraulic system pressure
3. Severe wear and/or broken pin

unit
1. Lines connected to wrong ports
1. Check line routing and connections
2. Parts assembled wrong; steering control unit improperly timed
2. Reassemble correctly and retime control valve
1. Lines connected to wrong cylinder ports
1. Inspect and correct line connections
Excessive free play at

steered wheels
Binding or poor centering of

steered wheels
Steering control unit locks

up
Steering wheel oscillates or

turns by itself
Steered wheels turn in

opposite direction when
operator turns steering
wheel
ACTION
STEERING PUMP
No pump output
L6-26
1. Air trapped inside steering pump
1. Bleed air from pump and/or system
2. Broken pump drive shaft
2. Inspect hoist and steering pump,

replace drive shaft
3. Excessive circuit leakage
3. Check for external leaks, internal

system pressure loss
4. No oil to pump inlet
4. Check hydraulic tank oil level.

Make certain pump inlet shut-off
valve is open.
L06027
TROUBLE
Low pump output
POSSIBLE CAUSE
1. Low pump pressure
1. Check unloader valve operation

and adjust pressure if necessary.
Check compensator adjustment
pressure. Check system relief
valves
2. Internal pump wear
2. Repair or replace steering pump
3. Restricted inlet
3. Make certain shut-off valve is

open. Check suction hose. Clean
tank strainers.
4. Insufficient oil supply

Make certain shut-off valve is
open.
5. High pressure filter restricted
5. Replace filter element
1. Defective pressure control

valves.
2. Internal steering pump wear
2. Repair or replace pump
3. Excessive leakage in brake system
3. Inspect brake system and check

pressures
1. Defective or improperly adjusted pressure control(s)

valves and replace if necessary.
1. Low compensator or unloader valve

setting
1. Check pressure and adjust pressure controls
2. Fluid too cold or viscosity too high
2. Warm oil before starting or install

proper viscosity oil
3. Air leak at pump inlet
3. Inspect inlet hose, connections

and shut-off valve
4. Insufficient inlet oil supply
4. Check hydraulic tank level. Clean

suction strainer. Make certain
shut-off valve is open
5. Internal pump damage
5. Repair or replace pump
1. Pressure compensator adjusted incorrectly or defective
1. Adjust pressure compensator or

repair if necessary.Check
unloader pressure settings.
2. Excessive internal leakage in steering

circuit
2. Measure component leakage

rates and replace defective components
3. Unloader valve pilot seat damaged
3. Replace unloader valve module
1. Excessive system pressure
1. Adjust system pressures
2. Low hydraulic fluid level
2. Service hydraulic tank
3. Worn steering or hoist pump
3. Repair or replace pump(s).
Loss of pressure
Excessive or high peak

pressure
Noise or squeal
Erratic pump (load/unload)

cycle
Excessive heat
J06027
ACTION
J6-27
TROUBLE
POSSIBLE CAUSE
ACTION
FLOW AMPLIFIER
Slow or hard steer
1. Stuck amplifier spool
1. Disassemble valve, check amplifier spool for damage or obstruction
2. Obstruction in orifice, directional spool
2. Disassemble valve, check directional spool and orifices for damage or obstruction
3. Incorrect relief valve pressure setting
3. Check and correct relief valve

setting
1. Leaking shock and suction relief valve
1. Disassemble valve, check and

clean shock and suction valves.
Replace valves if necessary.\
2. Pressure setting of shock valve too low
2. Adjust pressure settings
1. Defective steering control unit

unit
1. Air in LS line
1. Bleed air from LS line
2. Priority valve spring compression weak
2. Disassemble flow amplifier.

Replace priority valve spring.
3. Obstruction in orifice in LS or PP
port
3. Disassemble flow amplifier.

Inspect and clean orifice.
Free wheeling (no end

stop)
Inability to steer (no pressure build-up)
Resistance when initially

turning steering wheel
L6-28
L06027
SECTION L7
HOIST CIRCUIT
INDEX
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-3

HOIST CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
High Pressure Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Inlet Sections - Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Spool Sections - Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-5
Hoist Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-5
Bleeddown Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
Hoist-up Limit Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
Overcenter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
HOIST CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-7
Float Position Of Pilot Valve With Truck Body On Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-8
Power Up Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-10
Hold Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-12
Power Down Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-14
Float Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-16
L07023
Hoist Circuit
L7-1
NOTES
L7-2
Hoist Circuit
L07023
HOIST CIRCUIT
The following information describes the basic hoist
system circuit as shown in Figure 7-1. Detailed component operation is outlined under the individual
component descriptions.
Hydraulic fluid is supplied by a tank (1) located on
the left frame rail. The tanks service capacity is
approximately 250 gal. (947 l). Hydraulic oil is
routed to a tandem gear type pump (2). A second
pump, coupled to the rear of the hoist pump, supplies oil for the steering and brake systems. The
pumps are driven by an accessory drive at the end
of the traction alternator.
Hoist pump output is directed to a pair of high pressure filters (3), mounted to the inboard side of the
fuel tank.
Hydraulic oil from the hoist filters is directed to the

hoist valve (7), mounted above the pumps The hoist
valve directs oil to the body hoist cylinders (10) for
raising and lowering of the dump body. Hoist valve
functions are controlled by the operator through the
lever connected to the hoist pilot valve (4) located in
the hydraulic components cabinet. A hoist limit solenoid (5) located in the bleeddown manifold shifts the
hoist valve out of POWER UP before the hoist cylinders extend to their maximum physical limit.
When the hoist valve is in the HOLD or FLOAT position, hoist circuit oil flows to the front (8) and rear (9)
service brakes, cooling the wet disc brakes during
truck operation.
Hydraulic hoses deteriorate with age

and use. Prevent possible malfunctions by inspecting all hoses periodically. Replace any hose showing
wear, damage or deterioration.
FIGURE 7-1. HOIST CIRCUIT SCHEMATIC

1. Hydraulic Tank
2. Hoist Pump
3. High Pressure Filter
5. Hoist Limit Solenoid
L07023

7. Hoist Valve
8. Brake Cooling Oil Supply (Front)
9. Brake Cooling Oil Supply (Rear)
10. Hoist Cylinder
Hoist Circuit
11. Quick Disconnect

13. Check Valve
L7-3
Hydraulic Tank
The hydraulic tank supplies hydraulic oil for the hoist,
steering and brake circuits. The tank is located on
the left hand frame rail forward of the rear wheels.
The service capacity of the tank is 250 gal. (947 l).
Type C-4 hydraulic oil is recommended for use in the
hydraulic system. Oil used in the hoist circuit flows
through 100 mesh wire suction strainers to the inlet
hoses of the pump. Air drawn into the tank during
operation is filtered by air filters located on the top of
the tank. Oil level can be checked visually at sight
glasses located on the face of the tank.
lows differential pressure input signals generated by

the hoist pilot valve as the operator moves the hoist
control lever while raising and lowering the dump
body.
Hydraulic Pump
The hoist system hydraulic pump is a tandem, gear
type pump driven by a drive shaft on the end of the
traction alternator. The pump has a total output of
246 gpm (931 l/m) at 1900 rpm and 2500 psi (17, 235
kPa).
A smaller, piston type, pressure compensated pump
rated at 66 gpm (250 l/m) @ 1900 rpm, coupled to
the hoist pump, supplies oil to the steering system
and brake apply system.
Hoist pressure is limited to 2500 psi (17,235 kPa) by
internal relief valves located in the hoist control valve
inlet sections.
High Pressure Filters
Hoist pump output oil is directed to the high pressure
filters, mounted on the inboard side of the fuel tank.
The filter assemblies are equipped with a bypass
valve which permits oil flow if the filter element
becomes excessively restricted. Flow restriction
through the filter element is sensed by an indicator
switch. This switch will turn on a cab mounted red
warning light to indicate filter service is required. The
indicator light will illuminate when restriction reaches
approximately 40 psi (276 kPa). Actual filter bypass
will result when the filter element restriction reaches
approximately 50 psi (345 kPa).
Hoist Valve
The hoist valve (Figure 7-2) is mounted on a modular
assembly containing the hoist valve, overcenter manifold, and both hydraulic pumps. This assembly is
bolted to brackets attached to the frame rails behind
the main alternator. The hoist valve is a split spool
design. (The term split spool describes the spool
section of the valve.) The hoist valve precisely fol-
L7-4
FIGURE 7-2. HOIST VALVE

1. Inlet Section
2. Work Ports Spool
Section
3. Tank Ports Spool
Section
4. Inlet Section
5. Inlet Port
6. Outlet Port
7. Spool Section Cover
8. Separator Plate
Inlet Sections - Hoist Valve

Each of the front and rear inlet sections of the hoist
valve contains of the following components:
Flow control valve and main relief valve
Secondary Low pressure relief valve
Anti-void check valve
Load check valve
The flow control portion of the flow control and main
relief valves allow pump flow to the service brake
cooling circuit unless the body is being raised or lowered. The relief portion of the valve is direct acting
and has the capacity to limit the working pressure at
full pump flow.
Hoist Circuit
L07023
The secondary low pressure relief is located between

the low pressure core and the outlet to the brake
cooling circuit. It provides for pressure relief if pressure spikes occur in the low pressure passage area.
The load check allows free flow from the inlet to the
high pressure core and prevents flow from the high
pressure core to the inlet.
The anti-void check valve allows free flow from the
low pressure core to the high pressure core and prevents flow from the high pressure core to the low
pressure core.
Spool Sections - Hoist Valve
Work Ports (Rear) Spool Section
The rear spool section of the hoist valve consists of
the following components:
Pilot ports
Main spools
Work ports
Check poppets
The pilot ports are located in the spool section cover.
These ports provide connections for a pilot line to the
hoist pilot valve. Each work port has a corresponding
pilot port.
Tank Ports (Front) Spool Section

The primary low pressure valves are located in the
front spool section of the hoist valve. These valves
maintain back pressure on the low pressure passage
and direct the hoist cylinder return oil back to the
hydraulic tank.
Hoist Pilot Valve
The hoist pilot valve (Figure 7-3) is mounted in the
hydraulic components cabinet behind the operators
cab. The hoist pilot valve spool is spring centered to
the neutral position and is controlled directly by the
operator through a lever mounted on the console
between the operator and passenger seat. A cable
connects the cab mounted lever to the hoist pilot
valve in the hydraulic components cabinet.
When the operator moves the lever, the pilot valve
spool moves and directs pilot flow to the appropriate
pilot port on the hoist valve. The pilot flow causes the
main spool to direct oil flow to the hoist cylinders.
The hoist pilot valve is equipped with a one way load
check valve which allows free flow from the center
passage to bridge core and prevents reverse flow.
The valve also contains the power down relief valve
(2), used to limit power down pressure to 1500 psi
(10.4 MPa).
The work ports provide for a line connection between

the spool section and the hoist cylinders. One main
spool for each work port is spring biased at both end
to block the work port from the high and low pressure
cores when there is no flow through the spool cross
holes.
When there is flow through the pilot ports to the
spools, a positive differential pressure at the top of
the spool will overcome the bottom spring bias and
the spool will shift to connect the work port to the
high pressure core.
When there is flow from the main valve work port to
the pilot port through the cross-holes, a positive differential pressure at the bottom of the spool will overcome the top spring bias and the spool will shift to
connect the work port to the low pressure core.
The check poppets located in the spool section permit free flow from the work port to the pilot port and
restrict flow from the pilot port to the work port. These
check poppets control spool response and spool
movements during void conditions.
FIGURE 7-3. HOIST PILOT VALVE

2. Relief Valve
3. Supply Port
L07023
Hoist Circuit
4. To Hoist Valve
(Rod End)
5. To Hoist Valve
(Base End)
L7-5
Bleeddown Manifold
Overcenter Manifold
The pilot valve/hoist valve hydraulic circuit is routed

through the bleeddown manifold, located on the left
frame rail. The hoist-up solenoid and pilot operated
check valve described below are contained in the
manifold. Refer to Section L4 for additional information concerning these components.
The overcenter manifold (4, Figure 7-4), located on

the pump module at the rear of the hoist valve (1)
contains the counterbalance valve (2). This valve
controls the pressure of the cushion of oil in the
annulus area of the hoist cylinder when the body
approaches the maximum dump angle. The valve
limits the maximum pressure build-up by relieving
pressure in excess of 3000 psi (20, 400 kPa), preventing possible seal damage.
Hoist-up Limit Solenoid

The hoist-up limit solenoid (5, Figure 7-1), located on
the bottom of the bleeddown manifold, is used in the
hydraulic circuit to prevent maximum hoist cylinder
extension.
The solenoid valve is a 3-way valve, and is controlled
by a proximity switch (hoist limit switch) located near
the body pivot and the right rear suspension upper
mount.
Quick disconnect fittings (5) mounted on the bottom

of the manifold allow service personnel to dump the
load in a disabled truck by connecting jumper hoses
from an operational truck, utilizing its hydraulic system.
When the body is nearly fully raised, the body activates the magnetic proximity switch, signalling the
solenoid to open the raise pilot line to tank, and
close the raise pilot line to the hoist valve, stopping
further oil flow to the hoist cylinders.
Refer to Section D, Electrical System (24VDC) for
adjustment procedure of the hoist limit switches
Pilot Operated Check Valve
The pilot operated check valve (6, Figure 7-1),
located in the bleeddown manifold, is opened by
power down pilot pressure to allow oil in the raise
port to by-pass the hoist up limit solenoid for initial
power down operation while the solenoid is activated
by the hoist limit switch.
FIGURE 7-4. PUMP MODULE

1. Hoist Valve
2. Counterbalance
Valve
3. Needle Valve
L7-6
Hoist Circuit
4. Overcenter Valve
5. Quick Disconnects
7. Hoist Pump
L07023
The following pages describe the hoist circuit operation in the FLOAT, POWER UP,
HOLD, and POWER DOWN positions. (Refer to Figures 7-5 through 7-9.)
L07023
Hoist Circuit
L7-7
Float Position Of Pilot Valve With Truck Body On

Frame
Figure 7-5 shows the position of the hoist pilot valve
when the truck body is resting on the frame. However, the hoist valve internal valves and spools will
be in the position shown in Figure 7-7.
Oil from the hoist pump enters the inlet sections of
the hoist valve in port (11), passes through check
valve (18), and stops at the closed high pressure
passage (19) at the two main spools (7 & 8) as
shown in Figure 7-4.
Pressure builds to approximately 60 psi (414 kPa) on

the pilot of the flow control valve (2) causing the
valve to compress the spring and open, allowing the
oil to flow the through hoist valve port (23) to the service brakes for brake disc cooling and eventually
back to the tank. Between the hoist valve port (23)
and the brakes or heat exchanger, the cooling supply
tees to orificed regulator valves. If supply pressure
attempts to increase above 35 psi (240 kPa), the regulator valve opens and dumps to tank.
Oil also flows out hoist valve port (12) to port (12) on
the pilot valve, through the hoist pilot valve spool,
and out pilot valve port (10) to the tank. This oil flow
is limited by orifices in the inlet sections of the hoist
valve and therefore has no pressure buildup.
L7-8
Hoist Circuit
L07023
FIGURE 7-5. FLOAT POSITION

1. Hoist Relief Valve (2500 psi)
2. Flow Control Valve
3. Secondary Low Pressure Valve
(250 psi)
4. Snubber Valve
5. Rod End Work Port
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
L07023
9. Head End Work Port

11. Supply Port
12. Pilot Supply Port
14. Raise Pilot Port
15. Down Pilot Port
16. Power Down Relief Valve
(1500 psi)
Hoist Circuit
17. Anti-void Check Valve

18. Load Check Valve
19. High Pressure Passage
20. Low Pressure Passage
22. Primary Low Pressure Valve
(26 psi)
23. Brake Cooling Circuit Port
L7-9
Power Up Operation
(Figure 7-6)
The hoist pilot valve spool is moved to the power up
position when the operator moves the lever rearward
in the cab. The pilot supply oil coming in port (12) is
prevented from returning to the tank and, instead, is
directed out port (14) through hoist limit solenoid (13)
in the bleeddown manifold and into port (14) of the
hoist valve.
From there it goes to the top of the head end spool
(8), builds pressure on the end of the spool, causes
the spool to move down compressing the bottom
spring, and connects the high pressure passage (19)
to head end port (9). Working oil flow in the high
pressure passage is now allowed to flow through the
spool (8) and out port (9) to extend the hoist cylinders.
Even though a small amount of oil flows through the
check poppet in the top of spool (8), raise pilot pressure at ports (14) increases to slightly higher pressure than the required hoist cylinder pressure. As a
result, the pilot supply pressure in ports (12) also
increases causing back pressure to occur in the
spring area of the flow control valve (2). This overcomes the pilot pressure on the other end of the flow
control valve causing it to close and direct the incoming pump oil through the head end spool (8) to the
hoist cylinders to extend them. At this time, oil flow to
the brake cooling circuit is stopped.
If at any time the resistance to the flow of the pump
oil coming into the inlet section causes the pressure
to increase to 2500 psi (17,238 kPa), the pilot pressure against hoist relief valve (1) causes it to open
and allow flow to exit out port (23) to the brake cooling circuit and to return to the tank.
If the load passing over the tail of the body during

dumping attempts to cause the body to raise faster
than the oil being supplied by the pump, the oil
returning from the annulus area of the hoist cylinders
passing through the counterbalance valve manifold
controls how fast the hoist cylinders can extend due
to the external force of the load. The speed is controlled by counterbalance valve.
During the normal raise process, the raise pilot pressure supplied to the counterbalance valve (24) will
open the cylinder return ports fully any time raise
pressure is above 666 psi (4,600 kPa). As the load
shifts toward the tail of the body, the raise pressure
decreases. As it drops below 666 psi (4,600 kPa),
the valve starts restricting oil flow causing a backpressure to the annulus area. If raise pressure were
to drop to 0 psi (kPa), return pressure would increase
to 3000 psi (20,400 kPa) maximum.
When the operator releases the hoist lever, the
valves change to the HOLD position. If the body
raises to the position that activates the hoist limit
switch located above the right rear suspension
before the operator releases the lever, the hoist limit
solenoid (13) is energized. The solenoid valve closes
the raise pilot port (14) on the hoist and releases the
hoist pilot valve raise pilot pressure at port (14) to
tank, allowing the head end spool (8) to center and
shut off supply of oil to the hoist cylinders. This prevents maximum extension of the hoist cylinders.
As the hoist cylinders extend, oil in the annulus area

of all three stages must exit sequentially from the cylinders. Initially, the rod end spool (7) ports are
closed. As the returning oil entering port (5) builds
low pressure, it flows through the check-poppet in the
top of the spool, through ports (15), through the pilot
valve spool, and out port (10) of the pilot valve to the
bleeddown manifold and to the tank.
No pressure is present on the top of spool (7). Cylinder return pressure passes through the check-poppet
in the bottom of spool (7) to build pressure under the
spool which moves the spool upward compressing
the top spring. This movement allows the returning
cylinder oil to flow into the low pressure passage (20)
to the primary low pressure relief valve (22). Approximately 26 psi (179 kPa) causes this valve to open,
allowing the oil to flow out port (10) to the tank.
L7-10
Hoist Circuit
L07023
FIGURE 7-6. POWER UP POSITION

(250 psi)
4. Snubber Valve
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
L07023

11. Supply Port
15. Down Pilot Port
(1500 psi)
Hoist Circuit

(26 psi)
L7-11
Hold Operation
(Figure 7-7)
The pilot valve spool is positioned to allow the pilot
supply oil entering port (12) to return to the tank
through port (10). Pilot supply pressure in ports (12)
then decreases to no pressure allowing flow control
valve (2) to open and route the incoming pump oil to
the brake cooling circuit through port (23) and back
to the tank.
L7-12
Both pilot ports (14 & 15) in the pilot valve are closed
by the pilot valve spool. In this condition pressure is
equalized on each end of each main spool (7 & 8)
allowing the springs to center the spools and close all
ports to trap the oil in the cylinders and hold the body
in its current position.
Hoist Circuit
L07023
FIGURE 7-7. HOLD POSITION

(250 psi)
4. Snubber Valve
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
L07023

11. Supply Port
15. Down Pilot Port
(1500 psi)
Hoist Circuit

(26 psi)
L7-13
Power Down Operation

(Figure 7-8)
When the operator moves the lever to lower the
body, the hoist pilot valve is positioned to direct the
pilot supply oil in ports (12) through ports (15) to the
top of the rod end spool (7).
Pilot pressure increases to move the spool down
compressing the bottom spring. Movement of the
spool connects the high pressure passage (19) to the
rod end (annulus area) of the hoist cylinders. At the
same time, the flow control valve (2) is forced to
close as pilot pressure increases thus directing the
incoming pump oil to the hoist cylinders through
spool (7) and check valve in the overcenter manifold
rather than back to the tank. Oil flow to the brake
cooling circuit ceases when the flow control valve
closes.
As oil attempts to return from the head end of the

hoist cylinders, it initially encounters the closed head
end spool (8). Pressure increases on the bottom end
of the spool causing it to move upward. This allows
the returning oil to go into the low pressure passage
(20), build up 26 psi (179 kPa) to open the primary
low pressure relief (3), and exit the hoist valve
through port (10) to the tank.
As the body descends and the hoist limit solenoid is
no longer activated, the pilot operated check valve is
no longer necessary.
If the body is at the maximum up position, the hoist

limit switch has the hoist limit solenoid activated,
therefore closing the raise port (14) on the hoist
valve. Power down pilot pressure in ports (15)
pushes open the pilot operated check valve (21)
located in the bleeddown manifold so the pilot pressure in ports (14) is open to tank through the Pilot
valve spool.
L7-14
Hoist Circuit
L07023
FIGURE 7-8. POWER DOWN POSITION

(250 psi)
4. Snubber Valve
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
L07023

11. Supply Port
15. Down Pilot Port
(1500 psi)
Hoist Circuit

(26 psi)
L7-15
Float Operation
(Figure 7-9)
When the operator releases the lever as the body
travels down, the hoist pilot valve spool returns to the
FLOAT position. In this position all ports (10, 12, 14,
& 15) are common with each other. Therefore, the
pilot supply oil is returning to tank with no pressure
build-up thus allowing the flow control valve (2) to
remain open to allow the pump oil to flow through
hoist valve port (23) to the brake cooling circuit and
eventually returning to the tank.
The 26 psi (179 kPa) in the low pressure passage

causes oil to flow to the rod end of the cylinders to
keep them full of oil as they retract. When the body
reaches the frame and there is no more oil flow from
the cylinders, the main spools center themselves and
close the cylinder ports and the high and low pressure passages.
With no blockage of either RAISE or DOWN pilot

ports (14 & 15) in the pilot valve, there is no pressure
on the top of either main spool. The oil returning from
the head end of the hoist cylinders builds pressure
on the bottom of the head end spool (8) exactly like
in POWER DOWN allowing the returning oil to transfer to the low pressure passage (20). The back pressure in the low pressure passage created by the
primary low pressure relief valve (22) causes pressure under the rod end spool (7) to move the spool
upward. This connects the low pressure passage to
the rod end of the hoist cylinders.
L7-16
Hoist Circuit
L07023
FIGURE 7-9. FLOAT POSITION

(250 psi)
4. Snubber Valve
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
L07023

11. Supply Port
15. Down Pilot Port
(1500 psi)
Hoist Circuit

(26 psi)
L7-17
NOTES
L7-18
Hoist Circuit
L07023
SECTION L8
HOIST CIRCUIT COMPONENT REPAIR
INDEX
HOIST CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3

HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-4
O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-4
INLET SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-5
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6
REAR SPOOL SECTION (Work Ports) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-8
FRONT SPOOL SECTION (Tank Ports) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-9
HOIST PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-12
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-13
L08032
Hoist Circuit Component Repair
L8-1
HOIST CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-17
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-18
Assembly - Quill and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-19
Quill Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-19
Installation Of Check Balls And Plugs In Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-20
Assembly of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-21
OVERCENTER VALVE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-22
DISABLED TRUCK DUMPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-23
Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-23
DUMPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-23
Raising the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-23
Lowering the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-23
L8-2
L08032
HOIST CIRCUIT COMPONENT REPAIR

HOIST VALVE
move hoist lever to LOWER position to allow

body to lower against safety cable and relieve
hoist cylinder pressure.
Removal
3. Thoroughly clean the exterior of the hoist

valve.
Relieve pressure before disconnecting hydraulic lines. Tighten all connections securely before
applying pressure.
penetrating the skin and cause serious injury
by a physician familiar with this type of injury is
not received immediately.
1. Ensure adequate overhead clearance and
raise truck body. Secure body in raised position with safety cable.
2. Using standard procedures, shut down engine
and turn key switch to the off position. Slowly
4. Mark, disconnect and cap or plug all line connections to help prevent hydraulic oil contamination. Refer to Figure 8-1.
5. Remove capscrews and lockwashers securing the hoist valve (5, Figure 8-1).
The hoist valve weighs approximately 425 lbs.

(193 Kg). Use a suitable lifting device that can
6. Attach a lifting device to the hoist valve and
remove valve from truck.
7. Move the hoist valve to a clean work area for
disassembly.
1. Hoist Cylinder
2. Brake/Hoist Return Oil
Manifold
5. Hoist Valve
6. Pump Drive Shaft
7. Hydraulic Tank
FIGURE 8-1. HOIST VALVE & PIPING
L08032
L8-3
O-Ring Replacement
NOTE: It is not necessary to remove the individual
valve sections to accomplish repair, unless
emergency field repair is required to replace the Orings between sections to prevent leakage.
Loosening and retightening of the main valve tie rod
nut could cause distortion resulting in binding or
severely sticking plungers, poppet and spools.
To replace the O-rings between the valve sections:
1. Remove the four tie rod nuts and washers (5,
Figure 8-2) from one end of the valve. Slide the
tie rods from the valve and separate the sections.
FIGURE 8-1. HOIST VALVE ASSEMBLY

4. Inlet Section (Front)
1. Inlet Section (Rear)
5. Nuts and Washers
2. Spool Section
6. Tie Rods
(Work Ports)
7. Tube
3. Spool Section
8. Separator Plate
(Tank Ports)
Installation
1. Attach a suitable lifting device that can handle
the load safely to the hoist valve. Move the hoist
valve into position and secure in place with capscrews, nuts and lockwashers. Tighten capscrews to standard torque.
Note: Valve should be positioned with separator plate
(8, Figure 8-2) toward front of truck.
2. Using new O-rings at the flange fittings, connect
hydraulic lines. Tighten flange capscrews to
standard torque. Refer to Figure 8-1 for hydraulic line location.
2. Inspect the machined sealing surfaces for

scratches or nicks. If scratches or nicks are
found, remove by lapping on a smooth flat steel
surface with fine lapping compound.
3. Lubricate the new O-rings lightly with multipurpose grease. Replace O-rings between sections. Stack the sections together making sure
O-rings between the sections are properly positioned.
4. Install the four tie rods with the dished washer
between the nut and housing (Figure 8-3).
5. A torque wrench should be used to tighten the
nuts in the pattern shown in Figure 8-4. The tie
rods should be tightened evenly to 105 ft. lbs.
(142 N.m) torque in the following sequence:
a. Tighten nuts evenly to 15 ft. lbs. (20 N.m)
torque in order 1, 4, 2, 3.
b. Tighten nuts evenly to 32 ft. lbs. (43 N.m)
c. Tighten nuts evenly to 105 ft. lbs. (142 N.m)
3. Connect pilot supply lines, tighten fittings

securely.
4. Start the engine. Raise body and remove safety
cable. Lower and raise body to check for proper
operation. Observe for leaks.
5. Service hydraulic tank if necessary.
FIGURE 8-3. TIGHTENING SEQUENCE

FIGURE 8-2. TIE ROD INSTALLATION
L8-4
L08032
1. Capscrew
2. Inlet Cover
3. Spring (Orange)
4. Flow Control & Main
Relief Valve
FIGURE 8-4. INLET SECTION DISASSEMBLY

8. O-Rings
5. Spring
9. Inlet Valve Body
6. Sleeve
10. O-Rings
7. Secondary Low
11. Check Valves
Pressure Relief
12. Springs
13. Cover
14. Capscrews
INLET SECTION
Disassembly
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Disconnect the external tube (7, Figure 8-2) at
the cover end and remove. Remove capscrews
(14, Figure 8-5), remove cover (13). Remove
springs (12), check valves (11) and O-rings
(10).
NOTE: Inlet section shown removed from main valve
body for clarity.
3. Remove capscrews (1) and cover (2). Remove
springs (3 & 5) and flow control/main relief valve
(4). Remove sleeve (6), low pressure relief (7)
and O-rings (8).
NOTE: If restrictor poppet removal in cover (2, Figure
8-5) is required, refer to Step 4 and Figure 8-6.
4. Remove sleeve (9), backup ring (8), O-ring (7),
backup ring (6). Remove backup ring (5), O-ring
(4), backup ring (3) and restrictor poppet (2).
5. Repeat steps 1 through 4 for the opposite inlet
section if disassembly is required.
FIGURE 8-5. RESTRICTOR POPPET REMOVAL

(Inlet Cover)
1. Inlet Cover
2. Restrictor Poppet
3. Backup Ring
4. O-Ring
5. Backup Ring
L08032
6. Backup Ring
7. O-ring
8. Backup Ring
9. Sleeve
L8-5
REAR SPOOL SECTION (Work Ports)

1. Discard all O-rings and backup rings. Clean all
parts in solvent and dry with compressed air.
2. Inspect all springs for breaks or distortion.
Inspect poppet seating surfaces for nicks or
excessive wear. All seats must be sharp and
free of nicks.
3. Inspect all bores and surfaces of sliding parts
for nicks, scores or excessive wear.
4. Inspect poppets in their respective bore for fit.
Poppets should move freely, through a complete revolution, without binding.
5. Inspect fit and movement between sleeve and
low pressure relief valve.
Assembly
1. Coat all parts including housing bores with
clean type C-4 hydraulic oil. Lubricate O-rings
lightly with a multipurpose grease.
2. If restrictor poppet (2, Figure 8-6) was removed,
reassemble in the order shown.
3. Install check valves (11, Figure 8-5) in their
respective bores. Install springs (12).
4. Install O-rings (10), and cover (13). Install capscrews (14). Tighten capscrews to 60 ft. lbs.
(81 N.m) torque.
Disassembly
NOTE: It is not necessary to remove the inlet
sections (1 or 4, Figure 8-2) to accomplish spool
section (2 or 3) disassembly.
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Remove capscrews and lift spool section cover
(1, Figure 8-9) from housing.
3. Remove poppet (1, Figure 8-7) from spool
cover. Remove and discard O-ring (3).
NOTE: The poppet (1) contains a small steel ball. Do
not misplace.
4. Remove and discard O-rings (4 & 5, Figure 88).
5. Remove restrictor poppet (1). Remove and discard O-ring (2) and backup ring (3), if used.
Note the position of the restrictor when removed
to insure correct reassembly.
6. Remove spool assembly (20, Figure 8-9). Note
the color of the lower spring (blue) to insure
proper location during reassembly. Also note
the V groove on top end of spool.
5. Install secondary low pressure relief (7) in

sleeve (6) and install assembly in housing (9).
Install flow control/main relief valve (4). Install
springs (3 & 5). Install cover (2). Install capscrews (1). Tighten capscrews to 60 ft. lbs. (81
N.m) torque. Connect external tube, tighten
nuts to 25 ft. lbs. (34 N.m) torque.
FIGURE 8-7. RESTRICTOR POPPET REMOVAL

2. O-ring *
3. Backup Ring *
FIGURE 8-6. POPPET AND BALL
1. Poppet
2. Steel Ball
L8-6
4. O-Ring
5. O-Ring
*Note: Items 2 and 3 not used on all valves.
3. O-Ring
L08032
FIGURE 8-8. WORK PORTS SPOOL SECTION ASEMBLY

1. Spool Cover
2. Spring Seat
3. Plug
4. O-Ring
5. O-Ring
6. Poppet
7. Ball
8. O-Ring
L08032
10. O-Ring
11. Spring
12. Restrictor Poppet (Red)
13. Spool Housing
14. Spool Assembly
15. Spool End
16. Spring (Blue)
17. O-Ring
18. Poppet
19. Spool Cover
20. Spool Assembly
21. Restrictor Poppet (Green)
22. Restrictor Poppet (White)
L8-7
Assembly
POPPET
COLOR
ORIFICE
DIAMETER
DRILL SIZE
Red
.140 in. (3.556 mm)
#28
Green
.093 in. (2.362 mm)
#42
White
.063 in. (1.6 mm)
#52
FIGURE 8-9. POPPET IDENTIFICATION

7. Remove plug (3) from end of spool. Remove
spring seat (2) and spring (11). Remove poppet
(21) and spool end (15).
NOTE: Pay special attention to poppets (12, 21 and
22 Figure 8-9) during removal to ensure proper
location during reassembly. Poppets may be
identified with a colored dot (Red, Green or white). If
poppets are not color coded, use the chart in Figure
8-10 and the specified drill bit to measure orifice
diameter for identification.
8. Repeat step 7 to disassemble opposite end of
spool (20). Note there is no plug or restrictor
poppet in opposite end and the spring is blue.
9. Remove spool assembly (14). At top end of
spool, remove plug (3). Remove spring seat (2)
and spring (11). Remove poppet (12) and spool
end (15).
10. At opposite end, remove plug (3), spring seat
(2) and spring (16). Remove restrictor poppet
(22) and spool end (15).
11. Remove cover (19), remove O-rings (4, 5 & 10).
Remove poppet (18).

1. Discard all O-rings and backup rings. Clean all
parts in solvent and blow dry with compressed
air.
2. Inspect all springs for breaks or distortion.
Inspect poppet seating surfaces for nicks or
excessive wear. All seats must be sharp and
free of nicks.
3. Inspect all bores and surfaces of sliding parts
for nicks, scores or excessive wear.
1. Lubricate O-rings (4, 5 & 10, Figure 8-9) with

clean hydraulic oil. Install O-rings in spool housing. Install poppet (18). Install cover (19) and
secure in place with capscrews. Tighten capscrews to 60 ft. lbs. (81 N.m) torque.
2. Install spring (11, Figure 8-9) in spool (20).
Install spring seat (2). Apply Loctite to the
threads of spool end (15). Install spool end and
tighten to 25 ft. lbs. (34 N.m) torque. Install
Green poppet (21). Apply Dri-loc #204 to the
threads of plug (3). Install plug and tighten to 15
NOTE: Poppets 12, 21 and 22 may be color coded
and must be installed in their original location.
3. Repeat step 2 for the opposite end of spool (20)
to install spring, spring seat, and spool end.
Make certain spring (16) is blue in color. (A poppet and plug are not installed in lower end.)
4. Lubricate spool assembly and carefully install in
spool housing as shown in Figure 8-11. Make
certain the V groove (1) in spool assembly (2)
is positioned up as noted.
5. Install spring (11, Figure 8-9) in top (grooved)
end of remaining spool (14). Install spring seat
(2). Apply Loctite to the threads of spool end
(15). Install spool end and tighten to 25 ft. lbs.
(34 N.m) torque. Install Red poppet (12). Apply
Dri-loc #204 to the threads of plug (3). Install
plug and tighten to 15 ft. lbs. (20 N.m) torque.
6. Repeat step 5 for the bottom end of spool (14).
Install spring (16) which is blue in color, spring
seat (2) and spool end (15). Apply Loctite to
spool end threads. Install spool end (15) and
tighten to 25 ft. lbs. (34 N.m) torque. Install
White poppet (22). Apply Dri-loc #204 to the
threads of plug (3). Install plug and tighten to 15
7. Lubricate the assembled spool and install in
spool housing as shown in Figure 8-11. Make
certain the V groove is in the up position.
NOTE: Spools (14, Figure 8-9) and (20) are
physically interchangeable. Make sure spool (14) is
installed toward the base port of the spool housing.
4. Inspect all poppets in their respective bore for

fit. Poppets should move freely through a complete revolution without binding.
L8-8
L08032
FRONT SPOOL SECTION (Tank Ports)

Disassembly
NOTE: It is not necessary to remove the inlet
sections (1 or 4, Figure 8-2) to accomplish spool
section disassembly and repair.
1. Match mark or identify each spool in respect to
its mating bore when removed.
2. Remove capscrews and lift spool section cover
(4, Figure 8-12) from housing.
3. Remove and discard O-rings (5 & 6).
4. Remove capscrews and remove bottom cover
(9) from spool housing. Remove and discard Orings.
5. Remove springs (8). Push spools (7) out of
housing bores.
FIGURE 8-10. SPOOL INSTALLATION
1. V Groove
2. Spool Assembly
3. Work Ports Spool

Section
8. If used, install O-ring (2, Figure 8-8) and backup

ring (3) on restrictor poppet (1). Install poppet in
spool housing as shown in Figure 8-9.
9. Install new O-rings (4, 5 & 10).
10. Install new O-ring (and backup ring if used) on
poppet (6, Figure 8-9). Make certain the small
steel ball (7) is installed in poppet. Install poppet
in cover (1).
11. With new O-rings (4, 5 & 10) installed, position
cover (1) over spool housing. Secure cover in
place with capscrews. Tighten capscrews to 60
Note: Cover must be positioned according to match
marks made during disassembly. Do not reverse
cover position.

1. Discard all O-rings. Clean all parts in solvent
and blow dry with compressed air.
2. Inspect springs for breaks or distortion.
3. Inspect housing bores and surfaces of spools
for nicks, scoring or excessive wear.
Assembly
1. Lubricate spools (7, Figure 8-12) with clean
hydraulic oil and re-install in their original bores.
Install springs (8).
2. Lubricate O-rings (5 & 6) with clean hydraulic
oil. Install O-rings in bottom of spool housing.
Install bottom cover (9) and secure in place with
capscrews. Tighten capscrews to 60 ft. lbs. (81
N.m) torque.
3. Lubricate O-rings (5 & 6) and install in top of
spool housing. Install top cover (4) and secure
in place with capscrews. Tighten capscrews to
4. If removed, install plugs (2) with new O-rings
(3).
L08032
L8-9
FIGURE 8-11. TANKS PORTS SPOOL SECTION ASSEMBLY

1. Spool Housing
2. Plug
3. O-Ring
L8-10
4. Spool Cover
5. O-Ring
6. O-Ring
7. Spool
8. Spring
9. Spool Cover
L08032
HOIST PILOT VALVE
Installation
Removal
1. Place the hoist control lever in the body down
position. Make certain the body is in the full
down position and resting on the frame.
Release the hoist control lever to return the
hoist valve spool to the FLOAT position.
2. Disconnect hydraulic lines (3, Figure 8-13) at
the hoist pilot valve (1) located in the hydraulic
components cabinet at the rear of the cab.
Remove capscrews (5).
3. Loosen and unthread jam nut (8). Unthread
sleeve (9) until cotter pin (6) and pin (10) are
exposed.
4. Remove cotter pin and pin.
5. Remove the hoist pilot valve mounting hardware (2) and remove valve from cabinet. Refer
to hoist pilot valve disassembly for repair
instructions.
1. Place the hoist pilot valve (1, Figure 8-13) into

position on the mounting bracket. Secure valve
in place with mounting hardware (2).
2. Position hydraulic lines (3) over valve ports
and assemble fittings. Tighten hydraulic line
connections securely.
3. Place hoist control lever in spring-centered
position. Adjust pilot valve spool until the centerline of the cable attachment hole extends
1.16 in. (29.5 mm) from the face of the valve
body.
4. Align control cable eye with pilot valve spool
hole and insert pin (10). Secure pin in place
with cotter pin (6).
5. Thread sleeve (9) upward until contact is
made with valve body. Move flange (4) into
position and secure in place with capscrews
(5).
6. Thread jam nut (8) against sleeve. Tighten jam
nut securely.
7. Start the engine and check for proper hoist
operation. Observe for leaks.
FIGURE 8-12. HOIST PILOT VALVE & PIPING

(Located in Hydraulic Components Cabinet)
2. Mounting Hardware
3. Hydraulic Tubes
L08032
4. Flange
5. Capscrew
6. Cotter Pin
7. Control Cable
8. Jam Nut
9. Sleeve
10. Pin
L8-11
Disassembly
1. Thoroughly clean the exterior of the valve.
Match mark components to assure proper reassembly.
2. Remove machine screw (15, Figure 8-14) seal

plate (16), wiper (13) and O-ring (12).
3. Remove snap ring (1), capscrews (6), cap (24),
spacer (23), and detent sleeve (22). Detent
Balls (2) and (21) will fall free when the cap and
detent sleeve are removed. Separate cap (24),
spacer (23) and detent sleeve (22), as this will
be necessary for reassembly.
4. Carefully slide the spool (14) out of the spool
housing (17). Remove seal retainer (25), wiper
(26) and O-ring (27) from spool (14).
5. Insert a rod in the cross holes of the detent pin
(3) and unscrew from spool (14). Slight pressure should be exerted against the detent pin
as it disengages and spring tension is released.
6. Remove spring seats (19), spring (4) and
spacer (5).
7. Remove relief valve (2, Figure 8-15) from the
spool housing (1).
8. Match mark the inlet and outlet housings in relationship to the spool housing to insure correct
location during reassembly.
9. Remove nuts (8 &10, Figure 8-14) and remove
tie rods (9). Separate the valve housings.
Remove O-ring (11). Remove the poppet check
and spring located on the outlet housing side of
the spool housing, from the spool housing.
FIGURE 8-13. HOIST PILOT VALVE

1. Snap Ring
2. Ball (4)
3. Detent Pin
4. Spring
5. Spacer
6. Capscrew
7. Outlet Housing
8. Nut
9. Tie Rod
10. Nut
11. O-Ring
12. O-Ring
13. Wiper
14. Spool
L8-12
15. Machine Screw

16. Seal Plate
17. Spool Housing
18. Inlet Housing
19. Spring Seat
20. Spring
21. Ball (1)
22. Detent Sleeve
23. Spacer
24. Cap
25. Seal Retainer
26. Wiper
27. O-Ring
FIGURE 8-14. RELIEF VALVE

1. Spool Housing
4. To Hoist Valve
2. Relief Valve
(Rod End)
3. Supply Port
5. To Hoist Valve
(Base End)
L08032

1. Clean all parts including housings in solvent
and blow dry with compressed air.
5. Install tie rods. Install tie rod nuts. Tighten tie

rod nuts to the torques shown in Figure 8-16.
2. Inspect seal counter bores, they must be free of

nicks or grooves.
6. Install a new O-ring (27, Figure 8-14) and wiper

(26). Install seal retainer (25).
3. Examine springs for breaks or distortion.
7. Install spacer (5), spring seats (19), and spring

(4). Thread detent pin (3) into spool (14). Slight
pressure will be required to compress the
detent spring. Tighten detent pin to 84-96 in.
lbs. (9-11 N.m) torque. Install spring (20). Carefully install spool into spool housing.
4. Inspect spool (14, Figure 8-14). The spool must

be free of longitudinal score marks, nicks or
grooves.
5. Test spool (14) in spool housing for fit. Spool
must fit freely and rotate through a complete
revolution without binding.
NOTE: The spool housing (17), spool (14), inlet
housing (18) and outlet housing (7) are not serviced
separately. Should any of these parts require
replacement, the entire control valve must be
replaced.
Assembly
1. Thoroughly coat all parts including housing
bores with clean type C-4 hydraulic oil.
2. If the inlet and outlet housings were removed
follow steps 3 through 5 for reassembly.
3. Install check poppet (2, Figure 8-16) and spring
(3) in spool housing (1).
4. Install new O-ring (4) in spool housing. Place
the inlet and outlet housings on the spool housing.
FIGURE 8-15. HOIST PILOT VALVE REASSEMBLY

1. Spool Housing
4. O-ring
2. Check Poppet
5. Outlet Housing
3. Spring
L08032
8. Apply grease to the cross holes of the detent

pin (3) to hold balls (21) and (2).
9. Slide detent sleeve (22) into cap (24) and place
over a punch. Using this punch, depress ball
(21) and insert balls (2) in detent pin cross
holes.
10. While holding down on ball (21), slide detent
sleeve (22) and cap (24) as an assembly over
the detent pin (3). Continue to insert detent
sleeve (22) until it contacts spring seat (19).
11. Secure cap (24) in place with capscrews (6).
Tighten capscrews (6) to 5 ft. lbs. (7 N.m)
torque. Install spacer (23) and snap ring (1).
12. Install a new O-ring (12) and wiper (13). Install
seal plate (16). Install machine screws (15).
13. Using new O-rings, install relief valve (2, Figure
8-15) in spool housing.
FIGURE 8-16. TIE ROD NUT TORQUE

1. Nut
4. Tie Rod
2. Tie Rod
5. Outlet Housing
3. Nut
L8-13
HOIST CYLINDERS
5. Carefully lower cylinder until it lays against the
inside dual tire. The hoist cylinder weighs
approximately 2500 lbs. (1135 kgs). Attach a
suitable lifting device that can handle the load
safely to the upper cylinder mounting eye.
Removal

lines. Tighten all connections securely before
applying pressure.
physician familiar with this type of injury is not
1. Insure engine and key switch have been Off
for at least 90 seconds to allow accumulator to
bleed down. Be certain the park brake is
applied.
6. Install a retaining strap or chain to prevent the

cylinder from extending during handling.
7. At the lower mount, straighten lock plate tabs to
allow capscrew removal. Remove all capscrews
(1, Figure 8-19), locking plate (2) and retainer
plate (3).
8. Carefully remove cylinder from frame pivot by
pulling outward. Move cylinder to a clean area
for disassembly.
NOTE: Do not lose spacer (6, Figure 8-19) between
cylinder bearing and frame.
9. Clean exterior of the cylinder thoroughly.
2. Disconnect the lubrication lines to the upper

and lower bearings of the hoist cylinder.
3. Remove capscrew and lockwashers from
clamps securing the hydraulic hoses to the hoist
cylinder. Cap and plug lines and ports to prevent excessive spillage and contamination.
Secure cylinder to frame to prevent movement.
The hoist cylinder weighs approximately 2500

lbs. (1135 kg). Some means of support is necessary to prevent it from falling or causing injury
when removing from the truck. Use a suitable lifting device that can handle the load safely.
4. At the upper mount, remove self-locking nut (4,
Figure 8-18) from pin retaining capscrew.
Remove capscrew (5). Use a brass drift and
hammer to drive pin (1) from bore of mounting
bracket.
FIGURE 8-17. HOIST CYLINDER UPPER MOUNT

1. Pin
2. Retainer Ring
3. Bearing
L8-14
4. Locknut
5. Capscrew
L08032
Installation
Install a retaining strap or chain to prevent the

cylinder from extending during handling. The
hoist cylinder weighs approximately 2500 lbs.
(1135 kg). Use a suitable lifting device that can
1. Raise the cylinder into position over the pivot
point on the frame. The cylinder should be positioned with the air bleed vent plug on top,
toward the front of the truck. Install spacer (6,
Figure 8-19). Align bearing eye with pivot point
and push cylinder into place.
2. Install retaining plate (3), locking plate (2),and
capscrews. Tighten capscrews to 220 ft. lbs.
(298 N.m) torque. Bend locking plate tabs over
capscrew flats.
3. Align the top hoist cylinder bearing eye with the
bore of the upper mounting bracket. Refer to
Figure 8-18.
4. Align retaining capscrew hole in pin with hole in
mounting bracket and install pin. Install capscrew (5) and self-locking nut (4) and tighten to
standard torque.
5. Install new O-rings in grooves on hose flange
connections and lubricate with clean hydraulic
oil. Position flanges over hoist cylinder ports
and install flange clamps. Secure clamps with
capscrews and lockwashers. Tighten capscrews to standard torque.
6. Reconnect lubrication lines for the upper and
lower hoist cylinder bearings.
7. Start engine, raise and lower body several
times to bleed air from cylinder. Check for
proper operation and inspect for leaks.
8. Service hydraulic tank if necessary.
L08032
FIGURE 8-18. HOIST CYLINDER LOWER MOUNT

1. Capscrew
2. Lock Plate
3. Retainer
4. Retainer Ring
5. Bearing
6. Spacer
L8-15
1. Rod & Third Stage

2. Second Stage Cylinder
3. First Stage Cylinder
4. Housing
5. Plate
6. Rod Bearing Retainer
7. Capscrew
8. Seal
9. Snap Ring
10. Cover
11. Capscrews
12. O-Ring
13. Bearing
14. Bearing
15. Seal
16. Seal
17. Bearing
18. Buffer Seal
19. Bearing
20. Rod Seal
21. Rod Wiper
22. Quill Assembly
23. Backup Ring
24. Seal
25. Cushion
FIGURE 8-19. HOIST CYLINDER ASSEMBLY
L8-16
L08032
Disassembly
1. If removal of the hoist cylinder eye bearings is
necessary, remove retainer ring (4, Figure 8-19)
and press out bearing (5).
2. Mount the hoist cylinder in a fixture which will
allow it to be rotated 180.
3. Position cylinder with the cover (10, Figure 820) mounting eye at the top. Remove capscrews (11) and lockwashers retaining the
cover to the housing (4).
4. Install two 0.88 in. dia. x 9 in. long, threaded
capscrews into the two threaded holes in the
cover (10). Screw the capscrews in evenly until
the cover can be removed. Lift cover straight up
until quill assembly (22) is clear. Remove O-ring
(12) and backup ring (23).
5. Remove capscrews (7) and plate (5) attaching
the rod bearing retainer (6) to the rod (1).
Remove the seal (8).
6. Fabricate a retainer bar using a 1/4" x 1" x 18"
(6 x 25 x 460 mm) steel flat. Drill holes in the
bar to align with a pair of tapped holes spaced
180 apart in the housing. Attach bar to housing
using capscrews (11).
NOTE: A retainer bar is required to prevent the first
and second stage cylinders from dropping out when
the housing is inverted.
7. Rotate the cylinder assembly 180, to position
the lower mounting eye at the top. Hook a lifting
device to the eye on the rod (1) and lift the rod
and third stage cylinder assembly out of the cylinder housing. Remove cushioin (25).
L08032
NOTE: As internal parts are exposed during

disassembly, protect machined surfaces from
scratches or nicks.
8. Rotate the cylinder housing 180. Remove the
retainer installed in step 6.
9. Fabricate a round disc 12.5 in. (318 mm) in
diameter 0.38 in. (10 mm) thick with a 0.56 in.
(14 mm) hole in the center. Align the disc over
the second (2) and first (3) stage cylinders at
the bottom of the cylinder housing.
10. Insert a 0.50 in. (13 mm) dia. x 53 in. (1350 mm)
threaded rod through the top and through the
hole in the disc. Thread a nut on the bottom end
of the threaded rod below the disc.
11. Screw a lifting eye on the top end of the rod.
Attach it to a lifting device and lift the second
and first stage cylinders out of the housing.
12. Remove lifting tools from the second and first
stage cylinder assembly.
13. Slide the second stage cylinder (2) down inside
the first stage cylinder (3). Remove snap ring
(9) from inside the first stage cylinder.
14. Remove second stage cylinder from first stage
cylinder by sliding it out the top.
15. Remove all old bearings, O-rings, and seals
from the hoist cylinder parts.
L8-17

NOTE: Use only fresh cleaning solvent, lint free
wiping cloth and dry filtered compressed air when
cleaning and handling hydraulic cylinder parts.
Immediately after cleaning and inspection, coat all
surfaces and parts with clean hydraulic oil (Type C4).
1. Thoroughly clean and dry all parts.

2. Visually inspect all parts for damage or excessive wear.
3. If cylinder bores or plated surfaces are excessively worn of grooved, the parts must be
replaced or, if possible, replated and machined
to original specifications.
4. The quill (2, Figure 8-21) should be checked for
tightness if it has not previously been tack
welded.
a. Check the quill for tightness by using special
tool SS1143 (Figure 8-21) and applying a
tightening torque of 1000 ft. lbs. (1356 N.m).
b. If the quill moves, remove quill, clean
threads in cover assembly and quill, and
reinstall using the procedure in Quill Installation.
5. When a cylinder assembly is dismantled, the
capscrews (7, Figure 8-20) should be checked
carefully for distress and, if in doubt, replace
them.
FIGURE 8-20. QUILL INSTALLATION

1. Cap Assembly
2. Quill Assembly
NOTE: SS1143 Tightening Tool can be made

locally. Request the following drawings from your
Area or Regional Service Manager:
SS1143 Tightening Tool - Assembly Drawing

SS1144 - Square Tube (3.50" x 3.50" x 0.19"
wall x 2.0" long)
SS1145 - Plate (2.50" x 2.50" x 0.25" thick)
SS1146 - Square Tube (3.00" x 3.00" x 0.25"
wall x 15.50" long)
SS1147 - Tube, Brass (1.75"O.D. x 1.50"
I.D.x 13.50" long)
SS1148 - Square Cut (2.50" x 2.50" x 0.75"
thick)
SS1149 - Hex Drive (1.75" Hex stock x 2.50"
long)
All materials are 1020 Steel except SS1147.
L8-18
L08032
Assembly - Quill and Cylinder

NOTE: Use only new seals, bearings and O-rings
during reassembly. Thoroughly lubricate all parts and
seals with hydraulic oil to aid in assembly and to
provide lubrication during initial operation.
Quill Installation
1. The plugs (3, Figure 8-22) and the check balls
(4) in the quill should be checked during any
cylinder repair to insure the plugs are tight and
ball seats are not damaged. Refer to Installation of Check Balls and Plugs in Quill.
2. Secure cap assembly (1) in a sturdy fixture.
Make certain threads in cap and threads on quill
are clean and dry (free of oil and solvent).
3. Using Loctite LOCQUIC Primer T (Komatsu
part number TL8753, or equivalent), spray mating threads of both cap assembly (1) and quill
assembly (2). Allow primer to dry 3 to 5 minutes.
4. Apply Loctite Sealant #277 (Komatsu part number VJ6863, or equivalent) to mating threads of
both cap assembly and quill assembly.
5. Install quill and use SS1143 tool to tighten quill
to 1000 ft. lbs. (1356 N.m) torque. Allow parts
to cure for 2* hours before exposing threaded
areas to oil.
* Note: If LOCQUIC Primer T (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
6. Tack weld quill in 2 places as shown in Figure 822.
7. Remove all slag and foreign material from tack
weld area before assembly of cylinder.
During future cylinder rebuilds, removal of the quill
will not be necessary, unless it has loosened or is
damaged. Removal, if necessary, will require a
break-loose force of at least 2000 ft. lbs. (2712 N.m)
torque after the tack welds are ground off.
FIGURE 8-21. PLUG & CHECK BALL

INSTALLATION
1. Cap Assembly
2. Quill Assembly
L08032
3. Plug
4. Check Ball
L8-19
Installation Of Check Balls And Plugs In Quill

The check balls (4, Figure 8-22) in the side of the
quill assembly (2) are held in place with threaded
plugs (3).
If a plug is missing and the check ball is not found in
the cylinder, the opposite side hoist cylinder and the
plumbing leading to the hoist valve should be examined for damage. The hoist valve itself should also
be checked to see if the ball or plug has caused
internal damage to the spool. Peening of the necked
down sections of the spool may result. Spool sticking may also occur under these circumstances.
Refer to Figure 8-23 for SS1158 tool that can be
made for installing or removing the check ball plugs.
Plugs should be checked during any cylinder repair
to be sure they are tight. If found to have any movement, they should be removed and the ball seat in
the quill checked to see if it is deformed.
If deformation of the ball seat has occurred,
the quill should be replaced.
If the ball seat area is not deformed, measure
the plug thickness as shown in Figure 8-21:
Older Plug is 0.25 0.02 in. thick. Newer plug is
0.38 0.02 in. thick.
1. Use the newer plugs and make certain threads

in quill tube and on plugs are clean and dry
(free of oil and solvent).
2. Use Loctite LOCQUIC Primer T (TL8753,
or equivalent), and spray mating threads of
both plugs (3, Figure 8-22) and quill assembly
(2). Allow primer to dry 3 to 5 minutes.
3. Apply Loctite Sealant #277 (VJ6863, or equivalent) to mating threads of both plugs and quill
assembly.
4. Place check balls (4) in quill tube (2) and
install plugs (3) with concave side facing ball.
Using SS1158 tool, tighten plugs to 70 ft.lbs.
(95 N.m) torque. Allow parts to cure for 2*
hours before exposing threaded areas to oil.
* Note: If LOCQUIC Primer T (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
5. Stake plug threads in two places (between
holes) as shown in Figure 8-22 to prevent
loosening of plug.
If removal of the plug is necessary in a later rebuild,
it will be necessary to carefully drill out the stake
marks and destroy the plug. A new plug should be
installed and staked as previously detailed.
FIGURE 8-22. SS1158 PLUG INSTALLATION & REMOVAL TOOL
L8-20
L08032
Assembly of Cylinder
1. Install seals (15, Figure 8-20) and bearing (14)
on second stage cylinder. Install bearings (19)
and buffer seal (18), rod seal (20) and rod wiper
(21) on first stage cylinder. Lubricate with clean
hydraulic oil (Type C-4).
12. Lubricate capscrews (1, Figure 8-24) with a lithium base grease. Install capscrews and plate
(2) and tighten to 575 ft. lbs. (780 N.m) torque.
2. Align and slide the second stage cylinder (2)

inside the first stage cylinder (3). Allow the second stage to protrude far enough to install the
snap ring (9) on the inside of the first stage cylinder.
3. Mount the housing (4) in the fixture with the
cover end positioned at the top. Install bearings
(19) and buffer seal (18), rod seal (20) and rod
wiper (21) in the housing.
4. Install lifting tool used during disassembly in the
second and first stage cylinder assembly.
5. Install bearings (13 & 24) on the first stage cylinder (3). Lift and align this assembly over the
housing (4). Lower the second and first stage
cylinders into the housing.
6. Install retainer used during disassembly to hold
the second and first stage cylinder in place
when the housing is rotated. Rotate housing
180 to position the lower mounting eye at the
top.
7. Install bearings (19) and buffer seal (18), rod
seal (20) and rod wiper (21) in the second stage
cylinder (2).
8. Attach a lifting device to the rod eye (1) and
align it over the housing (4). Install cushion (25)
on rod with chamfered corner towards rod eye.
Lower the rod into the housing. Lubricate the
rod with hydraulic oil.
9. Rotate housing 180 to position the cover end
at the top. Remove retainer installed in Step 5.
Install bearings (17) and seal (16) on the rod
bearing retainer (6).
10. Thread two guide bolts 4 in. (100 mm) long in
the end of the rod (1). Install seal (8) on the end
of the rod.
FIGURE 8-23. 3rd STAGE PISTON

1. 12 Pt. Capscrew
2. Plate
3. Piston
13. Install O-ring (12, Figure 8-20) and backup ring

(23) on cover (10). Align and lower cover onto
housing (4). Lubricate capscrews (11), install
capscrews and lockwashers. Tighten capscrews to 500 ft. lbs. (678 N.m) torque.
14. Install hoist cylinder eye bearing (5, Figure 819) and retainer rings (4) if removed.
11. Align piston rod bearing retainer (6) over guide

bolts and lower it over the end of the rod (1).
Remove guide bolts.
NOTE: Check capscrews (1, Figure 8-24) carefully
for distress and, if in doubt, replace them with new
parts.
L08032
L8-21
OVERCENTER VALVE MANIFOLD

The overcenter valve manifold is located to the rear
of the hoist valve. The internal counterbalance valve
relieves excessive pressure that can develop in the
annulus area of the hoist cylinders if the load sticks to
the tail of the body as the body goes overcenter while
dumping.
Figures 8-24 through 8-26 show the proper placement of the O-rings and backup-rings on the needle
valve, counterbalance valve and the cavity plug.
For information on how the overcenter valve functions, see Hoist Circuit Operation, this section. For
adjusting of the counterbalance valve, refer to the
Hydraulic Checkout Procedure in this Section.
FIGURE 8-26. CAVITY PLUG

1. O-Rings
2. Backup-Rings
FIGURE 8-24. NEEDLE VALVE

1. O-Rings
2. Backup-Rings
FIGURE 8-25. COUNTERBALANCE VALVE

1. O-Rings
2. Backup-Rings
L8-22
L08032
DISABLED TRUCK DUMPING

PROCEDURE
Sometimes it is necessary to dump a load from the
body of a truck when the hoist system is inoperable.
The following instructions describe the use of a
"good" truck to provide the hydraulic power required
to raise the body of the "disabled" truck to dump the
load.
In the example below, Figure 8-27 illustrates a typical
hookup from the good truck. The disabled truck may
be another Model 930E, or a different Komatsu
model.
Hookup
Be certain there is an adequate, clear area to dump
the loaded box. When the good truck is in position,
shut down the engine and allow the hydraulic system
to bleed down. Be certain pressure has bled off
before connecting 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 8-27) to
the power down circuit of the disabled truck.
(Hose must be rated to withstand 2500 psi (17
MPa) 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 a model 930E, the hoses
will be installed at the quick disconnects shown in
Figure 8-27 and will be crossed when connected.
1. Hoist Valve
2. Tubes to LH Hoist Cylinder
3. Power Down Quick Disconnect; Connect to
power up circuit of disabled truck
4. Power Up Quick Disconnect; Connect to power
down circuit of disabled truck
b. Remove the cap from the hoist pilot valve

relief valve (2, Figure 8-14) located in the
hydraulics components cabinet behind the
cab. While counting the number of turns,
slowly screw the relief valve adjustment
screw clockwise until it bottoms.
5. Repeat step 4 to dump the disabled truck.
Lowering the Body
6. Place the hoist lever of the good truck in FLOAT
to lower the body. If necessary, momentarily
place the hoist control in POWER UP until the
body is able to descend in FLOAT. Do not accelerate the engine.
DUMPING PROCEDURE
Raising the Body
3. On the disabled truck, move the hoist control
lever to power up and then release it to place
the hoist pilot valve in the HOLD position (leave
in this position during entire procedure).
4. Start the engine on the good truck, place the
hoist control in the power down position and
increase 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.
L08032
FIGURE 8-27. PUMP MODULE, HOSE HOOKUP
7. After body is lowered, shut down the truck,

bleed the hydraulic system and disconnect the
hoses.
8. Reduce power down relief valve pressure to
normal on good truck by turning the adjustment
counterclockwise the same number of turns as
required in Step 4 b.
9. Check power down relief pressure per instructions in Section L, Hydraulic Check-Out Procedure.
L8-23
NOTES:
L8-24
L08032
SECTION L9
HYDRAULIC SYSTEM FILTERS
INDEX
HYDRAULIC SYSTEM FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3

HOIST CIRCUIT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
Removal - Hoist Circuit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
Installation - Hoist Circuit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
Indicator Switch - Hoist Circuit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
STEERING CIRCUIT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-5
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-5
Removal - Steering Circuit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-6
Installation - Steering Circuit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-6
Indicator Switch - Steering Circuit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-6
INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-6
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-6
L09008
Hydraulic System Filters
L9-1
NOTES
L9-2
L09008
HYDRAULIC SYSTEM FILTERS

HOIST CIRCUIT FILTER
The hoist circuit filters (Figure 9-1) are located at the
back of the fuel tank below the right frame rail. The
filter provides secondary filtering protection for
hydraulic oil flowing to the hoist valve and hoist circuit components.
An indicator switch (5) is designed to alert the operator of filter restriction before actual bypass occurs.
The switch contacts close at 35 psid (240 kPa) to
actuate a warning lamp on the overhead display
panel. Actual filter bypass occurs at 50 psid (345
kPa).
NOTE: When the engine is initially started and the
hydraulic oil is cold, the warning lamp may illuminate.
Allow the hydraulic system oil to reach operating
temperature before using the warning lamp as an
indicator to change the element.
Refer to Section P, Lubrication and Service, for recommended normal filter element replacement interval. Earlier replacement may be required if the
restriction indicator lamp turns on.
Premature filter restriction may indicate a system
component failure and signal a service requirement
before extensive secondary damage can occur.
NOTE: An early indication of the filter warning light at
first installation may be due to restriction in the filter
as it cleans the system. Unless the fluid appears
contaminated or has a strong foul odor, do not
change the oil; replace only the filter element.
Filter Element Replacement

and lines. Tighten all connections before applying starting the machine.
immediately.
L09008
FIGURE 9-1. HOIST CIRCUIT FILTER

1. O-Ring
2. Pressure Tap
3. Filter Head
4. O-Ring
5. Indicator Switch
6. O-Ring
7. Backup Ring
8. Set Screw
9. Filter Element
10. Bowl
11. Drain Plug
12. O-Ring
13. Bottom Plug
L9-3
Installation - Hoist Circuit Filter
Removal - Hoist Circuit Filter

1. With the key switch OFF allow at least 90 seconds for the accumulators to bleed down.
1. Install new element (9). Install new O-ring (6)

and backup ring (7).
2. Remove drain plug (11, Figure 9-1). Remove

bottom plug (13) and drain oil from the housing
into a suitable container.
2. Install bowl on filter head and tighten. Lock in

place with setscrew (8).
Take care to avoid contact with hot oil if truck

has been operating. Avoid spillage and contamination!
3. Loosen setscrew (8). Remove bowl (10).
3. Install bottom plug (13), and drain plug (11).
Indicator Switch - Hoist Circuit Filter

The indicator switch (5, Figure 9-1) is factory preset
to actuate at 35 psid (240 kPa). The switch and warning light should be routinely tested as a part of the
regular vehicle maintenance program. Refer to Indicator Switch Test Procedure in this section.
4. Remove filter element (9).

5. Remove and discard backup ring (7) and O-ring
(6).
6. Clean bowl in solvent and dry thoroughly.
L9-4
L09008
STEERING CIRCUIT FILTER

The steering circuit filter (Figure 9-2) is located on
the inboard side of the fuel tank. The filter provides
secondary filtering protection for hydraulic oil flowing
to the bleeddown manifold valve for the steering and
brake systems.
An indicator switch (1) is designed to alert the operator of filter restriction before actual bypass occurs.
The switch contacts close at 35 5 psid (240 35
kPa) to actuate a warning lamp on the overhead display panel. Actual filter bypass occurs at 50 psi (345
kPa).
NOTE: When the engine is initially started and the
hydraulic oil is cold, the warning lamp may actuate.
Allow the hydraulic system oil to reach operating
temperature before using the warning lamp as an
indicator to change the element.
Refer to Section P, Lubrication and Service for recommended normal filter element replacement interval. Earlier replacement may be required if the
restriction indicator lamp turns on.
Premature filter restriction may indicate a system
component failure and signal a service requirement
before extensive secondary damage can occur.
NOTE: An early indication of the filter warning light at
first installation may be due to restriction in the filter
as it cleans the system. Unless the fluid appears
contaminated or has a strong foul odor, do not
change the oil; replace only the filter element.

applying pressure.
immediately.
L09008
FIGURE 9-2. STEERING CIRCUIT FILTER

1. Indicator Switch
2. Setscrew
3. Head
4. Pressure Tap
5. O-Ring
6. Filter Element
7. Bowl
8. O-Ring
9. Drain Plug
L9-5
INDICATOR SWITCH
Removal - Steering Circuit Filter

2. Remove drain plug (9, Figure 9-2) and drain oil
from the housing into a suitable container.
Use care to avoid contact with hot oil if the truck

has been operating. Avoid spillage and contamination!
The hydraulic filter indicator switch is factory preset

to actuate at 35 5 psid (240 35 kPa). Switch
adjustment is not necessary or recommended, however the switch and warning lamp should be tested
periodically for proper operation. The indicator switch
is not repairable and if inoperative, replace switch
assembly.
Figure 9-3 shows a pressure switch tester and Figure
9-4 shows a test block to accept the switch during
testing. The test block may be fabricated as shown.
3. Remove bowl (7) and element (6).

4. Remove and discard O-ring (5) on filter bowl.
5. Clean bowl in solvent and dry thoroughly.
Installation - Steering Circuit Filter
1. Install new element (6). Install new O-ring (5)
on bowl.
2. Install bowl on filter head and tighten.
3. Install drain plug (9), and O-ring (8).
Indicator Switch - Steering Circuit Filter
The indicator switch (1, Figure 9-2) is factory preset
to actuate at 35 5 psid (240 35 kPa). The switch
and warning light should be routinely tested as a part
of the regular vehicle maintenance program. Refer to
Indicator Switch Test Procedure in this section.
Test Procedure
2. Disconnect wiring harness and remove switch
from filter head.
3. Install switch in test block. Connect pressure
tester to pipe nipple. Reconnect wires to switch.
4. Turn key switch on. Pump up pressure to test
block while observing tester gauge and hydraulic oil filter warning light in cab. Light should turn
on at 35 5 psi (240 34.5 kPa). If not, test
bulb and switch as follows:
a. If lamp fails to light, remove wire (circuit #39)
from switch and short to ground. If warning
lamp does not light, replace bulb.
b. If lamp lights when wire #39 is grounded in
previous step, use an ohmeter to verify
switch contacts close at 35 5 psid (240
35 kPa).
5. If switch contacts fail to close, replace switch
assembly.
NOTE: The hydraulic filter warning lamp may be
activated by either the hoist or steering/brake circuit
filter indicator switches.
L9-6
L09008
The indicator switch tester may be ordered from:

Kent-Moore Heavy Duty Division
Sealed Power Corp.
29784 Little Mack
Roseville, MI 40866-9984
Phone: (313) 774-9500
FIGURE 9-3. INDICATOR SWITCH TESTER

Kent-Moore Part No. J-33884-4
FIGURE 9-4. INDICATOR SWITCH PRESSURE TEST BLOCK
L09008
L9-7
NOTES
L9-8
L09008
SECTION L10
HYDRAULIC CHECK-OUT PROCEDURE
INDEX
HYDRAULIC CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-3

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-3
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . L10-3
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-4
Pump Pressure Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-4
Steering Control Unit and Flow Amplifier Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-5
Bleeddown Manifold Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-5
STEERING/BRAKE PUMP STROKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-6
SHOCK AND SUCTION VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-7
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES . . . . . . . . . . L10-8
Pressure Gauge Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-8
Brake Cooling Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-8
Power Up Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-9
Power Down Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-10
Hoist Counterbalance Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-11
Preparation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-11
Counterbalance Valve Pressure Check Only: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-11
Counterbalance Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-11
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-12
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-12
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-13
930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET . . . . . . . . . . . . . . . . . . . . L10-15
930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET . . . . . . L10-16
L10015
Hydraulic Check-out Procedure
L10-1
NOTES
L10-2
L010015
HYDRAULIC CHECK-OUT PROCEDURE

GENERAL INFORMATION
The hydraulic check-out procedure is intended to
help the technician check, adjust, and diagnose
problems in the steering and hoist circuits. The technician should read the entire check-out procedure
prior to performing any steps to become familiar with
the procedures and all the warnings and cautions.
The check-out procedure begins by checking the
basic system before checking individual components.
Included on the last page is a data sheet to record
the information observed during the hydraulic system
check-out procedure. The data sheet is designed to
be removed, copied, and used during the check-out
procedure.
* Steps indicated in this manner should be
recorded on the data sheet for reference.

penetrating the skin and cause serious injury,
and possibly death, if proper medical treatment
by a physician familiar with this type of injury is
not received immediately.
components in the hydraulic circuits, or installing test gauges, ALWAYS bleed down hydraulic
steering accumulator.
The steering accumulators can be bled down by
shutting down the engine, turning key switch
Off, and waiting 90 seconds. Confirm the steering pressure is released by turning the steering
wheel; no front wheel movement should occur.
Bleed down brake system accumulators prior to
removing any hoses supplying oil to the brake
system.
STEERING CIRCUIT CHECK-OUT &

ADJUSTMENT PROCEDURE
The steering circuit hydraulic pressure is supplied
from the piston pump and steering accumulators.
Some steering system problems, such as spongy or
slow steering or abnormal operation of the low steering pressure warning light can sometimes be traced
to internal leakage of steering components. If internal
leakage is suspected, refer to Steering Circuit Component Leakage Test.
NOTE: Excessive internal leakage within the brake
circuit may contribute to problems within the steering
circuit. Be certain that brake circuit leakage is not
excessive before troubleshooting steering circuit. For
Brake Circuit Test Procedure, refer to Section J,
Brake System.
The steering circuit can be isolated from the brake
circuit by releasing all steering system pressure and
then releasing all pressure from the brake accumulators and removing the brake system supply line (4,
Figure 10-2) from the bleeddown manifold (see
WARNING). Plug the brake supply hose and cap the
fitting at the bleeddown manifold to prevent high
pressure leakage.
Prior to checking the steering system, the hydraulic
steering and brake systems must have the correct
accumulator precharge and be up to normal operating temperatures. Refer to Steering Circuit Component Repair - Steering Accumulator Charging
Procedure in this section of the manual for accumulator charging instructions.
If the steering and brake pump has just been

installed, it is essential that the steering pump
case is full of oil prior to starting the engine.
Refer to Steering Circuit Component Repair Steering and Brake Pump, Section L6 for instructions.
The AC drive system rest switch, located on the

instrument panel, must be in the ON position and
the GF cutout switch in the CUTOUT position
during test procedures. (See Figure 3-1, page E34, Propulsion System, for GF switch location.)
L10015
L10-3
Equipment Requirements
The following equipment will be necessary to properly check-out the hydraulic steering circuit
Hydraulic schematic, refer to Section R.
Two 0-5000 psi (0-35,000 kPa) range calibrated
pressure gauges and hoses.
A graduated container marked to measure liquid
volume in cubic inches or milliliters.
Pump Pressure Control Adjustments

With the brake system functioning properly and the
parking brake on, proceed as follows:
1. Place selector switch in NEUTRAL, apply the
parking brake and place the rest switch in the
ON position and the GF cutout switch in the
CUTOUT position. Shut down engine and turn
key switch off. Wait 90 seconds for the steering
accumulators to completely bleed down before
opening circuits to take leakage measurements,
to make repairs, or to install or remove a gauge.
Be sure steering accumulator oil pressure has

been bled down. Turn the steering wheel; the
wheels should not move if all oil pressure has
been relieved.
2. Check hydraulic oil level in tank and add oil if
required. Be certain suction line shut-off valves
are open.

3. Pressure Test Port (TP2)
4. To Brake System
6. Steering Accumulator Bleeddown Solenoid
7. Pressure Test Port (TP3)
8. Supply to Flow Amplifier
9. Return from Flow Amplifier
14. Hoist Pilot Valve return
15. Return to Tank
17. Supply from Pump
3. Remove plug and install an accurate 5000 psi
(35,000 kPa) pressure gauge at the steering
pressure GPA test port (4, Figure 10-1)
located on the suction side of the pump. Install
a second 5000 psi (35,000 kPa) gauge in the
bleeddown manifold test port TP2 (3, Figure
10-2).
4. Turn unloader valve adjustment screw (2, Figure 10-1) clockwise until it bottoms out.
FIGURE 10-1. PUMP PRESSURE CONTROLS

1. Stroke Adjustment
2. Unloader Adjustment
L10-4
5. Back out the pressure compensator adjustment

screw (3), by turning counterclockwise.
3. Compensator Adjustment
4. GPA Port
L010015
6. Start engine and adjust pressure compensator

(3) to obtain 3325 psi (22,923 kPa) on the pressure gauge at the GPA pump port. Tighten
compensator jam nut.
* Record on Data Sheet
7. Shut down the engine and allow the accumulators to bleed down.
8. Back out unloader valve adjustment screw (2,
Figure 10-1) completely.
9. Start engine and allow pump pressure to build
until the pump unloads.
NOTE: When the steering pump unloads, pump
output pressure at the GPA pressure test port will
drop to approximately 200 to 400 psi (1380 to 2760
kPa).
10. Steer the truck to cause the accumulator pressure to drop until the pump loads.
11. Observe increasing pressure readings on the
gauge installed at the bleeddown manifold test
port TP2 (3, Figure 10-2).
When pressure increases to 3000 to 3050
psi (20,680 to 21,025 kPa), adjust unloader
valve by turning adjustment screw
clockwise until the pump unloads and
pressure begins to decrease.
12. Steer the truck slowly again while observing
TP2 steering pressure gauge.
Steering Control Unit and Flow Amplifier Leakage

Test
1. Disconnect the flow amplifier return line (9, Figure 10-2) at the bleeddown manifold. Plug the
port on the bleeddown manifold.
2. Disconnect steering control unit return line at
the flow amplifier. Install a plug in the open flow
amplifier port. Do not turn steering wheel with
hoses disconnected!
3. Start engine and allow steering system to reach
normal operating pressure.
4. Measure leakage from flow amplifier return
hose removed in step 1:
Maximum permissible leakage is 50 cubic
inches (820 ml) per minute.
If leakage is excessive, the flow amplifier
should be repaired or replaced.
5. Measure leakage from steering control unit
return hose removed in step 2:
Maximum permissible leakage is 10 cubic
If leakage is excessive, the steering control
valve should be repaired or replaced.
6. Shut down engine and allow accumulators to
bleed down completely. Steer the truck to verify
all pressure has bled off.
The pump must reload when pressure

drops to 2750 psi (18,960 kPa) minimum.
13. If minimum reloading pressure in step 12. is not
correct, repeat unloader valve adjustment,
steps 11. and 12.
NOTE: The critical pressure setting is the 2750 psi
(18,960 kPa) when the pump loads. The unloading
pressure follows the loading pressure adjustment
and should occur at approximately 3025 psi (20,855
kPa).
14. Tighten jam nut to lock pressure adjustment.
15. Steer truck to cause system to cycle several
times to verify system pressure begins to
increase (pump cycles from unload to load)
once pressure has dropped to 2750 psi (18,960
kPa).
Bleeddown Manifold Leakage Test

1. With hydraulic lines still disconnected from
Steering Control Unit and Flow Amplifier Leakage Test, disconnect the hoist pilot valve return
hose (14, Figure 10-2) located on the side of the
bleeddown manifold.
2. Before performing the next step, it will be necessary to draw a vacuum on the hydraulic tank
to prevent oil loss when the bleeddown manifold
tank return line is disconnected.
16. Shut down engine and allow accumulators to

bleed down completely. Turn the steering wheel
to verify no pressure remains.
17. Remove gauges and cap test ports.
L10015
L10-5
STEERING/BRAKE PUMP STROKE

ADJUSTMENT
Hydraulic tank oil level is above the level of this
return line. It is necessary to draw a vacuum on
the hydraulic tank to prevent a large amount of
oil draining from the tank with the return line disconnected from the bleeddown manifold.
3. Disconnect tank return line (15, Figure 10-2)
from bleeddown manifold. Connect hoist pilot
valve return hose removed in step 1 to the tank
return line.
4. Remove the vacuum on the hydraulic tank.
5. Start the engine and allow the system to build
pressure until the unloader valve unloads the
pump. Measure leakage at the open tank
return port on the bleeddown manifold.
Later model trucks are equipped with an adjustable

pump stroke control (1, Figure 10-1) to control the
volume of oil produced by the steering/brake pump.
Use of this feature is required only if the truck is operated at high altitude locations (greater than 10,000 ft.
(3,050 meters) above sea level). If the truck is operating at high altitudes, contact the Komatsu Area
Service Representative for instructions regarding
stroke control adjustment procedures.
For trucks operating at lower altitudes, this adjustment should not be changed from the factory setting
(adjusted fully counterclockwise). The factory setting
provides full pump flow for maximum performance.
Maximum permissible leakage is 33.0 cubic

If leakage is excessive, the bleeddown
solenoid (6, Figure 10-2), the steering
system relief valve (13), or the piloted
check valve (located on top of bleeddown
manifold) is defective and should be
replaced.
In the next step, DO NOT use the key switch to

shut down the engine and allow accumulators to
bleed down during the next operation. If the
instrument panel key switch is turned off, all
accumulator oil will be discharged through the
open port on the bleeddown manifold!
6. After test is complete, shut down the engine
using the shutdown switch located on the console.
7. Re-attach vacuum source to hydraulic tank and
draw a vacuum before disconnecting tank
return hose from pilot valve return hose. Attach
tank return hose to bleeddown manifold. Attach
hoist pilot return hose to fitting on manifold.
FIGURE 10-3. STEERING RELIEF VALVE

ADJUSTMENT
2. Plug
3. O-Ring
4. Relief Valve
Adjustment
8. Remove vacuum source. Remove test equipment and reinstall all remaining hoses to their
proper location.
9. Turn key switch to OFF position to allow steering accumulators to bleed down.
L10-6
L010015
SHOCK AND SUCTION VALVES
8. If pressure is incorrect during step 6 or 7, the

shock and suction valves must be replaced.
The following equipment will be necessary to properly test the steering circuit shock and suction valves:
Hydraulic schematic, refer to Section R.
Three 0-5000 psi (0-35,000 kPa) range calibrated
pressure gauges and hoses.
Before the shock and suction valves in the steering
circuit can be tested, steering system pressure must
be increased to obtain sufficient pressure for testing.
In addition, the steering relief valve pressure must be
raised above the pressure required to actuate the
shock and suction valves.
1. Install a 5000 psi (0-35,000 kPa) pressure

gauge at TP2 (3, Figure 10-2) in the steering
bleeddown manifold.
2. Install a 5000 psi (0-35,000 kPa) gauge in each
steering cylinder manifold test port. (Located on
frame crossmember, under engine.)
3. Raise steering relief valve pressure as follows:
a. Remove external plug (2, Figure 10-3) on
flow amplifier valve, using an 8 mm allen
wrench.
b. Insert a 5 mm allen wrench into opening and
gently bottom out adjustment (4) by turning
clockwise.
4. Start the engine and allow steering system to
build pressure.
5. While observing gauge at the TP2 steering
pressure test port, turn unloader valve adjustment (2, Figure 10-1) clockwise until approximately 3300 psi (22,750 kPa) is obtained.
NOTE: This pressure is near the pump compensator
pressure setting and the pump may not unload,
however it is not necessary for the pump to unload
during this test.
6. While observing the two gauges installed on the
steering manifold, steer the truck against the left
stop.
Pressure on one of the gauges should read
3100 psi (21,370 kPa).
NOTE: The shock and suction valves are only

serviced as complete units, and cannot be adjusted
while installed in the flow amplifier valve.
9. After the above test is complete, lower the
steering relief pressure to 2750 psi (18,960
kPa) as follows:
a. Steer full left or right and maintain a slight
pressure against the steering wheel.
b. Adjust steering relief valve, using the 5 mm
allen wrench to obtain 2750 psi (18,960 kPa)
on the gauge showing pressure.
10. After adjustment is complete, install plug (2, Figure 10-3) with O-ring (3) on valve body.
11. Reset unloader valve to specified unload pressure; back out the unloader valve adjustment
screw completely counterclockwise.
12. Steer the truck to reduce pressure in the steering circuit and cause the pump to load.
a. Observe increasing pressure readings on
the gauge installed at the steering pressure,
TP2 test port (3, Figure 10-2).
When pressure increases to 3000 to 3050
psi (20,680 to 21,025 kPa), adjust unloader
valve by turning adjustment screw
clockwise until the pump unloads and
feedback pressure begins to decrease.
b. Steer the truck again while observing the
steering pressure feedback gauge.
The pump must reload when pressure
drops to 2750 psi (18,960 kPa) minimum.
13. If minimum reloading pressure in step 12. is not
correct, repeat unloader valve adjustment.
NOTE: The critical pressure setting is the 2750 psi
(18,960 kPa) when the pump loads. The unloading
pressure follows the loading pressure adjustment
and should occur at approximately 3025 psi (20,855
kPa).

7. Steer the truck to the opposite stop.
The other gauge should read 3100 psi
(21,370 kPa).
L10015
L10-7
HOIST SYSTEM RELIEF VALVE AND

BRAKE COOLING CIRCUIT PRESSURES
NOTE: If relief valve or hoist valve assembly has
been replaced or rebuilt, hoist valve power up
pressure should be checked. Also, check the brake
cooling circuit for correct pressures.
Check hoist system power down relief pressure if
the hoist pilot valve has been replaced or rebuilt.

lines. Tighten all connections securely before
applying pressure.
The following equipment will be necessary to properly check-out the hoist relief and brake cooling circuit pressures:
Hydraulic schematics, refer to Section R.
Three 0-3500 psi (0-25,000 kPa) range calibrated
pressure gauges and hoses for hoist circuit
pressure readings.
Two 0-100 psi (0-1000 kPa) low pressure gauges
and hoses for brake cooling circuit pressure
readings.
Note: Hydraulic oil temperature
approximately 70F (21C) during test.
should
be
FIGURE 10-4. PUMP PRESSURE TAPS

1. Hoist Valve
2. Front Brake Cooling
Supply
3. Brake/Hoist Return
Manifold
Brake Cooling Circuit Test

1. Start engine and run at low idle. Place hoist
control lever in the FLOAT position.
Hoist pump outlet pressures at the filters
should be approximately 80 psi (550 kPa).
Pressure Gauge Locations

1. Install a 0-100 psi (0-1000 kPa) low pressure
gauge at the brake cooling circuit manifold
block (2, Figure 10-4) at the front of the hoist
valve (1) to monitor front brake cooling oil pressure.
2. Install a 0-3500 PSI (0-25,000 kPa) gauge in
the overcenter manifold (4) power down test
port marked TPD located on front face of manifold.
3. Install a 0-3500 PSI (0-25,000 kPa) gauge in
each hoist pump filter pressure test port.
4. Install a 0-100 psi (0-1000 kPa) low pressure
gauge at the upper left test port in the brake/
hoist return manifold (3) to monitor rear brake
cooling supply pressure.
Pressure at front and rear brake cooling

circuits (3 & 4, Figure 10-7) should be
approximately 25 psi (172 kPa) or less.
2. With engine at low idle, move the hoist control
lever to POWER UP.
circuits (3 & 4) should drop to 0 psi (0 kPa)
while body raises.
3. Increase engine speed to 1500 RPM. Place
hoist control lever in HOLD or FLOAT.
circuits (3 & 4) should be approximately 50
psi (344 kPa) or less.
4. With engine at 1500 RPM, move the hoist control lever to POWER UP.
L10-8
L010015

circuits (3 & 4) should drop to 0 psi (0 kPa)
while body raises.
c. Move hoist control lever to the power down

position and allow body to completely rest on
frame rails.
d. Disconnect tube from inlet section cover (2,
Figure 10-5). Disconnect hose(s) at top port.
Power Up Relief Pressure Test

The hoist valve contains two relief valves. The rear
inlet section (toward rear of truck) contains the relief
valve for the rear section of the hoist pump. The front
inlet section (toward front of truck) contains the relief
valve for the front section of the hoist pump.
1. To allow full extension of the hoist cylinders, disconnect the hoist up limit solenoid, located on
the bottom of the bleeddown manifold from the
wiring harness.
Be sure there is adequate (safe) overhead clearance before raising body to full up position.
2. With engine at low-idle, place hoist lever in

POWER UP position and hold until body is in
the full raised position. (Be certain gauges are
identified as to the front or rear section of the
pump when pressures are read.)
e. Remove capscrews (1) from cover (2).

Remove cover (1) and spring (3) from relief
valve (4).
f. Loosen jam nut on relief valve (4) and turn
screw in (clockwise) to increase pressure
or out (counter-clockwise) to decrease
pressure.
NOTE: Each 1/4 turn of the adjustment screw will
cause approximately 150 psi (1,034 kPa) change in
pressure.
g. Install spring (3) and cover (2) with new Orings (8). Install and tighten capscrews (1).
Install tube to cover fitting. Install hose(s) at
top port.
2. Check pressure again, repeating step 2. If necessary, repeat adjustment procedure until correct pressure is attained.
Pressure at both hoist pump filter test ports

should be 2500 100 psi (17,237 690
kPa).
Adjustment
If hoist relief pressure is incorrect on either gauge,
the corresponding relief valve should be readjusted.
Adjust relief valve in rear hoist valve inlet section if
the rear pump section pressure was incorrect and/or
adjust the relief valve in front hoist valve inlet section
if the front pump section pressure was incorrect.
1. If power up relief pressure is incorrect in either
the front or rear inlet section, adjust pressure as
follows:
a. Lower body until it is resting on frame rails
and shut down engine. Wait at least 90 seconds until accumulators bleed down.
b. Relieve all hydraulic pressure from hoist system.
L10015
FIGURE 10-5. INLET SECTION

(Front and Rear Inlet Sections are Identical)
1. Capscrew
2. Inlet Cover
3. Spring
4. Main Relief Valve
5. Spring
6. Sleeve
7. Secondary Low
Pressure Valve
8. O-Rings
9. Inlet Valve body
L10-9
Power Down Relief Pressure Test

NOTE: The hoist system power down relief valve is
located on the hoist pilot valve, located in the
hydraulic components cabinet, behind the cab.
1. If not installed previously, Install a 0-3500 psi
(0-25,000 kPa) pressure gauge at power down
circuit test port TPD on the overcenter manifold.
2. Recheck power down relief pressure (step 3)

after valve adjustment. Install cap on relief
valve.
3. Shut down engine, allow accumulators to bleed
down. Remove gauges, hoses etc.
2. Start engine and run at low idle. Allow the accumulators to fill and the steering pump to unload.
3. With the body resting on the frame and engine
at low idle, place hoist lever in the power down
position.
Pressure at the test port TPD on the
overcenter manifold should be 1500 75 psi
(10,340 517 kPa).
Adjustment
1. If power down relief pressure is not within specifications, adjust as follows:
a. Remove cap from power down relief valve
(2, Figure 10-6).
1.) To increase power down relief pressure,
turn adjusting screw in (clockwise).
2.) To decrease power down relief pressure,
turn adjusting screw counter-clockwise.
FIGURE 10-7. BRAKE/HOIST RETURN OIL

MANIFOLD
Pressure
4. Front Brake Supply
Pressure
5. Rear Brake Cooling
Oil (From Hoist
Valve)
6. Return From Hoist
Valve
7. Return From Hoist
Valve
8. Brake/Hoist Return
Oil Manifold
9. Front Brake Bypass

Pressure
11. Hoist
Return
Pressure
12. Front Brake Return
Pressure
15. Hoist Return to Tank
FIGURE 10-6. POWER DOWN RELIEF VALVE

1. Spool Housing
L10-10
2. Relief Valve
L010015
Hoist Counterbalance Valve Adjustment

Preparation:
1. With the engine shut down, the body resting on
the frame, the hoist valve in the FLOAT position
and hydraulic system pressure bled down,
loosen locknut on adjustment stem of needle
valve (3, FIGURE 10-8) on overcenter manifold
(6). Turn adjustment stem fully clockwise.
2. Remove plug from PILOT VENT port (4) on
overcenter manifold. This port will remain open
to atmosphere during adjustment; do not allow
dirt to enter open port.
Note: It is suggested a clean SAE #4 (1/4") hydraulic
hose is installed in the open port and the hose
pointed downward.
3. Install a 5000 psi (35,000 kPa) gauge at test
port TR on overcenter manifold. (Gauge will
measure rod end pressure; the pressure controlled by the counterbalance valve.)
Counterbalance Valve Pressure Check Only:
1. Start the engine. At low idle, raise the body and
as it extends to the third stage, read the pressure on the gauge connected to the TR port.
(All counterbalance valve pressures are read/
adjusted while hoist cylinders are in third stage.)
a. If pressure is 3000 psi (20.7 MPa) or above,
stop hoisting immediately.
Pressure is adjusted too high and must be
lowered. Refer to Counterbalance Valve
Adjustment and perform the adjustment
procedure.
b. If pressure is below 3000 psi (20.7 MPa),
increase engine speed by approximately 300
rpm and observe pressure on gauge.
1.) If pressure is still below 3000 psi (20.7
MPa), continue increasing engine speed in
steps of 300 rpm, while in third stage and
observing pressure gauge.
2.) Continue monitoring pressure gauge until
engine high idle is attained.
c. If gauge indicates 3000 psi (20.7 MPa) while
at high idle, in POWER UP and in third
stage, counterbalance valve adjustment is
correct.
d. If gauge does not indicate 3000 psi (20.7
MPa) while in third stage and at high idle (or
a lesser rpm during step 1b, 1.) adjust the
counterbalance valve.
L10015
FIGURE 10-8. COUNTERBALANCE VALVE

ADJUSTMENT
5. TPD Pressure Test
1. Hoist Valve
Port
3. Needle Valve
4. Pilot Vent Port Plug
Counterbalance Valve Adjustment

1. Loosen locknut on adjustment stem of counterbalance valve (2, FIGURE 10-8) (Labeled
CBV on manifold). Turn adjustment stem fully
clockwise to start adjustment procedure so
counterbalance valve pressure is as low as possible.
Note: Turning adjustment stem in (clockwise)
decreases the pressure. Turning the stem out
(counterclockwise)
increases
the
pressure.
Complete valve adjustment range is 3 turns.
2. Start the engine and operate at high idle. Raise
the body while observing the pressure gauge.
Slowly adjust counterbalance valve to
obtain 3000 psi (20.7 MPa) as the hoist
cylinder 3rd stage extends while in POWER
UP. When adjustment is complete, secure
locknut on adjustment stem.
3. Repeat Counterbalance Valve Pressure Check,
step 1. to verify proper adjustment.
4. Replace plug in PILOT VENT port. Remove
pressure gauge.
5. Turn needle valve adjustment stem fully out
and secure locknut.
L10-11
HYDRAULIC SYSTEM FLUSHING PROCEDURE

The following instructions outline the procedure for
flushing the hydraulic system.
Preparation
1. Verify and correct if necessary, the various relief
valves and adjustable hydraulic system components. (Refer to Hydraulic Checkout Procedure.)
2. Place selector switch in NEUTRAL, apply the
parking brake and place the rest switch in the
ON position. (Leave rest switch ON for all the
following procedures.)
a. Shut down engine and turn key switch OFF.
Be certain the Link Voltage warning
lamps turn off.
b. Allow at least 90 seconds for the steering
accumulators to bleed down.
c. Open the brake accumulator bleed down
valves on the brake manifold. (This will
return contaminants in the brake accumulators to the hydraulic tank.)
3. Thoroughly clean the exterior of the hydraulic
tank. Drain the hydraulic tank and flush the interior with a cleaning solvent. Inspect all hydraulic
hoses for deterioration or damage.
NOTE: If a system component fails, all flexible hoses

should be removed and back flushed with a cleaning
solvent. Inspect for small particles which may be
trapped inside the hose.
4. Remove, clean and reinstall the hydraulic tank

strainers. Change all high pressure filter elements.
5. Fill hydraulic tank with clean, Type C-4 hydraulic oil.
Flushing Procedure
1. Set all controls in the NEUTRAL position. Do
not steer the truck or operate controls until the
next step is completed.
2. Start the engine and run at 1000 RPM for five
minutes. This will circulate oil with all valves in
the neutral position.
3. To increase flow and turbulence in the system,
increase engine speed to full throttle and maintain for four minutes. This will carry contaminates to the hydraulic tank.
4. Shut down engine and turn key switch OFF.
Allow at least 90 seconds for the accumulators
to bleed down.
5. Close the brake accumulator bleed down
valves on the brake manifold (opened in step
2.c. of Preparation)
6. To enable full extension of the hoist cylinders,
disconnect hoist limit solenoid on bottom of
bleeddown manifold.
7. Start engine and run at 1000 RPM while performing the following:
a. Steer truck full left then full right - repeat ten
times.
b. Steer full left (keeping pressure against the
steering wheel) and hold for 10 seconds.
c. Steer full right (keeping pressure against the
steering wheel) and hold for 10 seconds.
NOTE: Hydraulic tank oil temperature should be 110
- 130F (43 - 54C) after accomplishing Step 6. If
not, repeat Step 3 to increase oil temperature to the
proper operating range.
8. Increase engine speed to full throttle and steer
full left and full right.
9. Return all controls to NEUTRAL.
6. Be certain suction line shut-off valves are open.

7. Bleed trapped air inside steering pump. (Refer
to Steering and Brake Pump, Section L.)
L10-12
L010015
The following procedures involve raising and

lowering the dump body. Be certain adequate
clearance is available before raising body to the
full UP position.
10. Reduce engine speed to 1000 RPM and perform the following:
In all of the following UP exercises, as the second stage starts out of the hoist cylinder in the
POWER UP mode, slowly decrease engine speed
to prevent sudden bottoming of the cylinders.
Severe damage to the hoist cylinders may occur
if this precaution is not followed.
a. Extend hoist cylinders fully and FLOAT
down - repeat ten times.
b. Extend hoist cylinders to full extension and
hold hoist lever in UP position for 10 seconds.

After the hydraulic system flushing procedure has
been completed, all system high pressure filter elements must be replaced.
1. Close both hoist pump suction line shut-off
valves. Close the steering pump suction line
shut-off valve.
2. Remove hoist, steering, and brake circuit
hydraulic filters, clean housings and install new
filter elements. (Detailed instructions may be
found in Section L9.)
3. Check hydraulic tank oil level and refill if necessary.
4. Open all (three) suction line shut-off valves.
c. Lower hoist cylinders and hold lever in

DOWN position for 10 seconds after cylinders are fully retracted.
11. Increase engine speed to full throttle and perform the following:
a. Hoist up to full extension, then allow cylinders to float down.
b. Return hoist control to FLOAT.
12. Operate the truck (on a typical haul cycle if possible) to exercise the braking functions a minimum of 30 times. Insure the braking is also
exercised in reverse, as would be seen in a typical haul cycle.
13. If the truck is equipped with any hydraulically
operated attachment, the attachment must also
be cycled in a similar manner, following the
checkout procedure or operational instructions
for the device.
14. Shut down engine and turn key switch OFF.
15. Allow at least 90 seconds for the accumulators
to bleed down. Turn the steering wheel to be
certain all pressure has been released.
16. Reconnect hoist limit solenoid on bleeddown
manifold.
L10015
L10-13
NOTES
L10-14
L010015
930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET
MACHINE MODEL ________UNIT NUMBER __________SERIAL NUMBER___________
__________ Steering Accumulators charged to 1400 psi (9650 kPa).

Operate hydraulic steering system to obtain proper operating temperature. Refer to Check-out
Procedures.
PUMP PRESSURE CONTROL ADJUSTMENTS

STEP 6___________ Steering pump compensator pressure
STEP 11__________ Steering pump unload pressure.
STEP 12__________ Steering pump load pressure.
STEERING CONTROL VALVE AND FLOW AMPLIFIER LEAKAGE TESTS
STEP 4___________ Flow amplifier return hose leakage.
STEP 5___________ Steering control unit return hose leakage.
BLEEDDOWN MANIFOLD LEAKAGE TEST
STEP 5___________ Bleeddown solenoid, steering relief, and piloted check valve leakage.
SHOCK AND SUCTION VALVES TEST
STEP 6___________ Shock and suction valve pressure, left steer.
STEP 7___________ Shock and suction valve pressure, right steer.
STEP 9___________ Steering relief valve pressure setting.
STEP 12__________ Steering pump reload pressure.
Name of Technician or Inspector Performing Check-Out
__________________________
Date __________________________
L10015
L10-15
930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM

DATA SHEET
MACHINE MODEL ___________ UNIT NUMBER_______ SERIAL NUMBER___________
Operate hydraulic system to obtain proper operating temperature. Refer to Check-out Procedures.
BRAKE COOLING CIRCUIT TEST

STEP 1 __________ Hoist pump outlet pressures, low idle, FLOAT position.
___________ Brake cooling circuit pressure, low idle, FLOAT position.
STEP 2 __________ Brake cooling circuit pressure, low idle, POWER UP/DOWN position.
STEP 3 __________ Brake cooling circuit pressure, 1500 RPM, HOLD/FLOAT position.
STEP 4 __________ Brake cooling circuit pressure, 1500 RPM, POWER UP/DOWN position.
POWER UP RELIEF PRESSURE TEST
STEP 2 __________ Hoist relief pressure, front pump section.
________________ Hoist relief pressure, rear pump section.
POWER DOWN RELIEF PRESSURE TEST
STEP 3 __________ Power down relief pressure.
HOIST COUNTERBALANCE VALVE PRESSURE TEST
STEP 3 __________ Counterbalance valve pressure.
Name of Technician or Inspector Performing Check-Out__________________________

DATE _________________________
L10-16
L010015
SECTION M
OPTIONS AND SPECIAL TOOLS
INDEX
FIRE CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-1
SPECIAL TOOL GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8-1
PAYLOAD METER III - ON BOARD WEIGHING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-1
RESERVE ENGINE OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-1
M01043
Index
M1-1
NOTES
M1-2
Index
M01043
SECTION M2
FIRE CONTROL SYSTEMS
INDEX
FIRE CONTROL SYSTEM (MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-3
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-3
Recharging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-4
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1 . . . . . . . . . . . . . . . . M2-5
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-5
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Linear Detection Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Power Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-6
Securing the Detection Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-7
Preliminary Test Before Final Hook-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-7
Installation Procedure for Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-9
Placing the Electric Detection & Actuation System Into Service . . . . . . . . . . . . . . . . . . . . . . . M2-9
INSPECTION AND MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-10
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-10
Normal Maintenance Based On Actual Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-10
IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-11
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . M2-13
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Fire Control Systems
M2-1
NOTES
M2-2
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FIRE CONTROL SYSTEM (MANUAL)

The fire control system aids in protecting the
machine in the event of a fire. The system consists
of:
Actuators
Pneumatic Actuator/Cartridge Receivers
Pressure Relief Valve
Check Valves
Dry Chemical Tanks
Hoses And Nozzles.
Operation
To actuate the fire control system, pull the safety ring
on either of the actuators and depress the lever. One
actuator is located in the cab near the operator.
Another actuator is located on the left fender structure near the bumper.
NOTE: Operating either actuator will activate fire
control system.
When either actuator is depressed, a nitrogen cartridge will pressurize the dry chemical tank. Once the
dry chemical tank has pressurized to a sufficient
pressure, a bursting disc in the tank outlet will break,
allowing the fluidized chemical to flow to the nozzles.
The nozzles will direct the agent at the fire and extinguish the flames.
Inspection and Maintenance

It is imperative that the fire control system is
inspected at least every six months. To insure that it
will operate effectively:
1. Check the system for general appearance,
mechanical damage and corrosion.
2. Inspect each chemical tank fill cap gasket for
damage and replace if necessary. Examine cap
for nicks, burrs, cross threading or rough edges.
3. Check the level of dry chemical. The level
should not be less than three inches (76 mm)
from bottom of fill opening. Dry chemical must
be free flowing, with no caking.
4. Insure that the vent in the fill opening threads is
not obstructed.
5. Remove the cartridge from the extinguisher and
examine the disc-seal. Replace seal if necessary. Install cartridge hand tight.
FIGURE 2-1. FIRE CONTROL SYSTEM

1. Cab Actuator
2. Remote Actuator
3. Safety Relief Valve
4. Check Valves
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FIGURE 2-2. NOZZLE AND BLOW-OFF CAP
5. Actuator Receiver
6. Cartridge
7. Bursting Disc Union
8. Dry Chemical Tank
M2-3
3. Remove each extinguisher from its bracket.

4. Disassemble bursting disc union and replace
the ruptured bursting disc with flat side toward
extinguisher.
5. Fill tank with dry chemical to not more than
three inches (76 mm) from the bottom of the fill
opening.
6. Inspect fill opening threads and gasket. If necessary clean threads.
7. Install the fill cap and tighten the cap hand tight.
8. Remove the cartridge guard from the dry chemical tank and remove the cartridge.
FIGURE 2-3. NOZZLES AND BLOW-OFF CAP
6. Inspect lines, fittings and nozzles for mechanical damage and cuts.
7. Check nozzle openings. The openings should
be packed with silicone grease or equipped with
plastic blow-off caps if equipped with nozzles as
shown in Figure 2-2. Nozzles of the type shown
in Figure 2-3 are not to be packed with grease.
Only the protective caps shown are to be used
on this type of nozzle.
8. Remove and inspect the cartridge of the remote
actuators. Replace if ruptured. Check operation
of puncture pin.
9. Replace any broken or missing lead and wire
seals.
9. Insure that the cartridge puncture pin is fully

retracted.
10. Weigh the new cartridge. The weight must be
within 0.25 ounce (7.0 grams) of the weight
stamped on the cartridge.
11. Screw the new cartridge onto the actuator
assembly, hand tight.
12. Replace the cartridge guard and install the dry
chemical tank into its bracket.
13. Connect line at the bursting union, and line at
the tank actuator.
14. Remove the cartridge guard from the remote
actuators and replace the cartridges.
15. Replace the cartridge guards, and install ring
pins on the push buttons.
16. Inspect hose, fittings and nozzles for mechanical damage. Replace all hose that has been
exposed to fire areas.
Recharging Procedures
After actuating the fire control system, the system
should be recharged. Follow the procedure below for
each dry chemical tank and actuator installed:
17. Clean the nozzles and repack the openings with

silicone grease or install blow-off caps. Use
caps for new designed nozzles shown in Figure
2.1-2.
1. Relieve the pressure from the lines by pulling

the ring on the safety relief valve.
2. Disconnect line from tank actuator and remove
line from the bursting disc union.
M2-4
M02005
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1

The Checkfire Electric Detection and Actuation System - Series 1 (Figure 2-5) uses linear detection
wire. This is a two conductor heat rated thermo
cable. When the detection cable is subjected to
221F (105C) the insulating coating of the cable
melts allowing the conductors to short together closing the electric circuit to the squib which detonates
to depress the puncture pin and actuate the expellant cartridge.
Components of the checkfire electric detection and
actuation system are shown in Figure 2-5.
Control Module
(Figure 2-4):
Provides the electrical connections necessary
between the power lead and the linear detection
wire to the power lead supplying electrical power,
via the squib, to the actuator. Also provides a visual
check of power availability - pressing the switch button will illuminate the green indicator light if electrical power is available in the system.
FIGURE 2-4. CONTROL MODULE
FIGURE 2-5. CHECKFIRE ELECTRIC DETECTION/ACTUATION SYSTEM

1. Control Module
3. Linear Detection Wire
5. Test Kit (Not Shown)
2. Manual/Automatic Actuator
4. Power Wire
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M2-5
Actuator
(Figure 2-6)
Provides automatic and manual means of fire suppression system actuation. By pulling the ring pin
under the knob and then depressing the red knob,
the puncture pin will rupture the diaphragm in the
actuator and apply the system. Automatically, the
squib is fixed to rupture the cartridge disc when the
linear detection wire is exposed to temperatures in
excess of its rated range.
FIGURE 2-8. POWER WIRE
FIGURE 2-6. MANUAL/AUTOMATIC ACTUATOR
FIGURE 2-9. TEST KIT

1. Indicator Light Assembly
2. End-of-Line Detection Wire Jumper Assembly
Linear Detection Wire

(Figure 2-7):
Test Kit
(Figure 2-9):
Consists of a two conductor heat rated thermo cable.

The temperature rating of the cable is 221F 105C)
black wire or 356F (180C) using red wire. When the
cable is subjected to temperatures in excess of this
rating the insulating coating melts allowing the conductors to short together, closing the actuating circuit
to fire the squib.
Provides for checking of electrical continuity and consists of an indicator light assembly and an End-ofLine linear detection wire jumper assembly.
FIGURE 2-10. SQUIB

FIGURE 2-7. LINEAR DETECTION WIRE
Power Wire
(Figure 2-8):
Consists of a battery connector and conductor lead
wires to connect the actuation system to the truck
electrical system (battery circuit). The battery connector is equipped with a 5 ampere in line fuse
(replaceable).
M2-6
Squib
(Figure 2-10)
Is an electrically detonated component containing a
small exact charge of powder. When the actuation
circuit is closed by the linear detection wire melting,
an internal wiring bridge in the squib heats up causing the power charge to detonate, forcing the puncture pin to rupture the cartridge disc to release the
nitrogen gas charge.
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be on. This indicates the power wire is

installed correctly to the control module. If
light does not appear, check all connections
to insure they are snapped together. Retest
by depressing button. If light is not on, refer
to Troubleshooting The Electric Detection
System covered in this section.
Securing the Detection Wire

After the linear detection wire has been loosely
installed, secure it to the equipment being protected
as follows:
1. Begin at the control module with the first section of detection wire. If this section is sufficient
to cover the total hazard area, no additional
lengths are required. If additional lengths are
required, remove blank plugged connector from
the end of first length and add lengths until the
total hazard area(s) is covered.
b. If battery power is correct, proceed to checking total system power.
NOTE: Remember to leave closed blank plug

connection on the last length of detection wire.
When making connection, push plug into receptacle
until a "click" is heard (Figure 2-11). Plugs and receptacles are keyed to allow insertion only in one direction. After "click" is noted, apply a small amount of
back pull to confirm connection has been made.
FIGURE 2-12. POWER CHECK
FIGURE 2-11. LINEAR DETECTION WIRE

CONNECTOR
Do Not install squib to power lead at this time

(Figure 2-13).
2. Secure the wire every 12-18 in. (30-45 cm)

throughout the hazard area(s) using the black
nylon cable ties provided. Secure more often if
desired, or to keep the wire out of the way.
Secure the wire to mounting surfaces, decks,
struts, hydraulic hoses in the area, or any
secure, non-moving part of the protected equipment. Always keep the previously mentioned
guidelines in mind when installing the wire.
Preliminary Test Before Final Hook-Up
All necessary linear detection and power wire installation is now completed. Before arming the actuator
with the squib, it is necessary to check to insure all
connections are made properly.
1. The Power Wire
FIGURE 2-13. DO NOT CONNECT SQUIB
a. Depress the button on top of the control

module and note green indicator light (Figure
2-12). With button, depressed, light should
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M2-7
c. Proceed to the end of the last length of

detection wire and remove the jumper
assembly (Figure 2-15). Finally, put original
plugged blank connector onto detection wire.
The test module light should immediately go
out. If light does not go out refer to "Troubleshooting".
d. Remove the test kit from the system by, first,
disconnecting the squib connector from the
test module (Figure 2-17). NOTE: Retain
these components for possible later use.
! CAUTION !
Remove jumper to prevent fire suppression system from discharging when squib is installed in
electric detection and actuation system.
FIGURE 2-14. INSTALL JUMPER

2. The Linear Detection Wire
a. Using the furnished text kit, proceed to the
end of the last length of detection wire.
Remove the plugged blank connector (Figure 2-14) and install the jumper assembly.
NOTE: Retain plugged connector to be reinstalled
after testing is completed.
b. With jumper in place, screw squib connector
into receptacle on test module (Figure 2-15).
Test module light should immediately illuminate. This test confirms that the wire is properly installed and will function as designed. If
test module light does not illuminate on test
module, refer to the "Troubleshooting" section.
FIGURE 2-15. INSTALL TEST MODULE

ASSEMBLY
M2-8
FIGURE 2-16. REMOVE JUMPER ASSEMBLY
FIGURE 2-17. REMOVE INDICATOR LIGHT

ASSEMBLY
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Installation Procedure for Squib

After all testing has been completed and all test kit
components removed, proceed to arm the system.
Using wrench, insert squib into upper right inlet hole

on actuator body and firmly tighten (Figure 2-18).
After installing squib into actuator body, loosen protective shipping cap from squib and remove bridge
(Figure 2-19).
Always install squib into actuator body first,

before installing connector onto threaded body
of squib. Possible injury could result if squib was
actuated outside of actuator body.
Install squib connector onto threaded stud of squib
(Figure 2-20). Hand tighten as firmly as possible.
FIGURE 2-18.
Placing the Electric Detection & Actuation

System Into Service
To place the electric detection and actuation system
into service, proceed as follows:
1. Check all fasteners for tightness. Insure jam nut
on actuator body is securely tightened.
2. Before installing actuator cartridge, push manual puncture lever several times to insure
smooth operation.
3. Insert ring pin in hole and attach lead wire seal
(See Figure 2-21).
FIGURE 2-19.
FIGURE 2-21. INSTALL ACTUATOR CARTRIDGE
4. Insert LT-5-R cartridge (PB0674) into lower

actuator body and hand tighten firmly.
FIGURE 2-20.
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5. Record date that system was placed in service.
M2-9
INSPECTION AND MAINTENANCE

SCHEDULES
Proper inspection and maintenance procedures

must be performed at the specified intervals to
be sure that the electric detection and actuation
system will operate as intended.
4. Weigh the actuation cartridge on the electric

detection and actuation system. Replace cartridge if the weight is 1/4 oz. (7 g) less than that
stamped on cartridge. Check the cartridge
threads for nicks, burrs, cross threading and
rough on feathered edges. Examine gasket in
bottom of electric detection and actuation system for elasticity. If the temperature is below
freezing, warm the gasket with body heat to
insure a good seal. Clean and coat lightly with a
high heat resistant silicone grease.
Daily
The machine operator should manually test system
power by pushing the button and noting illumination
of indicator light. This confirms battery power is available. If light is not illuminated, refer to "Troubleshooting" covered in this section.
Normal Maintenance Based On Actual Operating
Hours
Total system should be checked monthly or sooner,
depending on working conditions or truck maintenance to perform total system check.
NOTE: The squib should be replaced after being in
service for five years. The proper disposal of the old
squib should be done by actuating the squib within
the actuator body. To do this, remove actuator LT-5-R
cartridge (PB0674) from body. Install test jumper
assembly to end of linear detection wire assembly.
This jumper will service as a wiring short and cause
the squib to discharge.
FIGURE 2-22. REMOVE CARTRIDGE AND

DISCONNECT SQUIB
Remove jumper, clean actuator, install new squib

and reinstall cartridge.
Do Not reinstall cartridge at this time.
System is now back in service.
5. Test system power by depressing button on

control module. Note illumination of light while
button is depressed.
Record date of installation of new squib.

1. Check all mounting bolts for tightness.
2. Check all wiring connectors for tightness and
possible evidence of corrosion.
3. Inspect detection and power wire as follows:
a. Check for wear due to abrasion (at wall penetrations, around corners, etc.).
b. Check for damage from direct impact or
other abuse.
c. Check mounting locations for tightness.
d. Insure mounting hardware has not come
loose or been broken, either of which would
allow the wire to sag.
M2-10
6. Remove squib connector before proceeding

with next series of checks (Figure 2-22).
7. Using the furnished test kit assembly, proceed
to the end of the last length of detection wire.
Remove the plugged blank connector and
install the jumper assembly (retain plugged
blank connector to be reinstalled after testing is
completed).
8. With jumper in place, screw the squib connector
into receptacle on test module (Figure 2-23).
Light on the test module should immediately
illuminate. This test confirms that the detection
wire is properly installed and will function as
intended.
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10. Remove the test kit from the system by disconnecting the squib connector from the test module (Figure 2-24).
Failure to remove jumper assembly will cause

system discharge when squib is installed into
electric detection and actuation system.
11. Remove squib from actuator body and check
that it has not been fired. Reinstall squib and
wrench tighten firmly.
12. Reinstall squib connector to squib and firmly
tighten by hand.
13. Pull ring pin on electric detection and actuation
system actuator and push pin several times to
insure smooth movement. Reinstall ring pin and
attach lead wire seal.
14. Install actuation cartridge back into lower actuator body and tighten firmly by hand.
FIGURE 2-23. ATTACH INDICATOR LIGHT

ASSEMBLY (Test Module)
If test module light does not illuminate, refer to Troubleshooting The Electric Detection System, covered
in this section.
9. Proceed to the end of the last length of detection wire and remove the jumper assembly. Put
original plugged blank connector back on detection wire. Test module light should immediately
go out. If light does not go out, refer to Troubleshooting The Electric Detection System,covered in this section.
IN CASE OF FIRE
Procedure to follow during and after a fire. In the
event of a fire, the following steps should be taken:
1. Turn the machine off.
2. Manually activate fire suppression system, if
possible.
3. Move away from the machine taking a hand
portable extinguisher along if you can.
4. Stand-by with a portable fire extinguisher to put
out any possible re-ignition of the fire after the
fire suppression system is expended.
Explanation of the above steps.
1. If you leave the machine running, it may add
fuel to the fire or restart the fire with sparks.
2. May help put fire down more quickly.
3. By leaving the immediate fire area, you protect
yourself from windblown flames, explosions or
other dangers created by the fire.
FIGURE 2-24. REMOVE TEST MODULE
M02005
4. Having a hand portable fire extinguisher is

advised because remaining heat may cause
part of the fire to re-ignite after the fire suppression system has discharged. Depending on the
heat that remains, this may occur a number of
times, so remain alert until the equipment cools
and you are assured that re-ignition is not likely.
M2-11
What to Expect
When a fire suppression system discharges, there is
some noise, accompanied by clouds of dry chemical.
While breathing foreign particles is not pleasant, the
agent is non-toxic.
What to Do After the Fire is Out
The machinery should not be restarted until it has
been serviced and cleaned (water spray or steam
may be used to remove the dry chemical). If the electric detection and actuation system cannot be
recharged immediately, at least recharge the remainder of the fire suppression system so that manually
actuated protection is available.
Recharging the Electric Detection and Actuation
System
The recharge of the electric detection and actuation
system is similar to the original procedure for installing and placing the automatic detection system into
service. Follow these procedures as outlined previously in this manual, omitting the section which deals
with mounting the bracket and power wire.
Replace the entire length(s) of detection wire
involved in the fire area.
Before the system is put back into service, it is important that the inside chamber of the actuator be
cleaned thoroughly. Failure to do so may cause
excessive carbon build-up on the internal O-ring and
piston chamber. This build- up will also stop the
puncture pin from returning to its up-most position.
To clean actuator (See Figure 2-25):
1. Remove squib.
2. Remove actuator from bracket and loosen
upper portion of body.
3. Apply pressure to the bottom of the puncture
pin. This will force out the puncture pin and
spring.
FIGURE 2-25. ACTUATOR ASSEMBLY
4. Thoroughly clean carbon deposits from base of

stem, puncture pin, spring and inside surface of
body.
5. After all components are clean and dry, liberally
lubricate O-rings with silicone grease.
6. Reassemble actuator and push button manually
several times to insure free movement of puncture pin.
NOTE: When puncture pin is fully reset, cutting point
of pin will be located approximately 0.06 in. (1.6 mm)
below thread on lower actuator body (Figure 2-25).
M2-12
M02005
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM

TROUBLE: Green Indicator Light on Control Module Does Not Go On When Button is Depressed.
POSSIBLE CAUSES
Blown fuse in battery connector assembly
Look for possible short in external power wiring and

change fuse
Battery connection loose

Connector between power wiring unsnapped or wire
broken
Clean and tighten

Reconnect/install new length
Dead battery
Charge battery or install new one
Bulb burned out
Loosen green lens, install new bulb
TROUBLE: Test Module Light Will Not Illuminate.

POSSIBLE CAUSES
Jumper assembly not in place on end of detection

zone wiring
Install jumper assembly

Reconnect
Connector apart on either power or detection zone

wiring
Loosen green lens, install new bulb
Bulb burned out
Look for possible short in external power wiring and

change fuse
Blown fuse in battery connector assembly
Install new length
Wire broken
Charge battery or install new one
Dead battery
Clean and tighten
Battery connection loose
TROUBLE: Test Module Light Will Not Go Out

POSSIBLE CAUSES
Jumper assembly left in place on end of detection wire
Remove jumper. Reinstall plugged blank connector
Damaged section at detection wire
Replace damaged length(s) of detection wire.
TROUBLE: Detonated Squib

POSSIBLE CAUSES
Check for previous fire condition
Replace length(s) of detection zone wire. Replace

squib and recharge
Detection wire too close to heat source

Test jumper assembly left in place after testing
Check for broken points of security, move away from

heat source, and recharge
Remove jumper, reinstall plugged end of line connector
and recharge
M02005
M2-13
NOTES
M2-14
M02005
SPECIAL TOOLS
Part Number
Description
EB1759
Nitrogen
Charging Kit
Use
Suspension &
Accumulator
Nitrogen Charging
1. T Handle Valve
2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas
NOTE: Arrangement of parts may vary from
illustration shown, depending on Charging Kit P/N.
Part Number
Description
Use
EJ2626
Roller Assy.
Power Module
Remove & Install
(No longer
available as
complete unit)
EJ2271
Roller Mount
PC0706
Bearing
TH9449
Bearing
Retainer
Ring
TG1680
Roller
Retainer
Ring
C1645
Capscrew
0.75 -10 NC
x 2 1/4 in.
C1542
Lockwasher
0.75 in.
EH8686
M08015
Roller Ring
Special Tools
M8-1
Part Number
Description
PB8326
Offset Box End

Wrench,
Use
Miscellaneous &
Cab Mounting
1 7/16 in.
M8-2
Part Number
Description
TZ2734
3/4 in. Torque

Adapter
Part Number
Description
TZ2733
Tubular Handle
Part Number
Description
BF4117
Seal Installation
Tool
Front & Rear

Disc Brake
Floating Ring
Seal Installation
ED3347
Seal Installation
Tool
Rear Axle/Hub
Adaptor Floating Ring Seal
Installation
Special Tools
Use
Miscellaneous
Use
Use with
PB8326 &
TZ2734
Use
M08015
Part Number
Description
Use
EH4638
Sleeve Alignment Tool
Steering Linkage and Tie Rod

Assembly, Refer
to Section G
Part Number
Description
Use
EF9302
Wear Indicator
EB1723
Cap, Indicator
EF9301
Pin, Indicator
WA0010
O-ring, Indicator Pin
TL3995
O-ring, Indicator Cap
EB4813
Housing, Indicator
SV9812
O-ring, Housing
Part Number
Description
EF9160
Harness
M08015
Brake Disc
Wear, Refer to
Section J
Use
Payload Meter
Download, Refer
to Section M,
Payload Meter
Special Tools
M8-3
Part Number
Description
EH7817
Alignment Tool
Part Number
Description
PB4684
Hydraulic Coupling
Part Number
Description
PB9067
Bulkhead Connector
M8-4
Use
Upper Hoist Pin
Use
Miscellaneous
Use
Battery Jumper
Special Tools
M08015
930E-2 SPINDLE REMOVAL TOOL

Dimension "A" - Bolt Hole Diameter
Dimension "B" - Plate Outside Diameter
Dimension "C" - Bolt Circle Diameter
Dimension "D" - Plate Inside Diameter
Dimension "E" - Plate Thickness
M08015
Dimension "F" - Cylinder Height

Dimension "G" - Cylinder Outer Diameter
Dimension "H" - Cylinder Inner Diameter
Dimension "I" - Cylinder Wall Thickness
NOTE: Surface A-A must be parallel to surface B-B
within 0.062 in. after welding.
Special Tools
M8-5
TABLE 1. PUSHER TOOL DIMENSIONS

Dimension
Description
930E-2
"A"
Plate Bolt
Hole Diameter
1.37 in.
(34.8 mm)
"B"
Plate O.D.
22.75 in.
(577.9 mm)
"C"
Bolt Circle
Diameter
20.38 in.
(517.7 mm)
"D"
Plate I.D.
2.00 in.
(50.8 mm)
"E"
Plate Thickness
1.37 in.
(34.8 mm)
"F"
Pusher
Cylinder Height
5.25 in.
(133.4 mm)
"G"
Pusher
Cylinder O.D.
12.62 in.
(320.6 mm)
"H"
Pusher
Cylinder I.D.
9.00 in.
(228.6 mm)
"I"
Cylinder Wall
Thickness
1.81 in.
(46.0 mm)
M8-6
Refer to Section G, Drive Axle, Spindles, and

Wheels, for information on using the spindle tool to
properly remove the spindles from the machine.
Special Tools
M08015
SECTION M20
PAYLOAD METER III
INDEX
OPERATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5
Data Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5
Data Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
Suspension Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
Operator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Speed Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Body-Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Brake Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-8
Payload Meter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-8
Load Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-8
Wiring and Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
TCI Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
OPERATORS DISPLAY AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Reading the Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Reading the Load Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Using the Operator ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Using the Load and Ton Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Total Ton Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Total Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-11
Clearing the Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-11
Viewing Live Sensor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-11
Other Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-11
PAYLOAD OPERATION & CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-12
Description of Haul Cycle States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-12
Haul Cycle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-12
Load Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-13
M20008 11/03
Payload Meter III
M20-1
Carry Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-13

Measurement Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-13
SOURCES FOR PAYLOAD ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-13
Payload Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-13
Loading Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-14
Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-14
Swingloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-14
Speed and Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-14
HAUL CYCLE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-14
Haul Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-15
Haul Cycle Warning Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-16
M: Haul Cycle Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-17
N: Sensor Input Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-17
Alarm Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-17
Frame Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-17
Sprung Weight Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-18
Maximum Speed Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-18
PC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-18
PC Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-18
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-18
Installing the PLMIII Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-18
DOWNLOADING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-19
PLM III SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-20
Starting Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-20
Displayed Payload Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-20
Time Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-20
Connection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-20
Connecting to the Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-21
Configure the Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-21
Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-21
Setting the Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-22
Setting the Gauge Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-22
Setting the Frame Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-22
Setting the Truck Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-22
Setting the Komatsu Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-22
Setting the Komatsu Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-22
Clean Truck Tare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-23
Inclinometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-23
DATA ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-24
Creating a Query . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-24
M20-2
Payload Meter III
11/03 M20008
Sorting on Truck Unit Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-24

Sorting on Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-24
Sorting on Date Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-25
Sorting on Time Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-25
Payload Detail Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-26
Creating Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-26
Summary - one page report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-27
Detailed - multi-page report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-27
Creating Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-28
Exporting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-28
CSV Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-28
Compressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-29
Importing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-30
Deleting Haul Cycle Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-30
Viewing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-31
Deleting Alarm Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-31
TROUBLESHOOTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-32

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-32
Viewing Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-32
Real-Time Data Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-32
Testing the Payload Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-32
Creating Log Files of Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-33
Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-33
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-33
Abnormal Displays at Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-34
No Payload Display When Keyswitch is Turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-35
No Display on Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-36
No Display on Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-36
No Communications With PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-37
Load Lights Dont Light During Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-38
Load Lights Remain ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-39
Load Lights Remain ON During Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-39
Display Doesn't Clear When The Load Is Dumped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-39
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-40
Alarm 1 - Left Front Pressure High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-41
Alarm 2 - Left Front Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-41
Troubleshoot Wiring to Left Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-41
Alarm 3 - Right Front Pressure High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-42
M20008 11/03
Payload Meter III
M20-3
Alarm 4 - Right Front Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-42

Troubleshoot Wiring to Right Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-42
Alarm 5 -Left Rear Pressure High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-43
Alarm 6 - Left Rear Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-43
Troubleshoot Wiring to Left Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-43
Alarm 7 - Right Rear Pressure High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-44
Alarm 8 - Right Rear Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-44
Troubleshoot Wiring to Right Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-44
Alarm 9 - Inclinometer High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-45
Alarm 10 - Inclinometer Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-45
Troubleshoot Inclinometer Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-45
Alarm 13 - Body Up Input Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-46
Alarm 15 - Memory Write Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-47
Alarm 16 - Memory Read Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-47
Alarm 24 - System Key-On Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-47
Operator Switch Doesn't Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-48
Alarm 26 - User Switch Fault - SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-48
Alarm 27 - User Switch Fault - SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-48
Connector Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-49
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-50
PLMIII CHECK OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-51

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-51
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-51
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-51
PLMIII CHECKOUT PROCEDURE CONFIRMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-55
Flashburn Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-55
Confirmation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-57
PAYLOAD METER III COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20-58
M20-4
Payload Meter III
11/03 M20008
OPERATION SECTION
INTRODUCTION
Payload Meter III (PLMIII) measures, displays and
records the weight of material being carried by an offhighway truck. The system generally consists of a
payload meter, a gauge display, deck-mounted lights,
and sensors. The primary sensors are four suspension pressures and an inclinometer. Other inputs
include a body up signal, brake lock signal, and
speed.
Data Summary
5208 haul cycles can be stored in memory. The following information is recorded for each haul cycle:
Payload
Operator ID number (0000-9999)
Distance traveled loaded and empty
The amount of time spent empty run/stop,
loading, loaded run/stop, and dumping
Data Gathering
Windows 95/98/NT software is available to download, store and view payload and fault information.
The PC software will download an entire truck fleet
into one Paradox database file. Users can query the
database by date, time, truck type and truck number
to produce reports, graphs and export the data. The
software can export the data in '.CSV' format that can
be easily imported into most spreadsheet applications. The Windows software is not compatible with
the Payload Meter II system.
It is important that each payload meter be configured
for each truck using the PC software. The information for frame serial number and truck number is
used by the database program to organize the payload data. In addition, the payload meter must be
configured to make calculations for the proper truck
model. Improper configuration can lead to data loss
and inaccurate payload calculations.
Maximum speed loaded and empty with time of

day
Average speed loaded and empty
Empty carry-back load
Haul-cycle, loading, dumping start time of day.
Peak positive and peak negative frame torque
with time of day
Peak sprung load with time of day
Tire ton-mph for each front and average per rear
tires
The payload meter stores lifetime data that cannot be

erased. This data includes:
Top 5 maximum payloads and time stamps.
Top 5 positive and negative frame torque and
time stamps
Top 5 maximum speeds and time stamps
M20008 11/03
Payload Meter III
M20-5
System Diagram
Suspension Pressure Sensors
Operator Display
PLMIII uses a two-wire pressure sensor. The range

for the pressure sensor is 4000 psi (281 kg/cm2) and
the overload limit is 10,000 psi (700 kg/cm2). One
wire to the sensor is the supply voltage and the other
is the signal. The 0-4000 psi range is converted into
an electrical current between 4-20 ma. The supply
voltage for the sensor is nominally +18vdc. Each
pressure sensor has an 90" length of cable that is
terminated with #10 ring terminals. The cable is specially shielded and reinforced to provide mechanical
strength and electronic noise immunity. A typical part
number for the pressure sensor is PC1578.
The speedometer/display gauge is used as a speedometer and payload display. The top display is used
for speed and can display metric (km/h) or English
(mph) units. Grounding terminal #4 on the back of
the speedometer will switch the meter to display metric units. Leaving terminal #4 unconnected will cause
the gauge to display English units. The speedometer
can be adjusted using a calibration potentiometer in
the back just like existing speedometers.
Inclinometer
The inclinometer is used to increase the accuracy of
load calculations on an incline. The inclinometer
uses three wires. For the sensor, red is the +18vdc
supply voltage, black is ground and the white is the
signal. The incline signal is a voltage between 1 and
4 volts. Zero degrees of incline is represented by
2.6vdc on the signal line. The voltage signal will be
decreased by 0.103vdc for every degree of nose up
incline. A typical part number for the inclinometer
assembly is 7861-92-5330.
M20-6
The payload meter uses the lower display for payload information. The normal display mode shows
the current payload. The display can be changed to
show the load and total tons counter or the Operator
ID. Using the operator switch on the dash panel, the
current suspension pressures and incline can be displayed. The units for display are set using the PC
software. Payloads can be displayed in Short Tons,
Long Tons or Metric Tons. A typical part number for
this gauge is the PC0550.
Payload Meter III
11/03 M20008
Operator Switch
Payload Meter
The payload operator switch is used to set, view and

clear the Total Load Counter and Total Ton Counter.
It is also used to enter the Operator ID number (09999). This switch can also be used to view the suspension pressures and inclinometer. The payload
meter operator switch is located on the dashboard. It
is a two-way momentary switch. The top position is
the SELECT position. The SELECT position is used
step through the different displays. The lower position is the SET position. The SET position is used to
set the Operator ID or clear the load and total ton
counters. Normally the inputs from the switch to the
payload meter are open circuit. The switch momentarily connects the circuit to ground.
The payload meter is housed in a black aluminum

housing. There is a small window on the face of the
unit. Status and active alarm codes can be viewed
through the window. During normal operation, a twodigit display flashes 0 back and forth. Active fault
codes will be displayed for two seconds. These
codes are typically viewed using the laptop computer
connected to the serial communications port.
Speed Input
There is one 40-pin connector on the payload meter.

A jack-screw is used to hold the payload meter and
wire harness connector housings together. This
screw requires a 4mm or 5/32 hex wrench. The correct tightening torque for this screw is 25 lb-in. Four
bolts hold the payload meter housing to its mounting
bracket in the cab.
PLMIII uses a speed signal to calculate speed, distance, and other performance data. This input is critical to the proper operation of the system. PLMIII
receives this signal from the speedometer/operator
display on the dashboard. The same signal displayed to the operator is used by the system. Distance calculations are made based on the rolling
radius of the tires for a particular truck.
The circuit board inside the payload meter housing is

made from multi-layer, dual-sided surface-mount
electronics. There are no field serviceable components inside. The electronics are designed to withstand the harsh operating environment of the mining
industry. Opening the payload meter housing will
result in voiding the warranty.
Body-Up Switch
The payload meter has two RS232 serial communications ports and two CAN ports. Connections for
the two serial ports are available inside the payload
meter junction box. The two CAN ports are available
for future electronics systems.
The Body-Up input signal is received from a magnetic switch located on the inside of the truck frame,
forward the pivot pin of the truck body. This is the
same switch typically used for input to the drive system. When the body is down, the switch closes and
completes the circuit to 71-Control Power. 24vdc
indicates the body is down. Open circuit indicates
that the body is up.
Brake Lock Switch
The brake lock is used to lock the rear brakes on the
truck. It is necessary for the accurate calculation of
swingloads during the loading process. Without the
brake lock applied, the payload meter will not calculate swingloads during the loading process. Without
the brake lock, the payload meter will assume that
the truck was loaded using a continuous loader and
flag the haul cycle record. All other functions will be
normal regardless of brake lock usage. The brake
lock input comes from the switch located on the dash
panel. The brake lock switch connects the circuit to
ground.
Open circuit indicates brake lock off.
Ground indicates brake lock on.
M20008 11/03
Communications Ports
Serial port #1 is used to communicate with the dashboard display. It is also used to connect to the laptop
computer. The display gauge will remain blank when
the PC is using the serial port. This port initially operates with serial settings at 9600,8,N,1. These settings change automatically to increase the
communications rate when the PC is using the port.
This serial port uses a 3-wire hardware connection.
Serial port #2 is used to communicate to other onboard electronics like Modular Mining's Dispatch
system or the Scoreboard from Komatsu. This port
uses a 3-wire hardware connection. Connections to
this serial port need to be approved by Komatsu.
Several protocol options are available and detailed
technical information is available depending on
licensing.
Payload Meter III
M20-7
Keyswitch Input
Load Lights
PLMIII monitors the status of the keyswitch. 24vdc

indicates that the keyswitch is on, open indicates the
keyswitch is off. The payload meter does not receive
its electrical power from the keyswitch circuit. The
payload meter will remain on for several seconds
after keyswitch is removed. When the keyswitch
power is removed, payload meter performs a series
of internal memory operations before turning itself
off. To allow for these operations, the keyswitch
should be turned off for at least 15 seconds before
turning the keyswitch back on. The payload meter
will automatically reset itself without error if not
enough time is given for these operations. The display may blink briefly.
PLMIII uses load lights to indicate to the shovel operator the approximate weight of the material in the
truck. The load lights are illuminated only when the
brake lock is applied. The lights are controlled by the
payload meter through a series of relays in the junction box. The payload meter controls the relays with
24vdc outputs. A 24vdc signal from the payload
meter powers the relay coil and connects battery
power to the load light. When the relay is not powered by the payload meter, a pre-warm resistor connects the load light to a reduced voltage. This circuit
pre-warms the load light filaments and reduces the
inrush current when the light is fully illuminated. This
lengthens the operating life of the load lights.
Payload Meter Power
The load lights progressively indicate to the shovel

operator the approximate weight of the material in
the truck.
The payload meter receives its power from the battery circuit on the truck. Removing battery power
from the payload meter before removing keyswitch
and waiting 15 seconds may result in lost haul cycle
data. The payload meter turns itself off approximately
15 seconds after the keyswitch power is removed.
Some haul cycle data will be lost if battery power is
removed before waiting 15 seconds. The payload
meter system operates at a nominal voltage of 24vdc
at 1 to 2 amps depending on options. The payload
meter is designed to turn itself off if the supply voltage rises above 36vdc. The payload meter is also
protected by a 5 amp circuit breaker located in the
junction box.
Power to the load lights comes from the same battery
circuit. The load lights are powered through a relay.
The keyswitch circuit controls the relay. The load
lights are also protected by a 15 amp circuit breaker
in the junction box.
M20-8
A flashing green light indicates the next swingload

will make the measured load greater than 50% of
rated load. A solid green light indicates that the current load is greater than 50% of rated capacity.
A flashing amber light indicates the next swingload
will make the measured load greater than 90% of
rated load. A solid amber light indicates that the current load is greater than 90% of rated capacity.
A flashing red light indicates the next swingload will
make the measured load greater than 105% of rated
load. A solid red light indicates that the current load
is greater than 105% of rated capacity.
The optimal loading target is a solid green and amber
lights with a flashing red light. This indicates that the
load is between 90% and 105% of rated load for the
truck and the next swingload will load the truck over
105%.
Payload Meter III
11/03 M20008
Wiring and Termination

Most of the PLMIII truck connections use a heavyduty cable. This yellow multi-conductor cable uses a
16awg, finely stranded wire designed for continuous
motion operations. The conductors are protected by
a foil and braided shield for electronic noise immunity
and physical strength. This wire is typically terminated with a #10 ring terminal, part number VH2584.
Most connections for the PLMIII system are made in
the payload meter junction box.
TCI Outputs
The GE drive system on the 930E requires information from the payload meter regarding the loaded
condition of the truck. There are three outputs from
the payload meter to GE to indicate the relative load
in the truck. 24 vdc on the 73MSL circuit indicates
that the load is 70% of rated load. 24 vdc on the
73FSL circuit indicates the truck is 100% loaded.
The 73OSL circuit is not currently used.
M20008 11/03
Payload Meter III
M20-9
OPERATORS DISPLAY AND SWITCH
Using the Operator ID
Reading the Speedometer

The top window of the speedometer/display gauge is
the speedometer section. The display shows the
speed indicated by the frequency being received by
the gauge. This can be adjusted using the potentiometer on the back of the gauge. In addition, the
units for the display can be changed. Terminal #4
controls the displayed units. If #4 is grounded, the
display will be metric. If terminal #4 is left open, the
display will be in English units.
The current Operator ID number is recorded with

each haul cycle. The number can be between 0 and
9999.
To set the Operator ID:
1. Press the SELECT switch until Id= is displayed.
2. Hold the SET button until 0000 is displayed.
The first digit should be flashing.
3. Press the SET button again to change the
digit.
4. Press the SELECT button once to adjust the
second digit.
Reading the Load Display
5. Use the SET button again to change the digit.
The lower display on the speedometer/display gauge

is used for payload information. The SELECT position on the operator switch allows the user to scroll
through a number of useful displays. The order for
the displays is as follows:

third digit.
7. Use the SET button again to change the digit.
fourth digit.
9. Use the SET button again to change the digit
10. Press the SELECT button one more time to

enter the ID.
PL= Payload
Id= Operator ID
tL= Total Shift Tons
LC= Shift Load Counter
LF= Left Front Suspension Pressure
rF= Right Front Suspension Pressure
Lr= Left Rear Suspension Pressure
rr= Right Rear Suspension Pressure
In= Inclinometer
If no buttons are pressed for 30 seconds, the display

will return to normal operation. The number being
entered will be lost and the ID number returns to the
previous ID number.
Using the Load and Ton Counter

PLMIII allows the truck operator to monitor and track
the total tons hauled and the number of haul cycles
during the shift. This display can be cleared at the
beginning of each shift to allow the operator to record
how many loads and tons have been hauled during
the shift.
The display holds the displayed information until the

SELECT switch is pressed again. The suspension
pressures, inclinometer, and payload displays are
based on current sensor inputs.
Communications to the display use the same serial
link as the download connection. Whenever another
computer is connected to serial port #1 to download
or configure the system, the lower display will blank.
This is not the same connection used by mine dispatch systems.
Total Ton Counter

The Total Ton Counter records the number of tons
hauled since the last time it was cleared. This display is in 100s of tons. For example, if the display
432
shows
the total tons is 43,200. This display
can be cleared at the beginning of each shift to allow
the operator to record how many tons have been
hauled during the shift. The units are selected using
the PC software.
To view the Total Ton Counter press and release
the SELECT switch until
the gauge.
M20-10
Payload Meter III
tL= is displayed on
11/03 M20008
Total Load Counter

The Total Load Counter records the number of loads
hauled since the last time it was cleared. This display can be cleared at the beginning of each shift to
allow the operator to record how many loads have
been hauled during the shift.
To view the Total Load Counter press and release
the SELECT switch until
the gauge.
LC= is displayed on
The inclinometer displays whole degrees of incline.

Positive incline is truck nose up. The gauge will
quickly display the type of information shown every
10 seconds. For example, if the left-front pressure is
Lf= will flash on the display every

Only the payload display, PL= does not
being displayed,
minute.
display this information.
Left Front Pressure - To display the pressure in

the left-front suspension, press and release the
SELECT switch until
Clearing the Counters

Clearing the Total Ton Counter or Total Load Counter
clears both records.
Right Front Pressure - To display the pressure in

the right-front suspension, press and release the
SELECT switch until
rf= is displayed.
Left Rear Pressure - To display the pressure in

the left-rear suspension, press and release the
To clear the total ton and total load counter:

1. Press the SELECT switch until
Lf= is displayed.
tL=
SELECT switch until

or
LC= is displayed.
2. Hold the SET button until the display clears.
Lr= is displayed.
Right Rear Pressure - To display the pressure in

the right-rear suspension, press and release the
SELECT switch until
rr= is displayed.
Inclinometer - To display the truck incline, press

and release the SELECT switch until
displayed.
Viewing Live Sensor Data

The display can also be used to quickly show the current readings from the four suspension pressure sensors and the inclinometer. This can be used during
regularly scheduled service periods to check the
state of the suspensions. These displays are live
and will update as the values change.
The live displays cannot be cleared and the SET button will have no effect.
The units for the display are controlled by the configuration of the payload meter. If the payload meter is
set to display metric units, the pressures will be displayed in tenths of kg/cm2. For example, if the display shows
202 the actual value is 20.2 kg/
cm2. If the payload meter is set to display short tons,

the pressures will be displayed in psi (lbs/in2). To
convert from kg/cm2 to psi, multiply by 14.2 1kg/cm2
= 14.2 psi. There is no way to detect the units setting
for the gauge without the PC software.
M20008 11/03
In=
is
Other Display Messages

On startup of the payload meter system, the gauge
display will scroll the truck type that the PLMIII is configured for. For example, on a 930E, the gauge will
scroll,
----930E---.
If the PLMIII encounters memory problems, it will dis-
ER88
play
where 88 is the specific memory
error. In this very rare circumstance, the system
should be turned off for 30 seconds and restarted.
Payload Meter III
M20-11
PAYLOAD OPERATION & CALCULATION

Description of Haul Cycle States
The typical haul cycle can be broken down into eight
distinct stages or states. Each state requires the payload meter to make different calculations and store
different data.
States" or stages of a typical haul cycle
1. Tare Zone
2. Empty
3. Loading
4. Maneuvering
5. Final Zone
6. Hauling
7. Dumping
8. After Dump
Haul Cycle Description

A new haul cycle is started after the load has been
dumped from the previous cycle. The payload meter
will stay in the after_dump state for 10 seconds to
confirm that the load has actually been dumped. If
the current payload is less than 20% of rated load,
the payload meter will switch to the tare_zone and
begin calculating a new empty tare. If, after dumping, the payload has not dropped below 20% of rated
load the meter will return to the maneuvering or hauling states. In this case, the false_body_up flag will
be recorded in the haul cycle record.
While in the tare_zone state, and moving faster than
5 km/h (3 mph), the payload meter calculates the
empty sprung weight of the truck. This tare value will
be subtracted from the loaded sprung weight to calculate the final payload. The payload meter will
switch from the tare_zone or empty to the loading
state if swingloads are detected. By raising the
dump body while in the empty state the payload
meter can be manually switched back to the
tare_zone to calculate a new tare.
From the empty state, the payload meter will switch
to the loading state through one of two means. If the
brake lock is applied, the payload meter will be analyzing the suspension pressures to detect a swingload. If a swingload is detected, the meter will switch
to the loading state. The minimum size for swingload
detection is 10% of rated load. Swingload detection
usually takes 4-6 seconds. The second method to
switch from empty to loading is through continuous
M20-12
loading. This can happen if the brake lock is not

used during loading. If the load increases above
50% of rated load for 10 seconds without the brake
lock applied, the meter will switch to loading and
record the continuous_loading flag in the haul cycle.
The payload meter switches from loading to maneuvering as soon as the truck begins moving. The
maneuvering zone is 160m and is designed to allow
the operator to reposition the truck under the shovel.
More payload can be added anytime within the
maneuvering zone. Once the truck travels 160m (0.1
miles) the payload meter switches to the final_zone
and begins calculating payload. If the body is raised
while the payload meter is in the maneuvering state,
the no_final_load flag will be recorded in the haul
cycle record, no payload will be calculated, and the
meter will switch to the dumping state.
While in the final_zone moving faster than 5 km/h (3
mph), the payload meter calculates the loaded
sprung weight of the truck. The same advanced
algorithm is used to calculate the empty and loaded
sprung weights. The payload meter will switch from
the final_zone to the dumping state if the Body-Up
signal is received. If the truck has moved for less
than 1 minute in the final_zone, the payload meter
will calculate the final payload using an averaging
technique which may be less accurate. If this happens, the average_load flag will be recorded in the
haul cycle.
The payload meter switches to the dumping state
when the dump body rises. The payload meter will
switch from dumping to after_dump when the dump
body comes back down.
From the after_dump, the payload meter will switch
to one of three states:
1. If the average payload is greater than 20% of
rated load and no final payload has been calculated, the payload meter will return to the
maneuvering state. After the truck travels 160m
(0.1 mile) the meter will switch to the final_zone
and attempt to calculate the payload again. The
false_body_up flag will be recorded in the haul
cycle record.
2. If the average payload is greater than 20% of
rated load and the final payload has been calculated, the payload meter will switch back to the
hauling state. The false_body_up flag will be
recorded in the haul cycle record.
3. If the average payload is less than 20% of rated
load, the payload meter will switch to the
tare_zone and begin to calculate a new empty
tare.
Payload Meter III
11/03 M20008
SOURCES FOR PAYLOAD ERROR
Load Calculation
The final load calculation is different from the last
swingload calculation. The accuracy of the swing
load calculation depends on loading conditions and
the position of the truck during loading. The last
swingload calculation is not the value recorded in
memory as the final load. The final load is determined by a series of calculations made while the
truck is traveling to the dump site.
Carry Back
Carry back is calculated as the difference between
the current truck tare and the clean truck tare. The
clean truck tare is calculated using the PC software.
When the suspensions are serviced or changes are
made that may affect the sprung weight of the truck,
a new clean truck tare should be calculated.
Measurement Accuracy
Payload measurements are typically repeatable
within 1%. Accuracy for a particular scale test
depends on specific combinations of pressure sensors and payload meters as well as the specifics of
each scale test. Comparisons from different scale
tests are often made without considering the differences introduced by the specific installation and
operation of the scales for each test. In addition,
each pressure sensor and payload meter introduces
it's own non-linearity. Each truck becomes an individual combination of sensors and payload meter.
Errors from these sources can introduce up to a 7%
bias in the payload meter calculations for a specific
scale test, for an individual truck.
Because the PLMIII calculates a new empty tare for
each payload, a detailed scale test must weigh the
trucks empty and loaded for each haul cycle. Using
a simple average of 2 or 3 empty truck weights as an
empty tare for the entire scale test will introduce significant error when comparing scale weights to
PLMIII weights.
M20008 11/03
Payload Error
The number one source of error in payload calculation is improperly serviced suspensions. The payload meter calculates payload by measuring
differences in the sprung weight of the truck when it
is empty and when it is loaded. The sprung weight is
the weight of the truck supported by the suspensions.
The only method for determining sprung weight is by
measuring the pressure of the nitrogen gas in the
suspensions. If the suspensions are not properly
maintained, the payload meter cannot determine an
accurate value for payload. The two critical factors
are proper oil height and proper nitrogen charge.
If the suspensions are overcharged, the payload
meter will not be able to determine the empty sprung
weight of the truck. The suspension cylinder must be
able to travel up and down as the truck drives empty.
The pressure in an overcharged suspension can
push the suspension rod to full extension. In this
case, the pressure inside the cylinder does not accurately represent the force necessary to support that
portion of the truck.
If the suspensions are undercharged, the payload
meter will not be able to determine the loaded sprung
weight of the truck. The suspension cylinder must be
able to travel up and down as the truck drives loaded.
If the pressure in an undercharged suspension cannot support the load, the suspension will collapse
and make metal-to-metal contact. In this case, the
pressure inside the cylinder does not accurately represent the force necessary to support that portion of
the truck.
Low oil height can also introduce errors by not correctly supporting a loaded truck. This is why the correct oil height and nitrogen charge are the most
critical factors in the measurement of payload. If the
suspensions are not properly maintained, accurate
payload measurement is not possible. In addition,
suspension maintenance is very important to the life
of the truck.
Payload Meter III
M20-13
Loading Conditions
HAUL CYCLE DATA
The final load calculation of the PLMIII system is not

sensitive to loading conditions. The final load is calculated as the truck travels away from the shovel.
Variations in road conditions and slope are compensated for in the complex calculations performed by
the payload meter.
PLMIII records and stores data in its on-board flash

memory. This memory does not require a separate
battery. The data is available through the download
software.
Pressure Sensors
PLMIII can store 512 alarm records in memory.

When the memory is full, the payload meter will
erase the oldest 312 alarm records and continue
recording.
Small variations in sensors can also contribute to

payload calculation error. Every pressure sensor is
slightly different. The accuracy differences of individual sensors along the range from 0 to 4000 psi can
add or subtract from payload measurements. This is
also true of the sensor input circuitry within individual
payload meters. These differences can stack up 7%
in extreme cases. These errors will be consistent
and repeatable for specific combinations of payload
meters and sensors on a particular truck.
Swingloads
Swingload calculations can be affected by conditions
at the loading site. Parking the truck against the
berm or large debris can cause the payload meter to
inaccurately calculate individual swingloads. While
the PLMIII system uses an advanced calculation
algorithms to determine swingloads, loading site conditions can affect the accuracy.
PLMIII can store 5208 payload records. When the

memory is full, the payload meter will erase the oldest 745 payload records and continue recording.
All data is calculated and stored in metric units within

the payload meter. The data is downloaded and
stored in metric units within the Paradox database on
the PC. The analysis program converts units for displays, graphs and reports.
The units noted in the Table 1 are the actual units
stored in the data file. The value for the haul cycle
start time is the number of seconds since January 1,
1970 to the start of the haul cycle. All other event
times are referenced in seconds since the haul cycle
start time. The PC download and analysis program
converts these numbers into dates and times for
graphs and reports.
Speed and Distance

The payload meter receives the same speed signal
as the speedometer. This signal is a frequency that
represents the speed of the truck. The payload
meter uses this frequency to calculate speeds and
distances. The meter assumes a single value for the
rolling radius of the tire. The rolling radius may
change at difference speeds by growing larger at
higher speeds. The actual rolling radius of the tire
will also change between a loaded and empty truck.
The payload meter does not compensate for these
changes.
M20-14
Payload Meter III
11/03 M20008
Haul Cycle Data

The following information is recorded for each haul cycle:
Table 1: HAUL CYCLE DATA

Data
Unit
Remark
Truck #
alphanumeric
Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just the
truck number.
Haul Cycle Start Date/Time
seconds
Number of seconds from 1/1/70 to the start of the haul cycle, haul cycle starts when the meter transitions from dumping to empty state after the previous haul cycle, download program converts seconds
into date and time for display
Payload
tons
Stored as metric, download program allows for conversion to short or long tons.
Number of Swingloads
number
The number of swingloads detected by the payload meter
Operator ID
number
This is a 4 digit number that can be entered by the operator at the start of the shift.
Warning Flags
alpha
Each letter represents a particular warning message about the haul cycle, details are located on page
19.
Carry-back load
tons
The difference between the latest empty tare and the clean truck tare
Empty haul time
seconds
Number of seconds in the tare_zone and empty states with the truck moving
Empty stop time
seconds
Number of seconds in the tare_zone and empty states with the truck stopped
Loading time
seconds
Number of seconds in the loading state
Loaded haul time
seconds
Number of seconds in the maneuvering, final_zone and loaded states with the truck moving
Loaded stop time
seconds
Number of seconds in the maneuvering, final_zone and loaded states with the truck stopped
Dumping time
seconds
Number of seconds in the dumping state
Loading start time
seconds
Number of seconds from the start of the haul cycle to when the meter transitions from empty to loading
state
Dump start time
seconds
Number of seconds from the start of the haul cycle to the time when the meter switches from loaded to
dumping state
Loaded haul distance
Distance traveled while loaded
Empty haul distance
Distance traveled while empty
Loaded max speed
km/h
Maximum speed recorded while the truck is loaded
Loaded max speed time
seconds
Number of seconds from the start of the haul cycle to the time when the max speed occurred
Empty max speed
km/h
Maximum speed recorded while the truck is empty
Empty max speed time
seconds
Number of seconds from the start of the haul cycle to the time when the max speed occurred
Peak positive frame torque
ton-meter
Positive frame torque is measured as the frame twists in the clockwise direction as viewed from the
operators seat.
Peak frame torque time
seconds
Number of seconds from the start of the haul cycle to the peak torque, download program converts to
time for display
Peak negative frame torque
ton-meter
Negative frame torque is measured as the frame twists in the counter-clockwise direction as viewed
from the operator's seat.
Peak frame torque time
seconds
Number of seconds from the start of the haul cycle to the peak torque, download program converts to
time for display
Peak sprung load
tons
Peak dynamic load calculation
Peak sprung load time
seconds
Number of seconds from the start of the haul cycle to the peak instantaneous load calculation
Front-left tire-ton-km/h
t-km/h
Tire ton-km/h for haul cycle
Front-right tire-ton-km/h
t-km/h
Average rear tire-ton-km/h
t-km/h
Truck Frame Serial Number
alpha
The truck serial number from the nameplate on the truck frame
Reserved 1-10
number
These values are internal calculations used in the continued development of the PLMIII system and
should be ignored
M20008 11/03
Payload Meter III
M20-15
Haul Cycle Warning Flags
F: Final Zone to Dumping Transition
The payload meter expects haul cycles to progress in

a particular way. When something unexpected takes
place, the system records a warning flag. Several
events within the haul cycle can cause a warning flag
to be generated. Each one indicates an unusual
occurrence during the haul cycle. They do not necessarily indicate a problem with the payload meter or
payload calculation.
This message is generated when the payload meter

senses a Body-Up while it is calculating the final payload indicating that the operator has dumped the
load. It may also be generated if the Body-Up signal
is not properly reaching the payload meter and the
weight in the truck falls dramatically while the truck is
calculating the final payload.
H: False Body Up
A: Continuous Loading
This message is generated when the truck is loaded
over 50% full without the payload meter sensing
swingloads. This indicates that a continuous loading
operation was used to load the truck. It may also
indicate that the payload meter did not receive the
Brake Lock input while the truck was being loaded.
There may be a problem with the wiring or the Brake
Lock was not used. The payload meter will not measure swingloads unless the Brake Lock is used during the loading process.
B: Loading to Dumping Transition
This message indicates that the body was raised during the haul cycle without the load being dumped.
The Body-Up signal indicated that the truck was
dumping, but the weight of the truck did not fall below
20% of the rated load.
I: Body Up Signal Failed
This message indicates that the load was dumped
without a Body-Up signal being received by the payload meter. The weight of the truck fell below 20%,
but the payload meter did not receive a Body-Up signal from the sensor.

senses a body up input during the loading process.
This message is usually accompanied by a
no_final_load flag.
J: Speed Sensor Failed
C: No Final Load
K: New Tare Not Calculated

is unable to determine the final payload in the truck.
Typically, this means that the payload meter switched
from a loaded state to the dumping state before the
load could be accurately measured.
The payload meter was not able to accurately calculate a new empty sprung weight for the truck to use
as the tare value for the haul cycle. The tare value
from the last haul cycle was used to calculate payload.
D: Maneuvering to Dumping Transition
L: Incomplete Haul Cycle

senses a Body-Up input during the maneuvering or
repositioning process indicating that the operator has
dumped the load. It may also be generated if the
Body-Up signal is not properly reaching the payload
meter and the weight in the truck falls dramatically
while the truck is maneuvering or repositioning.
The payload meter did not have proper data to start

the haul cycle with after powering up. When the
PLMIII powers off, it records the data from the haul
cycle in progress into memory. This flag indicates
that this data was not recorded the last time the payload meter was shut down. This can happen when
the main battery disconnect is used to shut the truck
down instead of the keyswitch. A haul cycle with this
warning flag should not be considered accurate. Haul
cycles with this warning are displayed in red on the
Payload Summary window and are not included in
the summary statistics for reports or display.
E: Average Load or Tare Used

This message indicates that the recorded payload
may not be as accurate as a typical final load calculation. Typically, this is recorded when loading begins
before an accurate tare is calculated or the load is
dumped before the load can be accurately measured.
M20-16
This message indicates that the payload meter

sensed the truck loading and dumping without
receiving a speed signal.
Payload Meter III
11/03 M20008
M: Haul Cycle Too Long
Alarm Records
The haul_cycle_too_long flag indicates that the haul

cycle took longer than 18.2 hours to complete. The
times stored for particular events may not be accurate. This does not affect the payload calculation.
The payload meter stores alarm records to give service personnel a working history of the system. All
codes are viewed using the PC connected to the
payload meter. Active codes are also displayed on
the two-digit display on the meter itself. Each code
has a specific cause and should lead to an investigation for correction. Some failures can be overcome
by the payload meter. Haul cycle data will indicate if
an alarm condition was present during the cycle.
Failures with the suspension or inclinometer sensors
cannot be overcome.
N: Sensor Input Error

An alarm was set for one of the 5 critical sensor
inputs during the haul cycle. The five critical sensors
are the four pressure sensors and the inclinometer.
Without these inputs, the payload meter cannot calculate payload. A haul cycle with this warning flag
should not be considered accurate. Haul cycles with
this warning are displayed in red on the Payload
Summary window and are not included in the summary statistics for reports or display.
Table 2: FAULT CODE DATA

Fault Code
Name
Description
Left front pressure high
Input current > 22 ma
Left front pressure low
Input current < 2 ma
Right front pressure high
Right front pressure low
Left rear pressure high
Left rear pressure low
Right rear pressure high
Right rear pressure low
Inclinometer high
Input voltage < 0.565 vdc
10
Inclinometer low
Input voltage > 5.08 vdc
13
Body-up input failure
Payload meter detected dumping activity without receiving a body up signal
16
Memory write failure
Indicates possible memory problem at power start up. Cycle power and recheck.
17
Memory read failure
Indicates possible memory problem at power start up. Cycle power and recheck.
24
System key-on status
Payload Meter failed to correctly start at power up. Cycle power and recheck.
26
User switch fault - SELECT
Select switch on for more than 2 minutes, may indicate short to ground
27
User switch fault - SET
Set switch on for more than 2 minutes, may indicate short to ground
Frame Torque Data

Payload meter records the top 5 peak positive and
negative frame torque values and the time they
occurred. The frame torque is a measure of the
twisting action along the centerline of the truck. Positive frame torque is measured when the suspension
forces on the front of the truck act to twist the frame
in the clockwise direction as viewed from the operator's seat. Negative frame torque is measured when
the forces from the suspensions act in the opposite
direction.
M20008 11/03
For example, if the left front and right rear pressure

rises as the right front and left rear pressure drops,
the truck frame experiences a twisting motion along
the longitudinal centerline. In this case, the payload
meter will record a positive frame torque.
The 5 highest values in the positive and negative
direction are stored in permanent memory within the
payload meter.
Payload Meter III
M20-17
Sprung Weight Data
System Configuration
The payload meter is constantly monitoring the live

payload calculation. This value naturally rises and
falls for a loaded truck depending on road and driving
conditions. The payload meter records the top 5
highest payload calculations and the time they
occurred. This information is stored in permanent
memory inside the meter.
PLMIII needs to be configured for operation when it

is first installed on the truck. This process requires
several steps and uses the laptop computer to make
the necessary settings. The setup procedure can be
broken down into several steps:
Connecting the laptop to the PLMIII system.

Starting communications
Maximum Speed Data
Setting the time & date
The payload meter records the top 5 highest speeds

and the time they occurred. This information is
stored in permanent memory inside the meter.
Setting the truck type

Setting the truck ID
Setting the speedometer/display gauge units
PC SOFTWARE OVERVIEW
Installing the PLMIII Software
PC Overview
The CD ROM containing the Payload Data Management (PDM) Software will automatically begin installation when it is inserted into the drive on the PC. If
this does not happen, the software can be installed
by running the Setup.exe program on the CD ROM.
The PC software has several basic functions:

Configure the PLMIII system on the truck.
Troubleshoot and check the PLMIII system.
Download data from the PLMIII system.
Analyze data from the payload systems.
Configuration, troubleshooting and downloading

require a serial connection to the payload meter on
the truck. Analysis can be done at any time without a
connection to the payload meter.
Payload data is downloaded from several trucks into
one database on the PC. The database can be queried to look at the entire fleet, one truck or truck
model. The data can be graphed, reported, imported
or exported. The export feature can take payload
data and save it in a format that spreadsheet programs like Excel or word processing programs can
easily import.
M20-18
The minimum PC requirements for running the software is a Pentium 133Mhz with 64 MB of ram and at
least 300 MB of free hard drive space available. For
improved performance, the recommended PC would
be a Celeron, AMD K6-2 or better processor with 128
MB of ram running at 400 Mhz. The PDM Software
uses a powerful database to manipulate the large
amounts of data gathered from the PLMIII system.
Using a more powerful computer and added memory
to run the software can result in a significant improvement in performance. The software is written to use
a minimum 800x600 screen resolution.
Payload Meter III
11/03 M20008
DOWNLOADING DATA
PLMIII records many types of data. The PLMIII PC
software is designed to download the data from a
whole truck fleet. Instead of creating one data file for
each truck, the PC software combines all the data
from many trucks into one database on the hard
drive of the computer. The software then allows
users to query the database to create custom reports
and graphs. Data for individual trucks or groups of
trucks can be easily analyzed. This same data can
be exported for use in other software applications like
word processors and spreadsheet applications.
As the database grows, performance of the PC software for analysis will slow down. It may be helpful to
periodically export data. For example, query the
database to show the oldest quarter, month, or half
year and print out a summary report. Then export
the data to a compressed format and save the file in
a secure location. Once the data is exported, delete
the entire query results from the database. If necessary, the data can easily be imported back into the
main database for analysis at a future date. Removing this older data will improve performance.
To download the payload meter:

1. Connect to the payload meter and start the PC
software.
2. From the main menu, select "Connect to Payload Meter". The PC will request the latest status information from the payload meter. The
number of haul cycles and alarms will be displayed.
3. Select the " Begin Download" button. The PC
will request the payload and alarm data from the
payload meter and save it into the database.
This may take several minutes. A progress bar
at the bottom will show the approximate time
left.
The PC software downloads the data from the payload meter into a single Paradox database. The data
from all the trucks is added to the same database.
Downloading the payload meter can take several
minutes. The data is added to the database on the
laptop used to download.
To move the data to another computer, a query must
be run to isolate the particular data for export. Do not
press the operator switch on the dashboard while
downloading
M20008 11/03
Payload Meter III
M20-19
PLM III SYSTEM CONFIGURATION
Short Tons: Payload is displayed in short tons, distances and speeds will be displayed in Miles
Starting Communications
The PDM software allows users to download and
configure the system.
Metric Tons: Payload is displayed in metric tons, distances and speeds are displayed in Kilometers
Long Tons: Payload is displayed in long tons, distances and speeds are displayed in Miles
Time Units
Minutes and Seconds Example:
Five minutes and thirty-two seconds = 5:32
Decimal Minutes Example:
Five minutes and thirty-two seconds = 5.53
Connection Menu
Before connecting to the payload meter, select

"Change Program Options" and confirm that the program has selected the correct laptop serial port.
Most laptops use Comm 1 for serial communications.
The units displayed for reports and graphs by the PC
software can be set on this form. Click Done to
return to the main menu.
The connection screen displays basic system information to the user.
From the main menu, click the "Connect to Payload

Meter" button. The PC will try to connect to the payload meter and request basic information from the
system. In the event of communications trouble, the
PC will try 3 times to connect before "timing-out".
This may take several seconds.
Displayed Payload Units
Three options are available for the display of units in
the PC software, reports, and graphs:
Frame S/N should agree with the truck serial

number from the serial plate located on the truck
frame.
Truck Number is an ID number assigned to the
truck by the mine.
The Payload Meter Date / Time values come
from the payload meter at the moment of
connection.
Number of Haul Cycle Records is the number of
haul cycles records stored in memory and
available for download.
Number of Active Alarms shows how many
alarms are currently active in the system at the
time of connection. If there are active alarms, the
"Display Active Alarms" button is available.
Number of Inactive Alarms shows how many
alarms have been recorded in memory and are
available for download.
PLM Software Version displays the current
version of software in the payload meter.
The information on the connection menu comes from
the configuration of the payload system on the truck.
M20-20
Payload Meter III
11/03 M20008
There are also many configuration and download

options available from this screen. The Connection
Menu is updated only when the connection is first
made. It does not update automatically. To view
changes made while connected, the user must close
the window and reconnect to the payload meter.
The connection menu is displayed after a serial connection has been established and the PC software
has connected to the payload meter.
Setting the Date and Time
The time shown on the form is the time transmitted

from the payload when the connection was first
established.
Connecting to the Payload Meter

Communications to the PLMIII requires a laptop
computer running the PDM software. The software
connects to the payload meter through the meter's
serial port #1. This is the same port used by the
speedometer/display gauge. When the laptop is
using the serial port, the lower display on the operator gauge on the dashboard will be blank. This does
not affect the operation of the speedometer.
Connect the laptop to the system using the
EF9160 communications harness. The download
connector is typically located on the housing
mounted in the cab to the back wall. The PLMIII
system uses the same connection as the
Payload Meter II system.
Configure the Payload Meter
Configuration of the payload meter requires a serial
connection to the PLMIII system. Clicking the "Configure Payload Meter" button will bring up the Truck
Configuration screen and menu. This screen displays the latest configuration information stored on
the payload meter.
When changes are made to the configuration, the
"Save Changes" button must be pressed to save the
changes into the payload meter. To confirm the
changes, exit to the main menu and re-connect to the
payload meter.
The date and time are maintained by a special chip

on the PLMIII circuit board. The memory for this chip
is maintained by a very large capacitor when the
power is removed from the payload meter. This will
maintain the date and time settings for approximately
30 days. After this time, it is possible for the payload
meter to lose the date and time setting. It is recommended that the system be powered every 20 days
to maintain the date and time. If the date and time is
lost, simply reset the information using this procedure. It takes approximately 90 minutes to recharge
the capacitor.
Changing the date and time will affect the haul cycle
in progress and may produce unexpected results in
the statistical information for that one haul cycle.
To change the time:
1. Click on the digit that needs to be changed.
2. Use the up/down arrows to change or type in
the correct value.
3. Press the "Save Changes" button to save the
new time in the payload meter.
To change the date:
1. Click on the digit that needs to be changed.
2. Type in the correct value or use the pull-down
calendar to select a date.
3. Press the "Save Changes" button to save the
new time in the payload meter.
M20008 11/03
Payload Meter III
M20-21
Setting the Truck Number
Setting the Truck Type
1. From the Truck Configuration screen, use the

pull-down menu to select the truck type that the
payload meter is installed on.
2. Press the "Save Changes" button to program
the change into the meter.
Most mining operations assign a number to each

piece of equipment for quick identification. This number or name can be entered in the Truck Number
field. It is very important to enter a unique truck number for each truck using the PLMIII system. This
number is one of the key fields used within the haul
cycle database. The field will hold 20 alpha-numeric
characters.
1. On the Truck Configuration screen, enter the

truck number in the appropriate field.
Setting the Gauge Display Units

The Payload Meter Speedometer / Display Gauge
displays the speed on the upper display. The units
for the speed display are selected using a jumper on
the rear of the case.
The payload units on the lower display can be
changed from metric to short tons or long tons using
the Truck Configuration screen. This selection also
switches between metric (kg/cm2) and psi (lbs/in2) for
the live display of pressure on the gauge.
1. From the Truck Configuration screen, select the
payload units to be used on the lower display of
the speedometer/display gauge.
the change into the payload meter.
Setting the Frame Serial Number

Setting the Komatsu Distributor

This field in the haul cycle record can hold the name
of the Komatsu distributor that helped install the system. Komatsu also assigns a distributor number to
each distributor. This number is used on all warranty
claims. This Komatsu distributor number can also be
put into this field. The field will hold 20 alphanumeric characters.

distributor name or number in the appropriate
field.
Setting the Komatsu Customer
The frame serial number is located on the plate

mounted to the truck frame. The plate is outboard on
the lower right rail facing the right front tire. It is very
important to enter the correct frame serial number.
This number is one of the key fields used within the
haul cycle database. The field will hold 20 alphanumeric characters.
truck frame serial number in the appropriate
field.
M20-22
This field in the haul cycle record can hold the name
of the mine or operation where the truck is in service.
Komatsu also assigns a customer number to each
customer. This number is used on all warranty
claims. This Komatsu customer number can also be
put into this field. The field will hold 20 alphanumeric characters.

customer name or number in the appropriate
field.
Payload Meter III
11/03 M20008
Inclinometer Calibration
Clean Truck Tare
The payload meter uses the clean truck tare value to

calculate carry-back load for each haul cycle. The
carry-back stored in the haul cycle record is the new
empty tare minus the clean truck tare.
This procedure should be performed after service to
the suspensions or when significant changes are
made to the sprung weight of the truck. Before performing this procedure, be sure the suspensions are
properly filled with oil and charged. It is critical to
payload measurement that the proper oil height and
gas pressure be used.
Once the clean tare process is started, the payload
meter will begin to calculate the clean empty sprung
weight of the truck. This calculation continues while
the truck drives to the next loading site. Once the
procedure is started, there is no reason to continue
to monitor the process with the PC. The truck does
not need to be moving to start this procedure.
1. After cleaning debris from the truck and checking to see that the suspensions are properly
serviced, use the PLMIII software to connect to
the payload meter.
2. From the "Truck Configuration" screen, select
"Clean Truck Tare".
3. Be sure to follow the screen instructions.
M20008 11/03
The inclinometer calibration procedure is designed to

compensate for variations in the mounting attitude of
the inclinometer. The inclinometer input is critical to
the payload calculation.
This procedure should be performed on relatively flat
ground. Often the maintenance area is an ideal location for this procedure.
1. After cleaning debris from the truck and checking to see that the suspensions are properly
serviced, use the PLMIII software to connect to
the payload meter.
2. From the "Truck Configuration" screen, select
"Inclinometer".
3. With the truck stopped and the brake lock on,
press the Start button. This instructs the payload meter to sample the inclinometer once.
4. Turn the truck around. Drive the truck around
and park in the exact same spot as before, facing the other direction.
5. With the truck stopped and the brake lock on,
press the Start button. This instructs the payload meter to sample the inclinometer again.
The payload meter will average the two samples to determine the average offset.
6. Be sure to follow the screen instructions.
Payload Meter III
M20-23
DATA ANALYSIS
PAYLOAD SUMMARY FORM
The data analysis tools allow the user to monitor the

performance of the payload systems across the fleet.
Analysis begins when the "View Payload Data" button is pressed. This starts an "all trucks, all dates, all
times" query of the database and displays the results
in the Payload Summary Form.
The user can change the query by changing the
dates, times, or trucks to include in the query for display.
Haul cycles in the data grid box at the bottom can be
double-clicked to display the detailed results of that
haul.
Sorting on Truck Unit Number

The truck unit number is the truck unit number
entered into the payload meter when it was configured at installation. The query can be set to look for
all trucks or one particular truck number. When the
program begins, it searches through the database for
all the unique truck numbers and creates a list to
select from.
Choosing one particular truck number will limit the
data in the displays, summaries and reports to the
one selected truck. To create reports for truck number 374, select 374 from the pull-down menu and hit
the "Query Database and Display" button.
Creating a Query
The program defaults to show all trucks, all types, all
dates and all times for the initial query. The display
can be narrowed by selecting which trucks or types
to view and for what dates and times.
The query items are added in the "AND" condition. If
the user selects a truck # and date range, the query
will sort the data for that truck number AND the date
range.
M20-24
Sorting on Truck Type

The truck type is the size of the truck from the family
of Komatsu trucks. This allows the user to quickly
view results from different types of trucks on the
property. For example, a separate report can be
generated for 830E and 930E trucks.
Payload Meter III
11/03 M20008
2. Change the From date to July 1, 2000.
Sorting on Date Range

The default query starts in 1995 and runs through the
current date on the PC. To narrow the range to a
specific date, change the From and To dates.
For example, to view the haul cycle reports from
truck 374 for the month of July, 2000:
1. Select truck 374 from the Truck Unit pull-down
menu.
3. Change the To date to July 31, 2000.

4. Change the From time to 06:00.
5. Change the To time to 18:00.
6. Press the "Query Database and Display" to

view the results.
2. Change the From date to July 1, 2000.
This query will display haul cycles from January 5 to

January 8, from 6:00 AM to 6:00 PM.
Date
Time
Jan 5, 2000
Jan 6, 2000
Jan 7, 2000
Jan 8, 2000
Jan 9, 2000
0:00
6:00
3. Change the To date to July 31, 2000.

4. Press the "Query Database and Display" to
view the results.
12:00
Sorting on Time Range

The time range sorts the times of the day for valid
dates. Changing the time range to 6:00AM to
6:00PM will limit the payloads displayed to the loads
that occurred between those times for each day of
the date range. Times are entered in 24:00 format.
To view the haul cycle reports from the first shift for
truck 374 from January 5, 2000 to January 8, 2000:
1. Select truck 374 from the Truck Unit pull-down

menu.
M20008 11/03
18:00
24:00
Query : Date: 1/5/00 to 1/8/00
Daily Shift Time: 6:00 to 18:00
Haul Cycles Included in the Query
The shift times selected can extend the query past

the original date. If the dates set for the query are
January 5 to January 8 and the times were changed
to query the 6:00 PM (18:00) to 6:00 AM (06:00) shift,
the results would extend into the morning of the 9th.
This can been seen in the following example:
Payload Meter III
M20-25
Creating Reports
Date
Time
Jan 5, 2000
Jan 6, 2000
Jan 7, 2000
Jan 8, 2000
Jan 9, 2000
0:00
6:00
Reports can be generated and viewed on the screen

or printed. These reports are generated from the
query displayed on the Payload Summary Screen.
From the example in "Sorting on Time Range", the
report printed would only contain data from truck 374
during the month of July 2000, from 8:00 AM to 5:00
PM.
12:00
It is important to carefully select the query data and

press the "Query Database & Display" button before
printing a report.
18:00
24:00
Query : Date: 1/5/00 to 1/8/00
Daily Shift Time: 18:00 to 6:00
Haul Cycles Included in the Query
Payload Detail Screen

The Payload Detail screen gives the details for any
individual haul cycle. From the Payload Summary
screen, double-click on any haul cycle to display the
detail.
M20-26
Payload Meter III
11/03 M20008
NOTE: Some haul cycles may contain the Sensor

Input warning flag. This indicates that one of the four
pressure sensors or inclinometer was not functioning
properly during the haul cycle. Haul cycles with this
warning are displayed in red on the Payload
Summary window and are not included in the
summary statistics for reports or display.
Summary - one page report
A summary of the queried data can be printed onto 1
page. The cycle data is summarized onto one sheet.
Displayed is the speeds, cycle times, load statistics,
frame and tire data.
Detailed - multi-page report

The detail report starts with the summary report and
follows with pages of data for each haul cycle. The
detailed report prints date, time, payload, cycle times,
and cycle distances, speeds and the number of swing
loads.
M20008 11/03
Payload Meter III
M20-27
Exporting Data
Creating Graphs
The PLMIII software can generate graphs that
quickly summarize payload data. These graphs can
be customized for printing. Just like the reports, the
graphs are generated from the query displayed on
the Payload Summary screen. From the "Sorting
on Time Range" example, the graph that is printed
would only contain data from truck 374 during the
month of July 2000, from 8:00 AM to 5:00 PM.
It is important to carefully select the query data and
press the "Query Database & Display" button before
creating a graph.
1. From the Payload Summary Screen select the
Graph button at the bottom. The Histogram
Setup screen will display
The data from the database can be exported for use

with other software applications.
The data is
selected from the currently displayed query. The
exported data can be put into a ".CSV" file or a compressed ".zip" file.
The .CSV format allows data to be easily

imported into spreadsheet applications and word
processing applications.
The .Zip format allows data to be transferred
from one computer to the PDM Software
database on another computer. This offers a
compact way to transfer data from one computer
to another.
CSV Export
2. Enter the "Lowest Value". This will be the lowest payload on the graph. Any payloads less
than this value will be summed in the first bar.
3. Enter the "Highest Value". This will be the highest value on the graph. Payloads over this
value will be summed in the last bar.
4. Enter the "Incremental Change". This will
determine the number of bars and the distance
between them. The program limits the number
of bars to 20. This allows graphs to fit on the
screen and print onto 1 page.
5. Press the Create Graph button.
The graph will be displayed based on the query settings from the Payload Summary screen. The graph
can be customized and printed.
M20-28
CSV stands for Comma Separated Value. This is an

ASCII text file format that allows spreadsheet applications like Excel and Lotus 123 to import data easily. To export the data into a ".csv" file, press the
"Export" button at the bottom of the payload sumary
screen and select "To CSV". The program will
request a filename and location for the file.
Payload Meter III
11/03 M20008
Reserved 1-5, 7-10: These values are internal

calculations used in the continued development
of PLMIII and should be ignored.
Reserved 6: This value is the payload estimate
at the shovel just before the truck begins to
move.
Two sets of data are exported. At the top of the file

will be the haul cycle data. The columns, left to right
are:
Truck number
Haul cycle start date
Haul cycle start time
Payload
Swingloads
Operator ID
Warning Flags
Carry Back
Total Haul Cycle time
Empty Running Time
Empty stop time
Loading time
Loaded running time
Loaded stopped time
Dumping time
Loading start time
Dumping start time
Loaded haul distance
Empty haul distance
Loaded maximum speed
Time when loaded maximum speed occurred
Empty maximum speed
Time when loaded maximum speed occurred
Maximum + frame torque
Time when the maximum + frame torque
occurred
Maximum - frame torque
Time when the maximum - frame torque
occurred
Maximum sprung weight calculation
Time when the maximum sprung weight
calculation occurred
Left Front Tire-kilometer-hour
Right Front Tire-kilometer-hour
Average Rear Tire-kilometer-hour
Frame serial number
M20008 11/03
The second series of data below the haul cycle data

is the alarms. The alarm columns, left to right are:
The alarm type

The date the alarm was set
The time the alarm was set
Alarm description
The date the alarm was cleared
The time the alarm was cleared
Compressed
This export function allows the data from one laptop

to be transferred to another computer. This can be
useful when a service laptop is used to download
multiple machines and transfer the data to a central
computer for analysis. This can also be used to copy
haul data from a particular truck onto a diskette for
analysis.
The file format is a compressed binary form of the
displayed query. The file can only be imported by
another computer running the PDM Software.
Payload Meter III
M20-29
Deleting Haul Cycle Records
To export data in ZIP format:

1. Confirm that the data displayed is the query
data that needs to be exported.
2. From the payload summary screen, press the
"EXPORT" button and select "To ZIP".
3. The program will ask for a filename and location.
Importing Data
This import function allows the data from one laptop
to be transferred to another computer. This can be
useful when a service laptop is used to download
multiple machines and transfer the data to a central
computer for analysis. This can also be used to copy
haul data from a particular truck from a diskette into a
database for analysis.
To import data, press the "IMPORT" button at the
bottom of the Payload Summary screen. The program will ask for a ".zip" file to import, locate the file
and press "Open". The program will only import
".zip" files created by another computer running the
PDM Software.
M20-30
To delete haul cycle records from the main database,

press the "Delete" button at the bottom of the Payload Summary screen. The program will display a
summary of the records from the displayed query. To
delete a record, select one at a time and press the
"Delete" button. It is recommended that records be
exported to a zip file for archival purposes before
deletion. Multiple records may be selected by holding down the Shift key. Pressing the "Delete All" button will select all the records from the current query
and delete them.
NOTE: There is no recovery for records that have

been deleted from the main database. It is highly
recommended that all records be exported and
archived in a compressed file format for future
reference before being deleted.
Payload Meter III
11/03 M20008
Viewing Alarms
From the Payload Summary screen, click the
Alarms button to display the alarm screen. The
alarms are sorted by the query settings from the Payload Summary screen. Alarms can be displayed as
Active or Inactive.
Deleting Alarm Records

To delete alarm records from the main database,
press the "Delete" button at the bottom of the Alarm
Display screen. The program will display a summary of the alarms from the query. To delete an
alarm, select one at a time and press the "Delete"
button. It is recommended that the query data be
exported to a .zip file for archival purposes before
deletion. Multiple records may be selected by holding down the Shift key. Pressing the "Delete All" button will select all the alarms from the current query
and delete them.
NOTE: There is no recovery for alarms that have

been deleted from the main database. It is highly
recommended that all records be exported and
archived in a compressed file format for future
reference before being deleted.
M20008 11/03
Payload Meter III
M20-31
TROUBLESHOOTING SECTION
TROUBLESHOOTING
Real-Time Data Display
Troubleshooting the PLMIII system is done through

the PC software you can:
View active alarms.

View the sensor inputs using the Real-Time Data
Display.
Test the payload lights.
Create log files of sensor inputs for further analysis.
These activities require a connecion to the
PLMIII system.
Viewing Active Alarms

Active alarms are alarms that have been set, but not
yet cleared. Each alarm is set when the conditions
for activation are held for 5 seconds. Each alarm is
cleared when the condition has been returned to normal range for 5 seconds. For example, 5 seconds
after the left-rear pressure sensor is disconnected,
the LR-Pressure Lo alarm will be activated. This can
be viewed using to the "Connect to Payload Meter"
screen. 5 seconds after the pressure sensor is reconnected, the alarm will clear and be recorded in
memory.
Active alarms are recorded in memory as "cleared"
when the keyswitch is turned off. When power is
restored to the payload meter, the alarms will be reactivated if the conditions still exist for 5 seconds.
To view active alarms:
software.
2. From the main menu, select "Connect to Payload Meter". The PC will request the latest status information from the payload meter.
3. If there are active alarms, the "Display Active
Alarms" button in the lower left corner will be
available. If the button is not available, there
are no active alarms at the time of connection.
The screen does not automatically refresh. If a
condition changes to cause an alarm, the user
must exit and re-enter the "Connect to Payload
Meter" screen.
The PC software can be used to view the 'live' input

readings from the payload meter. The numbers displayed are 1-second averages.
software.
3. Select the "Real Time Data" button. The data
screen will pop up. The PC will request the payload meter to begin transmitting data.
4. To exit, press the Close button.
The units for each measurement are determined by
the setting in the Program Options for the PC software. The four suspension pressures and inclinometer are shown. The status of the Body-Up and BrakeLock inputs is also shown. The haul cycle state and
speed is displayed. The current sprung weight is displayed. This differs from pure payload. The sprung
weight is a measurement of the weight of the truck
above the suspension. It does not include the tires,
spindles, wheel motors, drive case, or anything
below the suspensions.
Testing the Payload Lights
The real time data display also allows the user to
individually power the payload lights. This can be
useful for testing the lights. To turn on a particular
color payload light:
1. Click the check box beside the color light to
power.
2. Press the "Set Lights" button to turn on the light.
3. Uncheck the box and press "Set Lights" to turn
off the light.
The lights will return to their normal state when the
real time data display is closed.
M20-32
Payload Meter III
11/03 M20008
Creating Log Files of Inputs
Daily Inspections
The PC software can create a text file of the live data

stream from the payload meter. This can be very
useful for diagnostic purposes. The data is written
into a text data file in comma separated value format.
The data is recorded in metric units at 50 samples
per second. The data file can grow large very
quickly. Each sample writes one line into the ASCII
file in comma separated format.
An important part of maintaining the Payload Meter

III (PLMIII) system is monitoring the basic inputs to
the system. It is recommended that the truck operator walk around the truck and visually inspect the following:
Charging condition of the suspensions - not flat,
not overcharged.
Pressures in the suspensions - check
suspensions by using the operator gauge and the
operator switch.
The order for each line of data in is:

Date
Time
Sprung Weight
LF Pressure
RF Pressure
LR Pressure
RR Pressure
Incline
Speed
Body Up State (1=up)
Brake Lock State (1=on)
Payload State
Status Flags
Spare
Periodic Maintenance
It is recommended that the following items be
checked every 500 hours:
Confirm the suspension pressures using external
gauges.
Confirm proper suspension height.
Confirm suspensions do not collapse and make
metal-to-metal contact when the truck is loaded.
Confirm that inclinometer indicates positive (+)
values for truck nose up, and negative (-) values
for truck nose down.
To create a log file:

software.
3. Select the "Real Time Data" button. The real
time data screen will pop up. The PC will
request the payload meter to begin transmitting
data.
In addition, it may be useful to confirm proper operation of the suspensions by riding the truck during a
complete haul cycle. Record the suspension pressures using the CSV log file tool in the Payload Data
Manager software for the PC. The suspension pressures in this log file can be graphed to inspect for flat
or overcharged suspensions.
4. Click the "Set File Name" button and enter a

name and location for the text file. The default
extension is ".txt". This data can be easily
imported into spreadsheets as a comma separated value (.CSV) format.
5. Once the filename has been entered, the Start
Log and Stop Log buttons will be active.
6. Press the Start Log button to start taking data
and recording into the file. Once a file is
started, it cannot be stopped and started again.
7. Press the Stop Log button to stop recording
data. Attempting to start the log file again will
overwrite the previous file and erase the previous data. To gather more data, close the real
time data window, start it again and create a
new log file.
M20008 11/03
Payload Meter III
M20-33
Abnormal Displays at Power-Up

The payload meter performs several internal memory system checks every time it powers-up. In case of error, the
operator gauge may display an error code when power is applied to the PLMIII system.
Er:01 - Bad Truck Configuration error indicates that the meter encountered an error while reading the current truck
configuration record from memory.
Er:02 - Bad Calibration Record error indicates that the meter encountered an error while passing messages
between the microprocessors on the circuit board.
Er:03 - Interprocessor Communications error indicates that the meter encountered an error while passing messages between the microprocessors on the circuit board.
To resolve these errors:
If these errors persist after reprogramming, the primary and secondary processors then the payload meter
must be replaced.
M20-34
Payload Meter III
11/03 M20008
No Payload Display When Keyswitch is Turned ON

Confirm battery voltage in PLMIII junction box between TB45-A (positive) and TB45-X (ground).
Check the 5A circuit breaker (CB A) in PLMIII junction box.
Check all connectors and terminal connectors in the power circuits to the payload meter.
If two digit display on payload meter displays 00 then 88 on power up, continue to No Display on Operator
Display. This two digit display normally alternates 0 on each display. In the case of active alarms, this display
will show the code for each active alarm. The alarm codes are in the operation section.
M20008 11/03
Payload Meter III
M20-35
No Display on Speedometer
No Display on Operator Display
If the speedometer works but the operator displays remain blank, confirm payload connections at No Payload
Display When Keyswitch is Turned ON.
M20-36
Payload Meter III
11/03 M20008
No Communications With PC
In a case where the laptop PC will not properly connect to the PLMIII system:
Confirm power to the payload meter.
Confirm laptop serial port setting using the PC software. From the mail menu select "Change Program
Options". Confirm that the selected serial port is correct and that it is available.
Confirm that a Personal Digital Assistants (PDA) synchronization software is not using the serial port. Often,
PDA software like Palm Pilots HotSync software will take control of the serial port and not let other applications
use the serial connection. Close the synchronization software and retry the Payload Data Manager software.
Confirm Operator Switch use. If this switch works properly, it confirms that the communications wiring between
the payload meter and the junction box is functional.
Before the beginning of troubleshooting, turn keyswitch OFF. Wait 1 minute and turn keyswitch ON.
M20008 11/03
Payload Meter III
M20-37
Load Lights Dont Light During Loading

Confirm that the truck operator uses the Brake Lock / Neutral" switch during loading. Without this input, the
payload meter will not properly recognize swingloads.
Confirm bulbs in payload lights by using lamp check mode.
Confirm 15 A breaker CB-B in payload junction box.
To continue troubleshooting, turn on all the payload lights using the lamp check mode of the Payload Data
Manager software.
M20-38
Payload Meter III
11/03 M20008
Load Lights Remain ON

Load Lights Remain ON During Dumping
Display Doesn't Clear When The Load Is Dumped
Confirm the Body Up switch signal. When the Body Up signal is not properly received during dumping, the
payload meter may maintain the lights after the body is lowered.
Confirm the payload light wiring using the procedures in "Load Lights Don't Light During Loading".
M20008 11/03
Payload Meter III
M20-39
Calibration Problems
Confirm that the truck is empty and clean.
Confirm that the payload meter is in the proper haul state. The payload meter must be in the empty, or tare
zone states to begin calibration. This can be checked by using the real-time monitor mode of the Payload Data
Manager software.
The payload meter can be reset to acknowledge the beginning of a new haul cycle by raising the body when
the truck is empty. This may be necessary after servicing the suspensions.
M20-40
Payload Meter III
11/03 M20008
Alarm 1 - Left Front Pressure High

Alarm 2 - Left Front Pressure Low
Troubleshoot Wiring to Left Front Suspension
These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma.
The pressure sensor is designed to output 4-20ma over a pressure range of 4000 psi.
Confirm 18v sensor supply at TB46-L in payload junction box.
Confirm proper connection of signal circuit 39FD from left suspension connection box, TB42-B to payload
junction box TB46-F to payload meter connector R264, pin 39.
M20008 11/03
Payload Meter III
M20-41
Alarm 3 - Right Front Pressure High

Alarm 4 - Right Front Pressure Low
Troubleshoot Wiring to Right Front Suspension
Confirm proper connection of signal circuit 39FC from right suspension connection box, TB41-B to payload
junction box TB46-G to payload meter connector R264, pin 20.
M20-42
Payload Meter III
11/03 M20008
Alarm 5 -Left Rear Pressure High

Alarm 6 - Left Rear Pressure Low
Troubleshoot Wiring to Left Rear Suspension
M20008 11/03
Payload Meter III
M20-43
Alarm 7 - Right Rear Pressure High

Alarm 8 - Right Rear Pressure Low
Troubleshoot Wiring to Right Rear Suspension
M20-44
Payload Meter III
11/03 M20008
Alarm 9 - Inclinometer High

Alarm 10 - Inclinometer Low
Troubleshoot Inclinometer Wiring
These alarms indicate that the voltage to the payload meter from the inclinometer is out of range. The voltage on
signal 39FE should be greater than .5v and less than 5.0v as measured in the junction box between TB46-.
M20008 11/03
Payload Meter III
M20-45
Alarm 13 - Body Up Input Failure
The payload meter senses when the load is dumped without receiving a body-up signal. When the load quickly
drops below 50% without the body up signal, Alarm 13 is set. The alarm will be cleared when a normal dump cycle
is detected. A normal dump cycle will be detected when the body up signal is received, the load drops quickly and
the body down signal is received.
M20-46
Payload Meter III
11/03 M20008
Alarm 15 - Memory Write Failure

Alarm 16 - Memory Read Failure
Alarm 24 - System Key-On Status
These alarms indicate that the payload meter has encountered a problem internally with its memory. It is recommended that power to the payload meter be removed for 1 minute. First turn the keyswitch OFF. Wait 30 seconds, then turn the battery disconnect OFF. Wait 1 minute before restoring power.
In cases where repowering the payload meter does not restore normal operation, it may necessary to reprogram
the payload meter. All current data in memory will be lost. This will effectively restart the payload meter.
See Troubleshooting Abnormal Displays at Power-Up for more information.
M20008 11/03
Payload Meter III
M20-47
Operator Switch Doesn't Work

Alarm 26 - User Switch Fault - SELECT
Alarm 27 - User Switch Fault - SET
Confirm power to the Payload Meter Speedometer and Display gauge.
Confirm that a laptop is not connected to the PLMIII system.
Turn keyswitch OFF. Wait 1 minute and turn keyswitch ON. Confirm problem still exists.
M20-48
Payload Meter III
11/03 M20008
Connector Map
This diagram shows the general location of connectors, terminal boards and miscellaneous connections.
M20008 11/03
Payload Meter III
M20-49
Connectors
M20-50
Payload Meter III
11/03 M20008
PLMIII CHECK OUT PROCEDURE

and TB45-X.
1vdc.
General Description
The process consists of attaching dummy loads in
place of the suspension pressure sensors and
checking the pressures indicated by the payload
meter. In addition, connecting to the payload meter
using a laptop PC in order to confirm the latest software version and the rest of the inputs and outputs of
the system.
Tools Required
Payload Data Manager software
EF9160 - Download Harness
EJ3057 - Harness Str, PLMIII test (4 needed).
Checkout Procedure
1. Attach one EJ3057 Harness Structure to the
left-front suspension connection box. The red
alligator clip attaches to the 39F circuit at TB42A. The white alligator clip attaches to the 39FD
circuit at TB42-B. The EJ3057 acts as a
dummy load to simulate a suspension pressure
sensor for the payload system.
right-front suspension connection box. The red
alligator clip attaches to the 39F circuit at TB41A. The white alligator clip attaches to the 39FC
circuit at TB41-B.
left-rear suspension connection in the Rear suspension connection box. The red alligator clip
attaches to the 39F circuit at TB61-A. The
white alligator clip attaches to the 39FB circuit
at TB61-C.
right-rear suspension connection in the Rear
suspension connection box. The red alligator
clip attaches to the 39F circuit at TB61-A. The
white alligator clip attaches to the 39FA circuit at
TB61-B.
5. In the PLMIII junction box, check the input voltage on circuit 39G between TB45-B and TB45X. This voltage should be 24vdc from the batteries.
6. Turn the keyswitch ON. The speedometer/display gauge on the dashboard will scroll the
truck type across the lower display. The payload meter defaults to 930E.
This voltage should be 18vdc
8. Return to the cab and check the speedometer/

display gauge. The gauge will display the current payload. With the EJ3057 harnesses
attached at the sensor locations, the payload
should be 0.
NOTE: The display can be used to quickly show the
current readings from the four suspension pressure
sensors and the inclinometer. This can be used
during regularly scheduled service periods to check
the state of the suspensions. These displays are live
and will update as the values change. The display is
changed by pressing the 'SELECT' button on the
dashboard. The sequence of displays is:
PL= Payload
Id= Operator ID
tL= Total Shift Tons
LC= Shift Load Counter
LF= Left Front Suspension Pressure
rF= Right Front Suspension Pressure
Lr= Left Rear Suspension Pressure
rr= Right Rear Suspension Pressure
In= Inclinometer
NOTE: The live displays cannot be cleared and the

SET button will have no effect.
NOTE: The units for the display are controlled by the
configuration of the payload meter. The payload
meter defaults to display metric units, the pressures
will be displayed in tenths of kg/cm2. For example, if
the display shows
202 the actual value is 20.2
kg/cm . If the payload meter is set to display short

tons, the pressures will be displayed in psi (lbs/in2).
To convert from kg/cm2 to psi, multiply by 14.2233.
14.2233 psi (lbs/in2) = 1 kg/cm2.
7. In the PLMIII junction box, check the sensor

supply voltage on circuit 39F between TB46-L
M20008 11/03
Payload Meter III
M20-51
NOTE: The inclinometer displays whole degrees of

incline. Positive incline is when front of truck is pointing up.
15. Press and hold the SELECT button on the
rr=
will be displayed. Release

dashboard.
the button and the right-rear pressure will be
displayed. This value should be in metric units.
The nominal value should be 23.4 kg/cm2
(332psi). Values between 17.6 and 29.2 kg/
cm2 (250 psi and 416 psi ) are acceptable.
NOTE: The gauge will quickly display the type of

information being displayed every 1 minute. For
example, if the left-front pressure is being displayed,
Lf= will quickly display every minute. Only the

payload display, PL= does not display this infor-
In=
dashboard.
the button and the inclinometer value will be
displayed. This value is in degrees. The incline
will depend on how the truck is set during
assembly. Values between 3 are acceptable. It is not necessary to zero this reading by
adjusting the attitude of the inclinometer in the
buddy seat.
mation.
Id=

dashboard.
the button and the Operator ID will be displayed. This value should be 0.
tL=

dashboard.
the button and the total tons will be displayed.
This value should be 0.
PL=
dashboard.
the button and the current payload will be displayed.
LC=
dashboard.
will be displayed.
Release the button and the number of loads will
be displayed. This value should be 0.
Lf=
dashboard.
the button and the left-front pressure will be displayed. This value should be in metric units.
18. Connect a laptop to the PLMIII system. Typically an EF9160 download cable is used. The
payload meter connector is behind the buddy
seat on the back wall on the side of the PLMIII
mounting bracket. The laptop must have the
Payload Data Manager software installed.
19. Run the PC software.
20. From the main menu, select "Connect to Payload Meter".
rf=

dashboard.
the button and the right-front pressure will be
displayed. This value should be in metric units.
Lr=

dashboard.
the button and the left-rear pressure will be displayed. This value should be in metric units.
M20-52
Payload Meter III
11/03 M20008
21. The Connection Menu will be displayed. Select

"Configure Payload Meter".
22. Confirm that the PLMIII software version

matches the latest available version. As of 09May-01 the EJ0575-1 software version will display as "01/28/01A". The latest version can be
found at http://www.kms-peoria.com/payload. If
the version does not match the latest indicated
on the internet, download the latest and update
the PLMIII software using the Flashburn software. See Checkout Procedure Confirmation
for more information.
23. Using the Truck Configuration menu, set the following:
NOTE: The frame serial number is located on a plate

mounted to the truck frame. The plate is outboard on
the lower right rail facing the right front tire. It is very
important to enter the correct frame serial number.
This number is one of the key fields used within the
haul cycle database. The field will hold 20 alphanumeric characters.
On the Truck Configuration screen, enter the
frame serial number in the appropriate field.
Press the "Save Changes" button to program the
change into the payload meter.
25. Setting the Customer Unit Number.
NOTE: Most mining operations assign a number to
each piece of equipment for quick identification. This
number or name can be entered in the Customer
Unit Number field. It is very important to enter
customer unit number. This number is one of the key
fields used within the haul cycle database. The field
will hold 20 alpha-numeric characters. If no truck
number has been specified, enter the frame serial
number.
On the Truck Configuration screen, enter the
truck number in the appropriate field.
26. Setting the Komatsu Distributor.
Set the time.

Set the Date to todays date.
Set the Gauge display units to Metric, Short Tons
or Long Tons according to the final destination of
the vehicle. If nothing has been specified, set to
Metric Tons.
Set the truck type to the proper truck model.
Press the Save Changes button to program the
24. Setting the Frame Serial Number.
M20008 11/03
NOTE: This field in the haul cycle record can hold the
name of the Komatsu distributor that helped install
the system. Komatsu also assigns a distributor
number to each distributor. This number is used on
all warranty claims. This Komatsu distributor number
can also be put into this field. This number is one of
the key fields used within the haul cycle database.
The field will hold 20 alpha-numeric characters. If
the distributor is not known, enter "UNKOWN".
On the Truck Configuration screen, enter the distributor name or number in the appropriate field.
27. Setting the Komatsu Customer.
Payload Meter III
M20-53
NOTE: This field in the haul cycle record can hold the
name of the mine or operation where the truck is in
service. Komatsu also assigns a customer number to
each customer. This number is used on all warranty
claims. This Komatsu customer number can also be
put into this field. This number is one of the key
fields used within the haul cycle database. The field
will hold 20 alpha-numeric characters. If the customer is not known, enter "UNKOWN"
On the Truck Configuration screen, enter the customer name or number in the appropriate field.
chnge into the payload meter.
28. Press "Save Changes" and close the Truck
Configuration screen and the Connection Menu.
29. From the main menu select "Connect to Payload Meter".
30. From the Connection Menu select "Configure
Payload Meter". Confirm that all previous
changes have been saved and close the Truck
Configuration form.
31. From the Connection Menu select "Real Time
Data".
32. Confirm that the suspension pressures are

within range. The nominal value should be 23.4
kg/cm2 (332psi).
Values between 17.6 and
2
29.2 kg/cm (250 psi and 416 psi ) are acceptable. Record the values displayed.
33. Confirm that the inclinometer is within range
and record the value.
34. Confirm that the Body Up input is working correctly. Place a steel washer on the body up
switch. The real time data screen should indicate "No". Remove the washer and the real
time data screen should indicate "Yes". The
Haul Cycle State should change to "Dumping".
35. Confirm that the Brake Lock input is working
correctly. Turn the Brake Lock on using the
switch on the dashboard. The real time data
screen should indicate "On". Turn the Brake
Lock off. The real time data screen should indicate "Off".
36. Turn on the green payload lights by checking
"Green Light" and pressing the "Set Lights" button. Check to be sure that only the green payload lights on the truck are illuminated.
37. Uncheck the green light and turn on the amber
payload lights by checking "Amber Light" and
pressing the "Set Lights" button. Check to be
sure that only the amber payload lights are illuminated.
38. Uncheck the amber light and turn on the red
payload lights by checking "Red Light" and
pressing the "Set Lights" button. Check to be
sure that only the red payload lights are illuminated.
39. Uncheck all the payload lights and press the
"Set Lights" button. Confirm that all the lights
are off.
NOTE: The weight shown on the real time data

screen is the sprung weight and includes the weight
of the truck. Given the suspension pressure dummy
loads, the nominal value shown should be 112 short
tons (101 metric tons).
40. Use the procedure for speedometer calibration

for the particular truck type to simulate a 25
MPH (40.2 Km/h) speed signal. Confirm that
this value is displayed by the speedometer on
the dashboard and the real time data screen.
The value can be 1 MPH (2 km/h). The brake
lock must be off for the PLMIII to recognize
speed input.
41. On the PC, close the Real Time Screen and the
Connection Menu and return to the Main Menu.
M20-54
Payload Meter III
11/03 M20008
42. Remove the EJ3057 harness from the left front

suspension junction box, TB42-A and TB42-B.
PLMIII CHECKOUT PROCEDURE

CONFIRMATION
43. Wait at least 1 minute and remove the EJ3057

harness from the left-rear connections in the
rear junction box, TB61-B and TB61-C.
Flashburn Programming

harness from the right-rear connections in the
rear junction box, TB61-A and TB61-C.
Before beginning, be sure the ".kms" file required to

program the product and you know where to find it on
your computer.

harness from the right-front connections in the
right-front junction box, TB61-B and TB61-C.
Programming will reset all the truck configuration

information.
46. Wait at least 1 minute.

47. From the main menu of the PC software press
the "Connect to Payload Meter" button.
48. From the Connection Menu select "Display
Active Alarms". Confirm that the four alarms
displayed occurred in the proper order;
General Instructions:
NOTE: BEFORE STARTING THIS PROCEDURE,

RECORD
THE
PAYLOAD
METER
CONFIGURATION INFORMATION.
This information can be found using the Payload
Data Manager software. After programming, it will be
necessary to restore this information in the payload
meter configuration.
Left-front suspension low

1. Turn off power to the payload meter by turning
the keyswitch OFF.
Left-rear suspension low

Right-rear suspension low
2. Start the "Flashburn" software installed on the

laptop.
Right-front suspension low

49. Close all screens and disconnect the laptop
from the PLMIII system.
Flashburn
1. Power
OFF
Before programming, power must be

turned off to the target device. Be sure
the power is turned off before continuing.
2. Select
Port
3. Select
File
4. Power
ON
< Back
Next >
Cancel
3. Confirm that the payload meter power is OFF

and press NEXT".
M20008 11/03
Payload Meter III
M20-55
4. Confirm the proper communications port for the

programming laptop. This is usually COM 1.
Press NEXT.
Flashburn
1. Power
OFF
Flashburn
1. Power
OFF
2. Select
Port
2. Select
Port
Select the serial communications port to

use between the computer and the
target device. For most computers this
will be COM 1.
3. Select
File
COM 1
4. Power
ON
3. Select
File
Turn on power to the target device. This

will start the programming process.
Comm Port:
COM 1
Filename:
071000A.KMS
Status
Steps
Connection:
Complete
Preparation:
Complete
Programming:
Complete
Verification:
4. Power
ON
Complete
61 %
< Back
< Back
Next >
Cancel
Cancel
7. After successful programming, turn the key

witch OFF.
5. Press BROWSE and select the ".kms" file to
program into the payload meter. Press NEXT.
Flashburn
1. Power
OFF
Select the file that will be used to

program the target device. This file will
end with the ".KMS" extension.
2. Select
Port
Comm Port: COM 1

Filename:
*.KMS
8. Wait 20 seconds and turn the keyswitch ON.

9. The payload meter will need to be configured as
instructed in the manual using the Payload Data
Manager software on the laptop computer.
Browse
3. Select
File
4. Power
ON
< Back
Next >
Cancel
6. When instructed, turn the keyswitch ON in

order to power-up the payload meter. The PC
will begin to reprogram the payload meter. This
process takes approximately 5 minutes.
M20-56
Payload Meter III
11/03 M20008
Confirmation Checklist
Use the Real Time Data Screen in order to verify the checklist items in the table below.
Checklist Item
Value
Initials
PLMIII Software Version

User switch and display works properly
Left - Front Pressure
Right - Front Pressure
Left - Rear Pressure
Right - Rear Pressure
Inclinometer
Green light works properly
Amber light works properly
Red light works properly
Brake Lock input works properly
Body Up input works properly
Speed input works properly
Date
Truck
Signature
M20008 11/03
Payload Meter III
M20-57
PAYLOAD METER III COMPONENTS
Pressure Sensor - PC1578
PLMIII Controller - EG6514
All Reference dimensions are in mm.

Speedometer - PC0550
PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE

MANUFACTURED UNDER LICENSE F ROM
L.G. HAGENBUCH holder of
U.S. Patent Numbers 4,831,539 and 4,839,835
M20-58
Payload Meter III
11/03 M20008
SECTION M31
RESERVE ENGINE OIL SYSTEM
INDEX
RESERVE ENGINE OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-4
LED Monitor Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-4
Tank Fill Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-5
Filling Procedure (Remote fill feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-5
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
Every 10 Hours, or once each shift: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
Every 500 Hours: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-7
Circuit Breaker or Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-7
SYSTEM ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-8
M31002 12/03
Reserve Engine Oil System
M31-1
NOTES
M31-2
12/03 M31002

The reserve engine oil system is designed to add
more oil capacity to the engine sump and to reduce
frequent servicing of the engine oil. The constant circulation of oil between the engine sump and reserve
tank (9, Figure 31-1) increases the total volume of
working oil. This dilutes the effects of contamination
and loss of additives and maintains the oil quality
over longer periods. The system adds or removes oil
from the engine as required to maintain a constant
level which prevents over fills or under fills.
Filter (14) in the supply circuit protects the pumping
unit (11) and prevents transfer of contaminants to the
engine sump which might enter the tank during servicing. It also gives an added level of oil cleanup.
The normal supply system capacity of oil carried in
the reserve tank is roughly equivalent to the volume
in the engine. In the process of continuous adjustment of the engine oil level, there is a constant circulation of oil between the engine and the reserve tank.
The volume of oil in the tank becomes part of the
working oil for the engine. Oil change intervals may
usually be extended in proportion to the increased
working oil volume. Extension beyond a proportional
increase is often possible, but should be undertaken
only as determined by oil sampling and analysis.
Local conditions such as engine application, climate,
and fuel quality should be taken into consideration
before determining permissible oil life.
M31002 12/03
FIGURE 31-1. OIL RESERVE TANK

1. Suction Line
2. Remote Fill Line
3. Fill Valve
4. Engine Add Line
5. Fill Switch
6. Air Relief Valve
7. Tank Fill Line
8. Tank Fill Cap

9. Reserve Tank
10. Engine Add Line
11. Pumping Unit
12. Sight Gauge
13. Tank Add Line
14. Filter
M31-3
LED Monitor Light
Operation
Engine oil is circulated between engine oil pan (1,
Figure 31-2) and reserve tank (2) by two electrically
driven pumps (pump 1 and pump 2) within a single
pumping unit (4). The pumping unit is mounted on
the side of the reserve tank. The pump unit is
equipped with an LED monitor light on one side.
Pump 1 draws oil from the engine oil pan (1) at a
preset control point determined by the height of the
suction tube (6). Oil above this point is withdrawn
and transferred to the reserve tank. This lowers the
level in the engine oil pan until air is drawn.
Steady - Pump 1 is withdrawing oil from the

engine sump and bringing down the oil level.
Regular pulsing - Pump 2 is returning oil to the
engine sump and raising the oil level.
Irregular pulsing - Oil is at the correct running
level.
Air reaching the pumping unit activates pump 2,

which returns oil from reserve tank (2) and raises
the engine oil level until air is no longer drawn by
pump 1. Pump 2 then turns off. The running level is
continuously adjusted at the control point by alternating between withdrawal and return of oil at the
engine oil pan. The oil returning to the engine oil
pan is below the normal operating level to prevent
aeration of the oil.
FIGURE 31-2. RESERVE SYSTEM SCHEMATIC

1. Engine Oil Pan (Sump)
2. Oil Tank
3. Oil Filter
M31-4
4. Pumping Unit (1 & 2)

5. Air Relief Valve
6. Suction Tube
A. Oil Suction Line

B. Oil Return Line
C. Engine Oil Level
12/03 M31002
Tank Fill Control (Optional)

With the reserve oil system the engine oil level is
held constant, with only the reserve tank needing
routine filling. The fill system automatically controls
the filling of remote tank from a convenient ground
level position. Filling of the tank to the proper full
level is fast and accurate and accomplished in 2 to 3
minutes.
The reserve oil tank for the engine is designed to add
more oil capacity to the engine to reduce the frequent
servicing of the engine oil. The engine oil level must
still be checked every shift using the dipstick.
If the engine oil has been drained from the engine oil
pan, the new oil must be added through the engine
fill tube. After an oil change, both engine and reserve
tank must be full of oil before starting the engine.
NOTE: Do Not use the oil in the reserve tank to fill
the engine pan.
System switch (2, Figure 31-3) is an illuminated
push-pull power-on switch that powers the fill system. Start switch (3) is a momentary push button
switch that opens the fill valve mounted on the
reserve tank to begin the automatic filling of the
reserve tank. Supply oil under pressure flows
through the fill valve and into the tank.
Filling Procedure (Remote fill feature)
NOTE: This procedure adds oil to the reserve tank.
1. Connect the pressure supply hose from the
new oil supply to the quick coupler on the truck.
Open valve on supply hose to apply pressure.
2. Pull out on system switch (2, Figure 31-3) to
turn the fill system on.
FIGURE 31-3. RESERVE OIL TANK

REMOTE FILL
1. Remote Control
Box
2. System Switch
3. Push start switch (3). VALVE OPEN light (5)

should illuminate and the filling process will
begin.
3. Start Switch
4. FULL Light
5. VALVE OPEN
Light
4. When the tank is full, the VALVE OPEN light

will turn off and FULL light (4) will illuminate.
5. Close the oil supply valve in the fill hose.
6. Press and hold start switch (3) for a couple of
seconds to relieve oil pressure in the line.
7. Disconnect the new oil supply hose.
8. Push switch (2) in to turn fill system power off.
M31002 12/03
M31-5
SERVICE
Changing Oil
Between oil drains, the only normal servicing

required is routine replenishment of oil at the reserve
supply tank. Maintenance of running levels should be
checked routinely; manually before starting the
engine and with the LED system monitor on the
reserve tank pumping unit (11, Figure 31-1) when the
engine is running.
There is also an in-line filter (screen) installed at the
inlet of the fill valve (3, Figure 31-1). This filter
requires no periodic maintenance, but it can be
cleaned by removing it from the system and back
flushing through the filter.
CAUTION: Always check the engine oil level
before starting engine. Use the engine dipstick.
Every 10 Hours, or once each shift:
1. Drain both the engine sump and the reserve

tank. Refill both engine and reserve tank with
new oil to proper levels.
2. Change engine and reserve tank filters as
required.
3. Start engine and check for proper operation.
NOTE: Do not use the oil in the reserve tank to fill the
engine sump. Both must be at proper level before
starting engine.
The engine oil level should be checked with the
engine dipstick at every shift change. The oil level in
the reserve tank must also be checked at every shift
change. Oil must be visible in the middle sight gauge.
If not, add oil to the reserve tank until oil is visible in
the top sight gauge
1. Before starting engine, check oil level using

engine dipstick. Oil level should be in normal
operating range. If not, check the reserve system for proper operation.
2. The engine oil quality will be best if the reserve
tank is kept reasonably full. Check the oil level
in the reserve tank. As a minimum guideline, if
the oil is below the half-full level, fill the tank
manually so the oil is just visible in the top sight
glass or by using the automatic fill control
method.
3. After starting and warm-up, check engine oil
level signal (LED) to verify that the engine is
being maintained at the preset running oil level.
The signal should alternate between periods of
steady on and flashing.
Every 500 Hours:
1. Change all engine and system filters, if applicable.
2. More system failures result from bad electrical
connections than all other causes combined.
Check electrical system connections for tightness, corrosion and physical damage. Check
battery, alternator, oil pressure switch, junction
boxes, remote control fill box and circuit breakers.
3. Examine electrical cables over their length for
possible damage.
4. Small hose leaks can cause system malfunction. Examine all hoses, including those on the
reserve tank and the ones leading to and from
the engine for leaks, cracks or damage. Check
all fittings for tightness, leakage or damage.
M31-6
12/03 M31002
TROUBLESHOOTING
It is important to understand the LED signal for the
pumping unit. It is used primarily to verify that the
system is maintaining the oil level at the level of the
open end of the withdrawal tube in the engine oil pan.
The signal is also a valuable tool in troubleshooting
the system.
When the signal is steady (not flashing), pump 1 is
running and oil is being withdrawn from the engine
and being transferred to the reserve tank.
When the signal is flashing, pump 1 is drawing air
from the suction tube which triggers operation of the
pump 2 to operate and transfer oil back to the engine
from the tank (the flashing is actually the pulses of
pump 2). When the oil is at the correct level in the
engine, air and oil are alternatively entering the suction tube, with pump 1 commanding operation of
pump 2 with each portion of air that comes through
the line.
This is a complete test for proper operation of the
pumping unit. This operation can be accomplished
without running the engine by jumping the oil pressure switch that activates the system.
1. If the signal light is steady, pump 1 should be
pumping oil. Verify by loosening the hose at
pump 1 outlet to verify that oil is coming
through (pump 1 is marked by a groove on its
outlet).
2. Loosen the hose at the inlet of pump 1 to admit
air. Pump 2 should then run and the signal
should be flashing. Verify proper pumping of
pump 2 by loosening the hose at its outlet to
see that oil is coming through.
NOTE: There is a condition that would show a level

higher than the controlled point. If both the engine
and reserve tank are overfilled, there is no room in
the tank to draw the oil level down in the engine. In
this case, the LED signal would never start flashing
because pump 1 is never receiving air. It will
continue to pump oil from the engine to the tank, but
because the tank is full, the oil will be routed back to
the engine via the air relief valve on top of the tank.
There are two explanations for an overfilled tank and

engine:
When the tank is filled to FULL and the engine
is overfilled.
When oil is added directly to the engine between
oil changes. The system transfers the oil to the
reserve tank until it can not receive any more and
the engine remains overfilled. It is, therefore,
important that oil should be added only to the
reserve tank between oil changes; except, of
course, if the engine is extremely low.
Circuit Breaker or Fuse

The Reserve System is protected either by a 15 amp
circuit breaker or a 15 amp fuse located in the auxiliary control cabinet. If the truck is protected by circuit
breakers, it will be CB10. If the truck is protected by
fuses, the fuse will be in Fuse Block 2, position 10.
3. Re-tighten the inlet hose on pump 1. The pump

should again receive oil and the flashing should
stop.
M31002 12/03
M31-7
SYSTEM ELECTRICAL SCHEMATICS
FIGURE 31-4. SYSTEM SCHEMATIC

1. Pumping Unit (Pump 1 & Pump 2)
2. Engine Oil Pressure Switch
3. Engine Subframe
4. 15 Amp Circuit Breaker or Fuse (CB10

or Fuse Block 2, position 10)
5. Power Supply
6. Auxiliary Box
FIGURE 31-5. FILL SYSTEM SCHEMATIC

1. Fill Valve
2. Oil Level Sensor
(top of reserve oil tank)
3. 15 Amp Circuit Breaker
M31-8
4. Battery Disconnect Box

5. Ground Wire
6. Remote Fill Control Box
12/03 M31002
SECTION N
CAB COMPONENTS
INDEX
TRUCK CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-1
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-1
OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1
OPERATOR CAB CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
N01020
Index
N1-1
NOTES
N1-2
Index
N01020
SECTION N2
TRUCK CAB
INDEX
TRUCK CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4
Removal - Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4
Installation - Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-7
Door Jamb Bolt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-7
Door Handle Plunger Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-8
Door Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-9
Door Window Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-13
Door Handle or Latch Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-13
Door and Door Hinge Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Door Opening Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Adhesive Bonded Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Windshield And Rear Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-17
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Truck Cab
N2-1
NOTES
N2-2
Truck Cab
06/03 N02015
TRUCK CAB
Description
The truck cab is a fully insulated design incorporating
an integral ROPS structure for maximum operator
comfort and safety. All gauges, switches, and controls have been designed to simplify operation and
are placed within easy reach of the operator. Servicing of cab and associated electrical systems is simplified by use of heavy-duty connectors on the
various wiring harnesses. Hydraulic components are
located outside of the interior and are accessed
through covers (2, Figure 2-1) on the front of the cab.
DO NOT attempt to modify or repair damage to

the ROPS structure without written approval
from the manufacturer. Unauthorized repairs to
the ROPS structure will void certification. If modification or repairs are required, contact the servicing Komatsu Distributor.
FIGURE 2-1. CAB ASSEMBLY

1. Mounting Pad
2. Access Covers
3. Filter Cover
4. Windshield Wiper Arms
5. Stop Light (Service Brakes Applied)
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Truck Cab
6. Retard Light (Retarder Applied)

7. Lifting Eye
8. Rear, Side Glass
9. Front, Side Glass
N2-3
Prior to cab removal or repair procedures, it may be

necessary to remove the body to provide clearance
for lifting equipment to be used. If body removal is
not required, the body should be raised and the
safety cables installed at the rear of the truck.
Preparation
illuminated.
2. Place the drive system in the rest mode by turning the Rest switch on the instrument panel ON.

before attempting any repairs!





console.
NOTE: One of the link voltage lights is located
behind the operator's seat on the DID panel, two
others are located on the electrical cabinet.
position.


Removal - Cab
NOTE: The following procedure describes removal of

the cab as a complete module with the hydraulic
brake cabinet attached. All hoses and wire
harnesses should be marked prior to removal for
identification to ensure correct reinstallation:
1. Disconnect hydraulic hoses routed to frame
from fittings at rear of cab under brake cabinet
(3, Figure 2-2). (It is not necessary to disconnect hoses attached to, and routed under the
cab.) Cap all lines to prevent contamination.
2. Disconnect wire harnesses (4) at connectors
located under hydraulic cabinet.
3. Remove cable and hose clamps as needed for
cab removal
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Truck Cab
06/03 N02015
FIGURE 2-2. CAB HYDRAULIC AND ELECTRICAL CONNECTIONS

1. Cab
2. Hydraulic System Hoses
3. Hydraulics Components Cabinet

4. Electrical Harnesses
7. Evacuate air conditioning system:
4. Close heater shutoff valves located at the water

pump inlet housing on the right side of the
engine and at the water manifold. Disconnect
heater hoses at each valve and drain coolant
into a container.
a. Attach a recycle/recovery station at the air

conditioning compressor service valves.
(Refer to Section N, Operator Comfort for
detailed instructions.)
5. Remove clamps and heater hoses from fittings

underside of deck, below heater. Cap fittings
and plug hoses.
b. Evacuate air conditioning system refrigerant.

c. Remove the air conditioner system hoses
which are routed to the bottom of the cab
from the receiver/drier and compressor. Cap
hoses and fittings to prevent contamination.
6. Remove air cleaner restriction indicator hoses

near front, inside corner under cab.
8. Attach a lifting device to the lifting eyes provided on top of the cab.
An approved Recovery/Recycle Station must be
N02015 06/03
The cab assembly weighs approximately 5000

lbs. (2270 kg). Be sure lifting device is capable of
lifting the load.
Truck Cab
N2-5
9. Remove the capscrews and washers from each

mounting pad (1, Figure 2-1) at the corners of
the cab.
10. Check for any other remaining hoses or wiring
which may interfere with cab removal.
11. Lift the cab assembly off the truck and move to
an area for further service.
12. Place blocking under each corner of the cab to
prevent damage to floor pan and fittings before
cab is lowered to the floor.
CAB DOOR
The cab door assemblies are similar except for the
hinge side. Each is hinged on the rear edge with a
heavy duty hinge. For repairs on the door latches or
window controls it is usually better, but not necessary, to remove the door from the cab and lower it to
the floor for service.
Removal
1. If overhead space is available, raise body to
allow access to door with overhead hoist.
Secure body in raised position with safety
cables.
Installation - Cab
1. Lift cab assembly and align mounting pad holes
with tapped pads. Insert at least one capscrew
and hardened washer at each of the four pads
prior to lowering cab onto the truck.
2. Lower door glass far enough to allow insertion

of lifting sling when door is removed.
3. Remove door panel for access to power window motor harness connector. Disconnect
motor and remove cab harness from door.
2. After cab is positioned, insert the remaining

capscrews and hardened washers. (32 total).
Tighten the capscrews to 700 ft. lbs. (950 N.m)
torque.
4. Remove the retainer clip and bolt clip from the

travel limiting strap.
5. Insert lifting sling through door and attach to
hoist. Remove capscrews (a swivel socket
works best) securing door hinge to cab and lift
door from cab.
3. Route wire harnesses to the electrical connectors on the rear corner of the cab (4, Figure 22). Align cable connector plug key with receptacle key and push plug onto receptacle. Carefully
thread retainer onto receptacle and tighten
securely. Install clamps if removed during cab
removal.
6. Place door on blocks or on a work bench to protect the window glass and allow access to internal components for repair.
4. Remove caps from hydraulic hoses and tubes

and reinstall. Reinstall hose clamps as required.
5. Install heater hoses and clamps on fittings on
underside of cab. Connect other end of hose to
fittings at shutoff valves on engine. Open heater
shutoff valves. Connect air cleaner restriction
indicator hoses.
Installation
6. Remove caps and reinstall air conditioning system hoses from compressor and receiver/drier.
7. Refer to Section N, Operator Comfort, for
detailed instructions regarding evacuation and
recharging with refrigerant.
8. Close brake accumulator bleed down valves.
1. Attach sling and hoist to door assembly, lift

door up to the deck and position door hinges to
cab.
2. Align door hinges with cab and install capscrews securing door to cab.
3. Attach the travel limiting strap with the bolt and
clip removed previously.
4. Reconnect door harness to receptacle mounted
in the cab floor.
5. Verify proper operation of power window and
door latch adjustment.
9. Close battery disconnect switch.

10. Service hydraulic tank and engine coolant as
required.
6. Install door panel.
11. Start the engine and verify proper operation of

all controls.
12. Complete air conditioning system recharging
procedures.
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Truck Cab
06/03 N02015
Door Adjustment
3. Hold a piece of paper such as a dollar bill

between where the door seal (4) will hit the skin
of the cab and firmly close the door ensuring
that it latches on the second catch. (The door
latch mechanism has a double catch mechanism.)
If adjustment is necessary to insure tight closure of

door, loosen striker bolt in the door jamb, adjust, and
retighten.
A rubber sealer strip is mounted with adhesive
around the perimeter of the door assembly to
exclude dirt and drafts. This sealer strip should be
kept in good condition and replaced if it becomes
torn or otherwise damaged.
4. The door seal should firmly grip the paper all

along the top, front, and bottom edge of the
door. If the paper is loose all around, repeat
Step 2. If the paper is firmly gripped, but can be
removed without tearing it, open door and
tighten the jamb bolt completely without affecting the adjustment.
Door Jamb Bolt Adjustment

Over a period of time, the door latch mechanism and
door seals may wear and allow dirt and moisture to
enter the cab. To insure proper sealing of the door
seals, the door jamb bolt may need to be adjusted
periodically.
5. If the paper slips out from the door seal easily

along the top and not at the bottom, the door
itself will have to be "adjusted". Or if the paper
slips out easier at the bottom than at the top,
the door will have to be "adjusted".
If seals are tight at bottom of door, but not at top,

place a 4 x 4 block of wood at the bottom edge of
the door, below the handle. Close the door on the
wood block and press firmly inward on the top
corner of the door. Press in one or two times,
then remove the wood block and check seal
tension again using the paper method. Seal
compression should be equal all the way around
the door. If seal is still loose at the top, repeat
procedure again until seal compression is the
same all the way around.
If seal compression is greater at the top than at

the bottom of the door, place a 4 x 4 block of
wood at the top corner of the cab door. Then
press firmly inward on the lower corner of the
door. Press in one or two times, then remove the
wood block and check seal compression again.
Seal compression should be equal all the way
around the door. If seal is still loose at the
bottom, repeat procedure again until seal
compression is uniform all the way around.
Truck Cab
N2-7
FIGURE 2-3. DOOR JAMB BOLT ADJUSTMENT

1. Washer
2. Striker Bolt
3. Frame
4. Seal
Step A. If the door closes, but not tightly enough to

give a good seal between the seal on the door and
the cab skin:
1. Mark the washer location (1, Figure 2-3) portion
of the door jamb bolt with a marker, pen, or
pencil by circumscribing the outside edge of the
washer onto the jamb.
2. Loosen the door jamb bolt (2) and move straight
inwards 1/16" and retighten.
N02015 06/03
Step B. If the door bucks back when trying to close it,

the striker bolt (2, Figure 2-4) has probably loosened
and slipped down from where the catch can engage
with the bolt.
1. Open the door and close both claws (3 & 5, Figure 2-4) on the catch until they are both fully
closed.
Door Handle Plunger Adjustment

If the door handle becomes inoperative, it can either
be adjusted or replaced. The following is a procedure
for adjusting the exterior door handle plunger.
1. Determine the amount of free play in the door
release plunger by pushing in on the plunger
until it just contacts the door release mechanism. Measure the distance that the plunger
travels (Figure 2-5) from this position to where
the plunger is fully released.
FIGURE 2-5. MEASURING TRAVEL DISTANCE OF

PLUNGER
2. Remove door panel.

a. Remove hair pin clip (1, Figure 2-6) and bolt
(2) from the door check strap closest to the
door.
FIGURE 2-4. LATCH ASSEMBLY

1. Cab
2. Striker Bolt
3. Upper Latch
4. Door
5. Lower Latch
b. Remove 2 capscrews (3), which hold the

door strap bracket to the door.
2. Transfer the center of this opening onto the skin

of the cab nearest where the door jamb bolt is
located. Use a T-square or other measuring
equipment and mark on the cab with a pencil.
NOTE: Release the door catch before trying
to close the door.
3. Loosen and vertically align (center) the door
jamb bolt with this mark and tighten it firmly
enough to hold it in place but still allow some
slippage.
4. Carefully try to close door (4) and determine if
this has helped the "bucking" problem. If the
door latches but not firmly enough, follow procedures listed previously in "Step A". If the door
latch does not catch, move the bolt outward and
try again. When corrected, follow adjustment
procedures listed in "Step A" to ensure a good
seal. By design, if both seals are in good condition, proper adjustment of the outside seal will
ensure good contact on the inside seal to prevent dust and moisture from entering the cab.
N2-8
c. Disconnect wiring harness (4) to the window

regulator.
d. Open the door as far as possible in and
remove the internal door panel.
e. Before removing all door panel mounting
screws, support the panel to prevent the
assembly from dropping. Remove 15 mounting screws (5).
NOTE: Remove panel screws across the top, last.
Door glass and internal door panel will drop

when door panel screws are removed.
Truck Cab
06/03 N02015
Carefully lower the door panel a few inches. Hold

glass at top to prevent it from dropping. Slide the
door panel toward the cab to disengage the
window regulator roller (Figure 2-7) from the
track on the bottom of the glass. Slide the panel
away from the cab to disengage the other top
roller and lower roller from its tracks. Place the
panel out of the way after removal.
Door Glass Replacement

1. Remove hair pin clip (1, Figure 2-6) and bolt (2)
from the door check strap closes to the door.
a. Lift door glass and support at the top of the

frame.
b. Remove 2 screws (Figure 2-8) holding the
roller track to the bottom of the door glass.
3. Remove capscrew and nut from inside release
lever (1, Figure 2-14).
4. Remove the four mounting screws that holds
the latch mechanism in the door (2).
5. Remove door latch mechanism (4). Check to
see if door latch mechanism works properly by
performing the following test.
a. Close latch mechanism pawls
b. Operate inside door release lever to see if
pawls open. If pawls do not open, replace
assembly.
c. Close pawls again.
FIGURE 2-6.
d. Press the outside door button to see if pawls

open.
1. Hair Pin Clip

2. Door Strap Bolt
3. Strap Bracket
e. If mechanism operates properly go on to

Step 6. If mechanism does not work properly,
replace with a new door latch assembly then
continue with Step 6.
4. Wiring Harness
5. Panel Screws
6. Window Regulator
Mounting Screw
2. Remove 2 M8x12 capscrews (3), which hold

the door strap bracket to the door.
6. Remove the mounting screws (3) from the outside door handle. With the door handle
removed, adjust the plunger counter clock wise
to increase the height of the door handle
release button. Lock the plunger capscrew with
locking nut. Apply lock tight to prevent screw
from working loose.
3. Disconnect wiring harness (4) to the window

regulator.
4. Open the door as far as possible in order to
remove the internal door panel.
7. Reassemble door assembly by reversing the

previous steps.
Door glass and internal door panel will drop

when door panel screws are removed.
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Truck Cab
N2-9
5. Before removing all door panel mounting

screws, support the panel to prevent the
assembly from dropping. Remove 15 mounting
screws (5).
7. Remove 2 screws (Figure 2-8) holding the roller

track to the bottom of the door glass.
NOTE: Remove panel screws across the top last.

6. Carefully lower the door panel a few inches
(Figure 2-7). Hold glass at top to prevent it from
dropping. Slide the door panel toward the cab to
disengage the window regulator roller from the
track on the bottom of the glass. Then slide the
panel away from the cab to disengage the other
top roller and the lower roller from their tracks.
Place the panel out of the way after removal.
FIGURE 2-8.
8. Support glass in door frame as shown (1, Figure 2-9). Remove screws (2) that hold the
adapter for the window regulator track.
FIGURE 2-7.
FIGURE 2-9.
1. Support Block
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Truck Cab
2. Screws
06/03 N02015
Lift door glass up in the frame (1, Figure 2-12) so that

it is near the top. Holding the glass in place, tilt frame
out at the top. Lift frame and glass straight up and out
of door.
Bracket (2, Figure 2-9) at bottom of glass must

clear the door frame, if still on glass.
FIGURE 2-10.
1. Screws
2. Rubber Felt Insert
Remove the screw at the lower end of the window

channels. It is necessary to pull the rubber felt insert
(2, Figure 2-10) out of the channel in order to be able
to remove the screws.
9. Remove the trim material covering the screws
holding the window frame to the door. Remove
screws (1, Figure 2-11) holding window frame to
the door.
Note: Screws along the bottom of window frame may
be shorter than along the top and sides.
FIGURE 2-12.
1. Window Frame
2. Window Bracket
10. Move window glass and frame to an area where

the glass can be removed. Slide the glass down
and out of the window channels.
11. Before installing new window glass, first inspect
the window frame. In each corner there is an "L"
shaped bracket with 2 screws in it to hold the
corners of the frame together. Check the screws
(1, Figure 2-13) to be sure they are tight. Also
be sure the rubber felt insert in the window
channels is in good condition. Replace, if necessary.
12. Slide the new window glass into the window
frame glass channels. Move the glass to the top
of the frame.
FIGURE 2-11.
13. Lift window frame, holding glass at the top of the

frame, and lower the assembly into the door.
1. Screws
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Truck Cab
N2-11
FIGURE 2-13.
1. L Shaped Brackets
FIGURE 2-14.
1. Capscrw & Nut
2. Mounting Screws Latch
Be sure the one channel (5, Figure 2-14) which is

next to the door latch passes to the inside of the latch
assembly (4).
14. Lower glass in frame and support it as seen in
Figure 2-9.
15. Reinstall window frame screws which holds it to
the door frame.
Screws along the bottom of window frame may be

shorter than the ones along the sides and top. These
screws must be used in this area to prevent the window glass from being scratched or cracked. See Figure 2-11.
16. Install trim material over the top of screws that
holds the window frame to the door. Use a flat
blade screwdriver to assist with installing the
trim material. See Figure 2-15. Be careful not to
cut the retainer lip on the trim material.
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Truck Cab
3. Mounting Screw - Outside Door Handle

4. Latch Assembly
5. Window Frame
17. Install the 2 screws removed in step 8. Be sure

the rubber felt insert is back in place after
installing the screws.
18. Reinstall window regulator track bracket as
seen in Figure 2-7. Be sure nylon bushings and
gaskets are installed properly to prevent damage to the glass.
19. Lift window glass in frame and install window
regulator roller track to bracket installed in step
18. See Figure 2-8.
20. Holding window glass as seen in Figure 2-9 (a
few inches from the top.) install lower and upper
regulator rollers in their tracks. Start by moving
door panel (with window regulator) away from
cab just far enough to allow the rollers to enter
their tracks. Then with the rollers in the tracks
slide the panel toward the cab. Move the panel
just far enough to allow the upper regulator
roller to go into the track on the bottom of the
glass.
06/03 N02015
motor is engaged properly into the regulator

gear. Also, the regulator should be in the
"up" position before replacing the motor
assembly. Be sure the motor mounting
screws are tight.
b. If replacing the window regulator assembly,
the new regulator should be in the "up" position before being mounted.
4. Mount window regulator to the inner panel with
the 4 mounting screws removed in Step 2. Be
sure screws are tight.
5. Refer to door glass replace procedure and follow steps 20-23 to complete replacement.
Door Handle or Latch Assembly Replacement

The cab doors are equipped with serviceable latch
handle assemblies (inner and outer). If they become
inoperative, they should be replaced by a new
assembly. The outer latch handle assembly on each
door is furnished with a key-operated lock to enable
the operator to lock the truck cab while the truck is
parked unattended.
1. Follow steps 1-6 procedure for door glass
replacement.
2. Refer to Figure 2-14. Remove capscrew and
nut (1) from inside door handle.
FIGURE 2-15.
3. Remove 4 mounting screws (2) for the latch.

Remove old latch assembly.
* If replacing the latch assembly go to step 5.
21. Lift door panel, regulator and glass up to align

screw holes in the panel with holes in door
frame. Install screws that retain panel to door
frame.
22. Hook-up electrical connector for the window
regulator. Install the two cap screws that hold
the door strap bracket to the door frame.
4. If replacing the outside door handle, remove 3

screws holding handle to door panel (3, Figure
2-14).
Note: Only 1 screw is shown, the other 2 are behind
the latch assembly.
23. Align door check strap opening with holes in the

bracket and install bolt. Install the hair pin clip.
See Figure 2-6.
Door Window Regulator Replacement

1. Follow Steps 1-6 procedure for door glass
replacement.
2. Move inner panel assembly to a work area to
enable replacement of the window regulator.
Remove 4 mounting screws. See 6, Figure 2-6.
5. Install new latch assembly and align mounting

holes. Install 4 mounting screws. Be sure they
are tight.
6. Align inside door handle and install capscrew
and nut (3 Figure 2-14).
7. Follow steps 20-23 of the door glass replacement procedure to complete the repair.
3. Replacing Window Regulator Motor, or Window

Regulator Assembly:
a. If replacing the motor assembly of the window regulator, be sure the worm gear on the
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Truck Cab
N2-13
Door and Door Hinge Seal Replacement

1. The door assembly seal has only three members to it (sides and top) and is glued on the
door. This seal can be replaced by peeling the
seal away from the door frame. Then use a
suitable cleaner to remove the remaining seal
and glue material.
2. The area where the door seal mounts should be
free of dirt and oil. Spread or spray a glue which
is quick drying and waterproof onto the area
where the seal is to installed.
3. Install the seal so that the corners of the seal fit
up into the corners of the door frame (3, Figure
2-16).
4. The door hinge seal is glued to the hinge. Use
the same procedure as above for this seal (2,
Figure 2-17).
Door Opening Seal Removal
1. Starting at the lower center of the door opening,
pull up on one end of the seal. Seal should pull
loose from the cab opening lip. Pull seal loose
all the way around the opening (1, Figures 2-16
& 2-17).
FIGURE 2-16.
1. Door Opening Seal
2. Door Assembly Seal
2. Inspect cab opening lip for damage, dirt, or oil.

Repair or clean cab opening as necessary.
Remove dirt, old sealant etc. Be certain perimeter of opening is clean and free of burrs, etc.
Installation
1. Install the seal material around the door opening in the cab. Start at the bottom center of the
cab opening and work the seal lip over the
edge of the opening. Go all the way around the
opening. Be sure that the seal fits tight in the
corners. A soft face tool may be used to work
the seal up into the corners.
2. Continue going all the way around the opening.
When the ends of the seal meet at the starting
bottom center of the cab opening, it may be
necessary to trim off some of the seal.
NOTE: The ends of the seal material need to be
square-cut to assure a proper fit.
3. Fit both ends so that they meet squarely, then
while holding ends together, push them firmly
into the center of the opening.
N2-14
Truck Cab
FIGURE 2-17.
1. Door Opening Seal
2. Door Hinge Seal
06/03 N02015
GLASS REPLACEMENT
Replacement Procedure
Adhesive Bonded Windows
Recommended Tools/Supplies
Cold knife, pneumatic knife, or a piano wire
cutting device, long knife. Cutout tools are
available at an auto glass supply store.
The first concern with all glass replacement is

SAFETY! Wear heavy protective gloves and
safety eyeglass goggles when working with
glass.
1. Using chosen cut-out tool, slice into existing
urethane adhesive and remove window.
Heavy protective gloves

Safety eyeglass goggles
Windshield adhesives, proper cleaners, primers
& application gun
SM2897 glass installation bumpers (6 - 7 per
window)
Window glass (Refer to Parts Catalog)
2. Carefully clean and remove all broken glass

chips from any remaining window adhesive.
The surface should be smooth and even. Use
only clean water.
NOTE: Removal of all old adhesive is not required;
just enough to provide an even bedding base.
Recommended adhesives: SikaTack Ultrafast or

Ultrafast II (both heated). Vehicle can be put into
service in 4 hours under optimum conditions. Heated
adhesives require a Sika approved oven to heat
adhesive to 80 C (176 F).
Sikaflex 255FC or Drive (unheated). Vehicle can be
put into service in 8 hours under optimum conditions.
3. Using a long knife, cut remaining urethane from

vehicle, leaving a bed 2-4 mm thick. If existing
urethane is loose or otherwise unsound, completely remove. Leave the installation bumpers
in place, if possible. Clean metal with Sika Aktivator, allow ten minutes to dry. Then paint on a
thin coat of Sika Primer 206G+P and allow ten
minutes to dry.
Sika Corporation
30800 Stephenson Hwy.
Madison Heights, MI 48071
Toll Free Number: 1-800-688-7452
Fax number: 248-616-7452
http://www.sika.com or
http://www.sikasolutions.com
4. Using only the new side window(s) which are to

be bonded in place, center the new glass over
opening in the cab. Using a permanent marker,
mark on the cab skin along all the edges of the
new glass that is to be installed. All edges must
be marked on the cab in order to apply the
adhesive in the proper location.
5. Using Sika Primer 206G+P, touch up any bright
metal scratches on the metal frame of vehicle.
Do not prime existing urethane bed. Allow to dry
for ten minutes.
Due to the severe duty application of off-highway

vehicles, the cure times listed by the adhesive
manufacturer should be doubled before a truck is
moved. If the cure time is not doubled, vibration
or movement from a moving truck will weaken
the adhesive bond before it cures, and the glass
may fall off the cab.
If another adhesive manufacturer is used, be certain to follow that manufacturer's instructions for
use, including the use of any primers, and double
the allowances for proper curing time.
N02015 06/03
6. Using a clean lint free cloth, apply Sika Aktivator to the black ceramic Frit surrounding the
new window. Use a clean cloth and wipe off
Sika Aktivator. Allow ten minutes to dry.
7. For the side windows, be sure to utilize a total
of six or seven (SM2897) glass installation
bumpers to the cab, equally spaced around the
previously marked glass perimeter, approximately 0.75 in (19 mm) inboard from where the
edge of the glass will be when installed.
NOTE: Be careful not to place adhesive too far
inboard, as it will make any future replacement more
difficult.
Truck Cab
N2-15
8. Apply a continuous even bead of the adhesive

approximately 0.38 in. (10 mm) in diameter to
the cab skin at a distance 0.50 - 0.63 in. (13 - 16
mm) inboard from the previously marked final
location of the glass edges from Step 4.
Windshield And Rear Glass
9. Immediately install glass to the vehicle. Carefully locate the glass in place with the black
masking side towards the adhesive. Carefully
press firmly, but not abruptly, into place assuring that the glass is properly seated. DO NOT
POUND THE GLASS INTO PLACE.
Special tools are available from local tool suppliers

that are helpful in removing and installing automotive
glass.
Two people are required to remove and install the

windshield or rear glass. One person inside the cab,
and the other person on the outside.
Removal
10. Using a wooden prop and furnace/duct tape,

hold the glass in place for at least two (2) full
hours (or double the adhesive manufacturers
curing time, which ever time is longer).
1. If windshield is to be replaced, lift windshield

wiper arms out of the way.
2. Starting at the lower center of the glass, pull the
weatherstrip locking lip out (2, Figure 2-18 or 219). Use a non-oily rubber lubricant and a
screwdriver to release the locking lip.
NOTE: Do not allow the truck to move until double

the cure time for the adhesive has passed.
Otherwise, vibration or movement from a moving
truck will weaken the adhesive bond and the glass
may fall off the cab.
3. Remove glass from weatherstrip by pushing out

from inside the cab.
4. Clean weatherstrip grooves of dirt, sealant etc.
Be certain perimeter of cab glass opening is
clean and free of burrs etc.
Be certain to follow all the adhesive manufacturer's instructions for use, including full allowances for proper curing time. The curing time
may be as long as 48 hours (24 hours for some
adhesives, then double it) before a truck can be
driven.
11. Remove tape or prop from glass after the cure
time has expired.
FIGURE 2-18. Front Windshield

1. Glass
2. Locking Lip
N2-16
Truck Cab
3. Weatherstrip Material
4. Sheet Metal
06/03 N02015
Installation
1. If the weatherstrip material previously removed
is broken, weathered, or damaged in any way,
use new rubber weatherstrip material.
NOTE: Using a non-oily rubber lubricant on the
weatherstrip material and cab opening will make the
following installation easier:
3. After the glass is in place, go around the weatherstrip and push in on the locking lip (2, Figure
2-18 or 2-19) to secure the glass in the weatherstrip.
4. If windshield was being replaced, lower windshield wiper arms/blades back to the glass.
a. Install the weatherstrip around the opening in

the cab for the glass. Start with one end of
the weatherstrip at the center, lower part of
the window opening and press the weatherstrip over the edge of the opening.
b. Continue installing weatherstrip while going
all the around the opening. When the ends of
the weatherstrip meet at the starting point at
the lower, center area of the window opening, there must be 0.5 in. (12.7 mm) of overlapping material.
NOTE: The ends of the weatherstrip material need to
be square-cut to assure a proper fit.
c. Lift both ends so that they meet squarely,
then while holding ends together, force them
back over the lip of the opening.
2. Lubricate the groove of the weatherstrip where
the glass is to be seated.
a. Lower the glass into the groove along the
bottom of the opening.
b. Two people should be used for glass installation. Have one person on the outside of the
cab and push in on glass against opening,
while the person inside uses a soft flat tool
(plastic knife) and goes around the glass to
work the weatherstrip over the edge of the
glass.
N02015 06/03
Truck Cab
FIGURE 2-19. Rear Window

1. Glass
2. Locking Lip
3. Weatherstrip Material
4. Sheet Metal
N2-17
NOTES
N2-18
Truck Cab
06/03 N02015
SECTION N3
CAB COMPONENTS
INDEX
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3

WINDSHIELD WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Wiper Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
WINDSHIELD WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
N03020
Cab Components
N3-1
NOTES
N3-2
Cab Components
N03020
CAB COMPONENTS
WINDSHIELD WIPERS
Installation
The windshield wipers are operated by a 24 volt electric motor. The wipers can be adjusted for a variable
intermittent delay or a constant low or high speed by
the switch mounted on the instrument panel.
Wiper Motor Replacement
Removal
1. Remove the five screws, inside of the cab, that
secure the visor assembly/access panel. Lower
the access panel.
2. Disconnect the wiper motor harness connector.
3. Remove nut (4, Figure 3-1), and disconnect the
linkage from the motor. Hold the linkage stationary while loosening the nut.
4. Remove three capscrews (3) and the washers
attaching motor (1) to plate (2). Remove the
motor assembly.
1. Place wiper motor (1, Figure 3-1) into position

on plate (2).
2. Install three capscrews (3) and the washers.
Torque the capscrews to 71-79 in. lbs. (8-9
Nm).
3. Align the motor output shaft with the linkage.
Install nut (4) and torque the nut to 16-18 ft. lbs.
(22-24 Nm). Hold the linkage stationary while
tightening the nut.
4. Reconnect the wiper motor harness connector.
5. Verify the wipers operate properly and park in
the proper position. Refer to Figure 3-3.
Wiper Arm Replacement

Removal
1. Note the position of wiper arm (1, Figure 3-2).
for installation purposes.
1. Lift the wiper arm cover and remove nut (2).
Remove washer (3).
2. Disconnect the washer hose, and remove the
wiper arm.
FIGURE 3-1. WINDSHIELD WIPER INSTALLATION

1. Wiper Motor
2. Plate Structure
N03020
3. Capscrew
4. Nut
FIGURE 3-2. WIPER ARM DETAIL

1. Wiper Arm
2. Nut
3. Spring Washer
Cab Components
4. Cap
5. Washer
6. Nut
N3-3
Installation
1. Place wiper arm (1, Figure 3-2) into the position
noted during removal. Install the washer and
nut (2). Tighten the nut to 142-177 in. lbs. (1620 Nm). Close the cover.
2. Connect the washer hose to the wiper arm.
4. If equipped, remove four capscrews (2, Figure

3-4), the washers, and the nuts that secure pillow blocks (3). Remove spacer blocks (1). Note
the orientation of the spacer blocks for assembly purposes.
3. Ensure the wipers arms operate properly and

park in the proper position after installation is
complete. Refer to Figure 3-3.
FIGURE 3-4. PILLOW BLOCK INSTALLATION

1. Spacer Block
2. Capscrew
3. Pillow Block
5. Remove the linkage from the wiper compartment.

Installation
1. Place the linkage into position in the wiper compartment.
FIGURE 3-3. PARK POSITION

1. Wiper Motor
2. Linkage Retainer
Wiper Linkage Replacement

Removal
1. Remove the wiper arms. Refer to Wiper Arm
Replacement in this section.
2. Remove wiper retainer (2, Figure 3-3) and disconnect the wiper linkage from the wiper motor
drive arm.
3. Remove nut (3, Figure 3-2) and the washer
from each wiper shaft.
N3-4
2. If equipped, place spacer blocks (1, Figure 3-4)

into position under pillow blocks (3). Install capscrews (2), the washers, and the nuts that
secure the pillow blocks.
3. Install nut (3, Figure 3-2) on each wiper shaft
and tighten finger-tight. Torque the nuts to 160177 in. lbs. (18-20 Nm). Do not overtighten.
The threads on the shafts are easily stripped
when improperly tightened.
4. Align the linkage and attach to the wiper motor
drive arm using retainer (2, Figure 3-3).
NOTE: When the motor is parked, the drive arm will
be in the 3 oclock position as shown in Figure 3-3.
5. Install the wiper arms. Refer to Wiper Arm
Installation. Ensure the wipers arms operate
properly and park in the proper position after
installation is complete.
Cab Components
N03020
WINDSHIELD WASHER
Operation
The windshield washer, mounted on the right side of
the hydraulic components cabinet behind the cab,
has a 3.8 liter (1 gal) plastic reservoir (1, Figure 3-5)
with a 24 volt electric pump (2).
The washer is controlled by the windshield wiper
switch mounted on the instrument panel and is activated by pressing the knob. When the switch is activated, washing solution is pumped through the outlet
hose (3) and fed to a jet located in each of the windshield wiper arms.
Service
If windshield washer maintenance is required, check
the strainer opening for obstructions and inspect the
hoses for damage. Check the voltage to the pump
from the control switch. If the pump is inoperable,
replace it with a new pump assembly.
Note: The pump is only available as an assembly
and cannot be repaired.
FIGURE 3-5. WINDSHIELD WASHER FLUID

RESERVOIR AND PUMP
1. Reservoir
2. Pump
N03020
Cab Components
3. Outlet Hose
4. Filler Cap
N3-5
OPERATOR COMFORT
OPERATOR SEAT
The operator's seat provides a fully adjustable cushioned ride for driver comfort and easy operation.
Adjustment
The following adjustments are available to the operator while sitting in the seat.
Headrest (1, Figure 32-5): Adjust up, down, fore,
or aft by moving headrest to desired position.
Armrests (3): Rotate adjusting knob until armrest
is at desired angle.
Backrest: Rotate knob (9) to adjust the backrest
angle.
Seat Belt Harness: Operator must always have
four-point seat belt harness (2) buckled in place
and properly adjusted during machine operation.
Air Lumbar Support: Use lumbar hand pump (8)
to adjust the air support. A release button on the
back of the hand pump releases the air from the
lumbar support.
Weight Adjustment: Adjust the weight
adjustment dial to match the approximate weight
of the operator. The dial ranges from 110 - 265
lbs. (50 - 120 kg).
Fore/Aft Adjustment: Lift lever (8) and hold.
Slide the seat to a comfortable position and
release the lever to lock the adjustment.
Seat Height: Lift lever (7) and then push the
lever down to raise the seat one level. Remove
body weight from the seat to allow it to adjust. To
lower the seat one level, push lever (7) down,
and then pull the lever up. Release lever to lock
the adjustment.
Seat Tilt: Pull lever (7) up to tilt the seat
rearward. Push the lever down to tilt the seat
forward. Release the lever to lock the
adjustment.
N3-6
FIGURE 32-108. OPERATORS SEAT

1. Headrest
2. Seat Belt
3. Armrest
4. Seat Belt Anchor
5. Weight Adjustment
Dial
Cab Components
6. Fore/Aft Lever
7. Seat Height/Tilt
Adjustment Lever
8. Lumbar Pump
9. Backrest Angle
Adjustment Knob
N03020
SECTION N4
OPERATOR COMFORT
INDEX
HEATER / AIR CONDITIONER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Fan Motor And Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-7
Environmental Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-7
OPERATOR CAB AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
PRINCIPLES OF REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
Refrigeration - The Act Of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-9
The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-9
AIR CONDITIONER SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Compressor (Refrigerant Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Expansion Block Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-11
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-11
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12
Trinary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-13
SYSTEM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-14
SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Handling and Reusing PAG Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Oil Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Replacing Oil After Servicing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Setting Up a New Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
Recycled Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
Reclaimed Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
Refrigerant Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
R-134a Refrigerant Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
N04024
Operator Comfort
N4-1
SERVICE TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-17

Recovery/Recycle Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-17
Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-17
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-18
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-18
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-19
Installing Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20
Purging Air From Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-21
Stabilizing the AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22
SYSTEM PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22
SYSTEM LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Electronic Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Tracer Dyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Soap and Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
SYSTEM REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
Servicing the Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26
Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28
Clutch Coil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28
Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28
Clutch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-29
RECOVERING AND RECYCLING THE REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-30
Performing the Recovery Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-30
Performing the Recycling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-30
Evacuating and Charging the AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-30
EVACUATING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-31
CHARGING THE AC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-33
Pre-Diagnosis Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-33
Preparing For Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-33
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-33
System Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-33
Diagnosis Of Gauge Readings And System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-34
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-35
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . N4-41
N4-2
Operator Comfort
N04024
OPERATOR COMFORT
HEATER / AIR CONDITIONER
Fan Control Knob
The heater/air conditioner assembly incorporates all

the controls necessary for regulating the cab interior
temperature; heated air during cold weather operation, and de-humidified, cool air during warm weather
operation.
Fan control knob (4, Figure 4-1) controls the cab air
fan motor. The fan motor is a 3-speed motor: low
(setting 1), medium (setting 2), and high (setting 3).
Speeds are selected by rotating the control knob
clockwise to the desired position. OFF is full counterclockwise position (setting 0).
Operation
Heat for the cab is provided by passing coolant from
the engine cooling system through a heater coil.
Blowers move air across the heating coil which
warms the air for heating or defrosting.
An engine driven refrigerant compressor passes
refrigerant through an evaporator coil mounted in the
same enclosure. The same blowers used for heating
move air across the evaporator to provide cooled air
through the outlet vents.
Heater/Air Conditioner Selector Switch

Selector switch (5, Figure 4-1) allows the operator to
select heat, A/C, or neither. The left position of the
switch activates the air conditioning and the right side
of the switch activates the heater. The middle position is OFF. Neither the heat nor the air conditioning
can be activated in this position.
NOTE: The air conditioner will not operate unless the
fan control knob is turned ON.
All heater and air conditioner controls are mounted

on a pod on the face of the enclosure. Refer to Figure 4-1 for the following:
Heater/Air Conditioner Vents
Each heater/air conditioner vent (6, Figure 4-1) is a
flapper type which may be opened or closed or
rotated 360 for optimum air flow. There are four
(three not shown) across the top of the panel, one
each in the right and left panel modules, and four
below the panel.
Defroster Control Switch
Defroster control switch (1, Figure 4-1) directs
heated air for windshield defrosting. "Down" position
of the toggle switch is OFF. "Up" position of the toggle switch is ON.
Heat Control Switch
Heater control 2, Figure 4-1) directs heated air to the
cab floor for heating of the cab. "Down" position of
the toggle switch is OFF. "Up" position of the toggle
switch is ON.
Temperature Control Knob
Temperature control knob (3, Figure 4-1) allows the
operator to select a comfortable temperature.
Rotating the knob counter-clockwise (blue arrow) will
select cooler temperatures. Full counter-clockwise
position is the coldest air setting. Rotating the knob
clockwise (red arrow) will select warmer temperatures. Full clockwise position is the warmest heater
setting.
FIGURE 4-1. A/C & HEATER CONTROLS
N04024
Operator Comfort
N4-3
COMPONENTS
Figures 4-2 and 4-4 illustrate both the heater system
and air conditioning system parts contained in the
cab mounted enclosure. Refer to Air Conditioning
System in this section for additional information
regarding air conditioning system components,
maintenance and repair.
Circuit Breakers
Before attempting to troubleshoot the electrical circuit in the heater enclosure, turn key switch ON and
verify circuit breaker CB31 (located on power distribution module behind operator's seat) and the internal heater circuit breaker have not opened by
verifying 24 VDC is present on the junction block
(38, Figure 4-4).
Relays
Five relays (9, Figure 4-2) control the air dampers,
A/C compressor and the heater valve. All five relays
require 12VDC through the coil which is supplied by
a 24VDC to 12VDC converter (2).
One relay (Relay 1) switches 24 volt current to actuate the A/C compressor clutch. The temperature
control switch, heater valve and the actuator motors
all operate on 12 VDC current.
Heater Core
Heater core (46, Figure 4-4) receives engine coolant through heater valve (14) when heat is selected.
If temperature control potentiometer (37) is placed
in between the red and blue area, or turned counterclockwise to the blue area, coolant flow should be
blocked.
If the selector switch (34) and heater valve appear
to be working properly, yet no heat is apparent in
heater core (46), the core may be restricted.
Remove and clean or replace the core.
FIGURE 4-2. CAB HEATER/AIR CONDITIONER

COMPONENTS
1. Enclosure
2. Converter (24 V to 12 V)
3. Water Control (Heater) Valve
4. A/C Refrigerant Hoses
5. Water Outlet (To Engine)
6. Water Inlet (From Engine Water Pump)
7. Evaporator Core
8. Heater Core
9. Relays
N4-4
Operator Comfort
N04024
Fan Motor And Speed Control
Filter
Fan speed is controlled by inserting resistor(s) (49 &

50) in series with the supply circuit to the blower
motor to reduce voltage. The number of resistors in
series is determined by the position of the fan speed
selector switch.
Service
At low speed, 3 resistors are used; at medium speed,

1 resistor is used; at high speed, the full 24 VDC is
supplied to the blower motor, bypassing all resistors.
Test
If motor (5) does not operate at any of the speed
selections, verify battery voltage is available at the
switches, relay, and circuit breakers (refer to electrical schematic, Section R). If voltage is present, the
motor is probably defective and should be removed
and replaced.
Filter (19) and cab filter (2, Figure 4-3) in the front
access panel of the cab need periodic cleaning to
prevent restrictions in air circulation. Restricted filters
will decrease the performance of the heater and air
conditioner. The recommended interval for cleaning
and inspection is 250 hours, but in extremely dusty
conditions, the filters may need daily service and
inspection, especially the outer panel filter on the cab
shell. The filter elements should be cleaned with
water and dried in a dust free environment before
reinstallation. Replace the filter element every 2000
hours or sooner if inspection indicates a clogged or
damaged filter.
If the motor operates at high speed, but does not

operate at reduced speed, inspect the resistors for
physical damage or an open circuit. Replace resistors as required.
Actuators
Two rotary actuator motors (8, Figure 4-4) are
installed inside the heater housing and are used to
actuate the flappers for the following:
Defroster outlet
Bi-level or floor outlets
A failure to switch one of the above modes of operation may be caused by a faulty actuator.
Test
Visually inspect the flappers (11, 43) and linkage for
the function being diagnosed. Make certain the flapper is not binding or obstructed, preventing movement from one mode to the other.
Verify voltage (12 VDC) is present at the actuator
when the toggle switch is closed or absent when the
toggle switch is opened.
FIGURE 4-3. CAB FILTER LOCATION

1. Access Cover
2. Cab Filter
If the correct voltages are present during operation of

the switch, disconnect the actuator from the flapper
and verify actuator force is comparable to a known
(new) actuator. If not, replace with a new actuator.
N04024
Operator Comfort
N4-5
FIGURE 4-4. HEATER/AIR CONDITIONER ASSEMBLY

1. Blower Housing
2. Blower Wheel
3. Cover Plate
4. Venturi
5. Motor, 24V
6. Motor Mount
7. Converter (24V-12V)
8. Actuator Motor
9. Screw
10. Spacer
11. Defrost Flapper
12. Snap Bushing
N4-6
13. Foam
14. Heater Valve
15. Grommet
16. Casing
17. Gasket
18. Filter Holder
19. Air Filter
20. Knob
21. Filter Holder
22. Foam Insulation
23. Nut
24. Flatwasher
25. Cover
26. Louver
27. Louver Adapter
28. Foam
29. Plate, Coil
30. Evaporator Core
31. O-Ring
32. Expansion Valve
33. Knob
34. Toggle Switch (3 pos.)
35. Overlay
36. Plate, Control
37. Potentiometer
38. Block, Junction
Operator Comfort
39. Thermostat
40. Hose
41. Switch, Blower
42. Screw
43. Discharge Flapper
44. Toggle Switch (2 pos.)
45. Bracket, Flapper
46. Heater Core
47. Relay (12V)
48. Circuit Breaker
49. Resistor (12 Volt)
50. Resistor (24 Volt)
51. Retainer, Blower
N04024
AIR CONDITIONING SYSTEM

Environmental Impact
Environmental studies have indicated a weakening of the earths protective Ozone (O3) layer in the outer stratosphere. Chloro-flouro-carbon compounds (CFCs), such as R-12 refrigerant (Freon), commonly used in mobile
equipment air conditioning systems, have been identified as a possible contributing factor of the Ozone depletion.
Consequently, legislative bodies in more than 130 countries have mandated that the production and distribution of
R-12 refrigerant be discontinued after 1995. Therefore, a more environmentally-friendly hydro-flouro-carbon.
FIGURE 4-5. BASIC AIR CONDITIONING SYSTEM

1. Blower Switch
2. Thermostatic Switch
3. Battery Supply
4. Circuit Breaker
5. Blower
6. Temperature Sensor
N04024
7. Evaporator
8. Expansion Valve
9. Suction Line
10. Test Gauges & Manifold
11. Compressor
12. Refrigerant Container
Operator Comfort
13. Magnetic Clutch

14. Compressor Drive Pulley
15. Receiver-Drier
16. Discharge Line
17. Condenser
N4-7
(HFC) refrigerant, commonly identified as HFC-134a or R-134a, is being used in most current mobile air conditioning systems. Additionally, the practice of releasing either refrigerant to the atmosphere during the charging/
recharging procedure is prohibited.
These restrictions require the use of equipment and procedures which are significantly different from those traditionally used in air conditioning service techniques. The use of new equipment and techniques allows for complete
recovery of refrigerants, which will not only help to protect the environment, but through the recycling of the refrigerant will preserve the physical supply, and help to reduce the cost of the refrigerant.
OPERATOR CAB AIR CONDITIONING
PRINCIPLES OF REFRIGERATION
Mining and construction vehicles have unique characteristics of vibration, shock-loading, operator
changes, and climate conditions that present different design and installation problems for air conditioning systems. Off-highway equipment, in general, is
unique enough that normal automotive or highway
truck engineering is not sufficient to provide the reliability to endure the various work cycles encountered.
A brief review of the principles of air conditioning is

necessary to relate the function of the components,
the technique of troubleshooting and the corrective
action necessary to put the AC unit into top operating
efficiency.
The cab tightness, insulation, and isolation from heat

sources is very important to the efficiency of the system. It is advisable to close all vents, even the
intakes of pressurization systems, when there are
high humidity conditions.
The general cleanliness of the system and components is important. Dust or dirt collected in the condenser, evaporator, or air filters decreases the
system's cooling capacity.
The compressor, condenser, evaporator units, hoses
and fittings must be installed clean and tight and be
capable of withstanding the strain and abuse they
are subjected to on off-highway vehicles.
Equipment downtime costs are high enough to
encourage service areas to perform preventative
maintenance at regular intervals on vehicle Air Conditioning (AC) systems. (Cleaning, checking belt
tightness, and operation of electrical components).
N4-8
Too frequently, the operator and the serviceman

overlook the primary fact that no AC system will function properly unless it is operated within a completely
controlled cab environment. The circulation of air
must be a directed flow. The cab must be sealed
against seepage of ambient air. The cab interior must
be kept free of dust and dirt which, if picked up in the
air system, will clog the intake side of the evaporator
coil.
Air Conditioning
Air conditioning is a form of environmental control. As
applied to the cab, it refers to the control of temperature, humidity, cleanliness, and circulation of air. In
the broad sense, a heating unit is as much an air
conditioner as is a cooling unit. The term air conditioner is commonly used to identify an air cooling
unit. To be consistent with common usage, the term
air conditioner will refer to the cooling unit utilizing
the principles of refrigeration; sometimes referred to
as the evaporator unit.
Operator Comfort
N04024
The Refrigeration Cycle
Refrigeration - The Act Of Cooling

There is no process for producing cold; there is
only heat removal.
Heat always travels toward cooler temperatures.
This principle is the basis for the operation of a
cooling unit. As long as one object has a
temperature lower than another, this heat transfer
will occur.
Temperature is the measurement of the intensity

of heat in degrees. The most common measuring
device is the thermometer.
All objects have a point at which they will turn to

vapor. Water boiling is the most common
example of heating until vapor is formed. Boiling
is a rapid form of evaporation. Steam is a great
deal hotter than boiling water. The water will not
increase in temperature once brought to a boil.
The heat energy is used in the vaporization
process. The boiling point of a liquid is directly
affected by pressure. By changing pressure, we
can control the boiling point and temperature at
which a vapor will condense. When a liquid is
heated and vaporizes, the gas will absorb heat
without changing pressure.
Reversing the process, when heat is removed
from water vapor, it will return to the liquid state.
Heat from air moves to a cooler object. Usually
the moisture in the cooled air will condense on
the cooler object.
Refrigerant - Only R-134a should be used in the
new mobile systems which are designed for this
refrigerant.
In an air conditioning system, the refrigerant is circulated under pressure through the five major components in a closed circuit. At these points in the
system, the refrigerant undergoes predetermined
pressure and temperature changes.
The compressor (refrigerant pump) takes in low pressure heat laden refrigerant gas through the suction
valve (low side), and as its name indicates, pressurizes the heat laden refrigerant and forces it through
the discharge valve (high side) on to the condenser.
Ambient air, passing through the condenser removes
heat from the circulating refrigerant resulting in the
conversion of the refrigerant from gas to liquid.
The liquid refrigerant moves on to the receiver drier
where impurities are filtered out, and moisture
removed. This component also serves as the temporary storage unit for some liquid refrigerant.
The liquid refrigerant, still under high pressure, then
flows to the expansion valve. This valve meters the
amount of refrigerant entering the evaporator. As the
refrigerant passes through the valve, it becomes a
low temperature, low pressure liquid and saturated
vapor. This causes the refrigerant to become cold.
The remaining low pressure liquid immediately starts
to boil and vaporize as it approaches the evaporator,
adding to the cooling. The hot, humid air of the cab is
pulled through the evaporator by the evaporator
blower. Since the refrigerant is colder than the air, it
absorbs the heat from the air producing cool air
which is pushed back into the cab. The moisture in
the air condenses upon movement into the evaporator and drops into the drain pan from which it drains
out of the cab.
The cycle is completed when the heated low pressure gas is again drawn into the compressor through
the suction side.
This simplified explanation of the principles of refrigeration does not call attention to the fine points of
refrigeration technology. Some of these will be covered in the following discussions of the components,
controls, and techniques involved in preparing the
unit for efficient operation.
N04024
Operator Comfort
N4-9
AIR CONDITIONER SYSTEM

COMPONENTS
Compressor (Refrigerant Pump)
The compressor is where the low pressure side of
the system changes to high pressure. It concentrates
the refrigerant returning from the evaporator (low
side) creating high pressure and a temperature much
higher than the outside air temperature. The high
temperature differential between the refrigerant and
the outside air is necessary to aid rapid heat flow in
the condenser from the hot refrigerant gas to much
cooler outside air.
To create high pressure concentration, the compressor draws in refrigerant from the evaporator through
the suction valve and during compression strokes,
forces it out through the discharge valve to the condenser. The pressure from the compressor action
moves the refrigerant through the condenser,
receiver-drier and connecting hoses to the expansion
valve.
The compressor is driven by the engine through a vbelt driving an electrically operated clutch mounted
on the compressor drive shaft.
Service Valves
Quick-connect hose end fittings with integral service
valves attach to system service ports for servicing
the unit. A manifold gauge set is connected into the
system at the service valve ports and all procedures,
such as discharging, evacuating and charging the
system, are performed through the service valves.
Condenser
The condenser receives the high pressure, high-temperature refrigerant vapor from the compressor and
condenses it to high pressure, hot liquid.
It is designed to allow heat movement from the hot
refrigerant vapor to the cooler outside air. The cooling of the refrigerant changes the vapor to liquid.
Heat exchange is accomplished using cooler air flowing through the condenser. Condenser cooling is
achieved by air flowing from the radiator fan along
with ram air provided by vehicle movement. The radiator fan moves more than 50% of condenser air flow
unless travel speed is at least 25 mph.
N4-10
Ram air condensers depend upon the vehicle movement to force a large volume of air past the fins and
tubes of the condenser. The condenser is usually
located in front of the radiator or on the roof of the
truck.
Condensing of the refrigerant is the change of state
of the refrigerant from a vapor to a liquid. The action
is affected by the pressure of the refrigerant in the
coil and air flow through the condenser. Condensing
pressure in an AC system is the controlled pressure
of the refrigerant which affects the temperature at
which it condenses to liquid, giving off large quantities of heat in the process. The condensing point is
sufficiently high to create a wide temperature differential between the hot refrigerant vapor and the air
passing over the condenser fins and tubes. This difference permits rapid heat transfer from the refrigerant to ambient air.
Receiver-Drier
The receiver-drier is an important part of the air conditioning system. The drier receives the liquid refrigerant from the condenser and removes any moisture
and foreign matter present which may have entered
the system. The receiver section of the tank is
designed to store extra refrigerant until it is needed
by the evaporator. The storage of this refrigerant is
temporary and is dependent on the demand of the
expansion valve.
A desiccant is a solid substance capable of removing
moisture from gas, liquid or solid. It is held in place
within the receiver between two screens, which also
act as strainers.
The receiver-drier is also equipped with a sight glass
and a moisture indicator. The sight glass can give a
good indication of the charge of the system. If the
sight glass is not clear, the system is low on refrigerant.
The moisture indicator is a device to notify service
personnel that the drier is full of moisture and must
be replaced. The indicator is blue when the component is free from moisture. When the indicator turns
beige or tan, the drier must be replaced.
Operator Comfort
N04024
Expansion Block Valve
Evaporator
The expansion block valve controls the amount of

refrigerant entering the evaporator coil. Both internally and externally equalized valves are used.
The evaporator cools and dehumidifies the air before

it enters the cab. Cooling a large area requires that
large volumes of air be passed through the evaporator coil for heat exchange. Therefore, a blower
becomes a vital part of the evaporator assembly. It
not only draws heat laden air into the evaporator, but
also forces this air over the evaporator fins and coils
where the heat is surrendered to the refrigerant. The
blower forces the cooled air out of the evaporator into
the cab.
The expansion valve is located near the inlet of the

evaporator and provides the functions of throttling,
modulating, and controlling the liquid refrigerant to
the evaporator coil.
The refrigerant flows through a restriction creating a
pressure drop across the valve. Since the expansion
valve also separates the high side of the system from
the low side, the state of the refrigerant entering the
valve is warm to hot high pressure liquid; exiting it is
low pressure liquid and gas. The change to low pressure allows the flowing refrigerant to immediately
begin changing to gas as it moves toward the evaporator. This produces the desired cooling effect.
The amount of refrigerant metered into the evaporator varies with different heat loads. The valve modulates from wide open to the nearly closed position,
seeking a point between for proper metering of the
refrigerant.
As the load increases, the valve responds by opening wider to allow more refrigerant to pass into the
evaporator. As the load decreases, the valve reacts
and allows less refrigerant into the evaporator. It is
this controlling action that provides the proper pressure and temperature control in the evaporator.
This system uses an internally equalized, block type
expansion valve. With this type valve, the refrigerant
leaving the evaporator coil is also directed back
through the valve so the temperature of the refrigerant is monitored internally rather than by a remote
sensing bulb. The expansion valve is controlled by
both the temperature of the power element bulb and
the pressure of the liquid in the evaporator.
NOTE: It is important that the sensing bulb, if
present, is tight against the output line and protected
from ambient temperatures with insulation tape.
N04024
Heat exchange, as explained under condenser operation, depends upon a temperature differential of the
air and the refrigerant. The greater the temperature
differential, the greater will be the amount of heat
exchanged between the air and the refrigerant. A
high heat load condition, as is generally encountered
when the air conditioning system is turned on, will
allow rapid heat transfer between the air and the
cooler refrigerant.
The change of state of the refrigerant in and going
through the evaporator coil is as important as that of
the air flow over the coil.
All or most of the liquid that did not change to vapor
in the expansion valve or connecting tubes boils
(expands) and vaporizes immediately in the evaporator, becoming very cold. As the process of heat loss
from the air to the evaporator coil surface is taking
place, any moisture (humidity) in the air condenses
on the cool outside surface of the evaporator coil and
is drained off as water.
At atmospheric pressure, refrigerant boils at a point
lower than water freezes. Therefore, the temperature
in the evaporator must be controlled so that the water
collecting on the coil surface does not freeze on and
between the fins and restrict air flow. The evaporator
temperature is controlled through pressure inside the
evaporator, and temperature and pressure at the outlet of the evaporator.
Operator Comfort
N4-11
ELECTRICAL CIRCUIT
Compressor Clutch
The air conditioner's electrical circuit is fed from an

accessory circuit and is fused with a 30-ampere circuit breaker.
An electromagnetic clutch is used in conjunction with

the thermostat to disengage the compressor when it
is not needed, such as when a defrost cycle is indicated in the evaporator, or when the system or
blower is turned off.
The blower control is a switch which provides a

range of blower speeds from fast to slow. When the
blower switch is turned on, current is available at the
compressor clutch. Once the blower is turned on, fan
speeds may be changed without affecting the thermostat sensing level.
The thermostat reacts to changing temperatures
which cause electrical contacts to open and close.
The thermostat has a capillary tube extended into the
evaporator coil to sense temperature.
When the contacts are closed, current flows to the
clutch field and energizes the clutch, causing the
swash plate inside the compressor to turn which
starts the refrigeration cycle. When the temperature
of the evaporator coil drops to a predetermined point,
the contacts open and the clutch disengages.
When the clutch is disengaged, the blower remains
at the set speed. After the evaporator temperature
rises about twelve degrees above the cutout point,
the contacts in the thermostat close and the refrigeration cycle resumes.
Thermostat
An electromagnetic clutch is used on the compressor
to provide a means of constant temperature control
of the cab. The clutch is controlled by a thermostat in
the evaporator which is set initially by the driver to a
predetermined point. Evaporator temperature is then
maintained by the cycling action of the clutch.
The stationary field clutch is the most desirable type

since it has fewer parts to wear. The field is mounted
to the compressor by mechanical means depending
on the type field and compressor. The rotor is held on
the armature by a bearing and snap rings. The armature is mounted on the compressor body.
When no current is fed to the field, there is no magnetic force applied to the clutch and the rotor is free
to rotate on the armature, which remains stationary
on the crankshaft.
When the thermostat or switch is closed, current is
fed to the field. This sets up a magnetic force
between the field and armature, pulling it into the
rotor. When the armature becomes engaged with the
rotor, the complete unit rotates while the field
remains stationary. This causes the compressor
crankshaft to turn, starting the refrigeration cycle.
When the switch or thermostat is opened, current is
cut off. The armature snaps back out and stops while
the rotor continues to turn. Pumping action of the
compressor is stopped until current is again applied
to the field. In addition, safety switches in the compressor clutch electrical circuit control clutch operation, disengaging the clutch if system pressures are
abnormal.
The thermostat is simply a thermal device which controls an electrical switch. When warm, the switch is
closed; when cold, it is open. Most thermostats have
a positive OFF position as a means to turn the clutch
off regardless of temperature.
The bellows type thermostat has a capillary tube connected to it which is filled with refrigerant. The capillary tube is attached to the bellows inside of the
thermostat. Expansion of the gases inside the capillary tube exerts pressure on the bellows, which in
turn closes the contacts at a predetermined temperature.
N4-12
Operator Comfort
N04024
Fan Clutch - The mid-range function actuates the

engine fan clutch, if installed.
Trinary Switch
This switch is mounted on the receiver-drier and has
three functions, as implied by the name:
1. Disengage the compressor clutch when system
pressure is too high.
2. Disengage the compressor clutch when system
pressure is too low.
3. Engage and disengage the radiator fan drive
clutch during normal variation of system pressure.
The Trinary switch performs three distinct functions to monitor and control refrigerant pressure in
the system. This switch is installed on the receiverdrier. The switch functions are:
Terminals 1 & 2 are connected internally through two,
normally closed pressure switches in series, the low
pressure switch and the high pressure switch.
High Pressure - This switch opens and

disengages the compressor clutch if system
pressure rises above the 300 - 350 psi range.
After system pressure drops to 210 - 250 psi, the
switch contacts will close and the clutch will
engage.
The switch functions will automatically reset when
system pressure returns to normal.
OPENS
CLOSES
Low
Pressure
15-30 psi descending

pressure
40 psi rising pressure
High
Pressure
300-350 psi
210-250 psi
Fan Clutch
35-60 psi below closing

pressure
200-230 psi rising pressure
The pressures listed above are typical of pressures at the receiver-drier. Due to normal system
flow losses and the distance between the service
port and the receiver-drier, it is expected that
actual system pressure displayed on the gauge
will normally be approximately 20 psi higher. This
factor should be observed when checking for
proper operation of the switch.
Terminals 3 & 4 are connected internally through a

normally open switch that is used to control the
clutch that drives the radiator fan. This switch closes
and causes the cooling fan clutch to engage when
system pressure rises to 200 - 230 psi. When pressure falls to 140 - 195 psi, the switch contacts open,
and the cooling fan clutch disengages
NOTE: One other pressure controlling device is

installed within the compressor. A mechanical relief
valve is located on the back of the compressor. The
relief valve will open at 500 - 550 psi. The purpose of
this valve is to protect the compressor in the event
that pressure should be allowed to rise to that level.
Damage to the compressor will occur if pressure
exceeds 550 psi.
Low Pressure - This switch opens and

disengages the compressor clutch if system
pressure drops into the 15 -30 psi range. When
pressure rises above 40 psi, the switch contacts
close, and the clutch engages the compressor.
Since temperature has a direct effect on
pressure, if the ambient temperature is too cold,
system pressure will drop below the low range,
and the pressure switch will disengage the
clutch.
N04024
Operator Comfort
N4-13
SYSTEM SERVICING
Servicing an air conditioning system really means

closely monitoring refrigerant flow. For this reason,
the following procedures deal extensively with the
proper use, handling, care and safety factors
involved in the R-134a refrigerant quality and quantity in an air conditioning system.
Because the refrigerant in an air conditioning system
must remain pressurized and sealed within the unit to
function properly, safety is a major consideration
when anything causes this pressurized, sealed condition to change. The following warnings are provided here to alert service personnel to their
importance before learning the correct procedures.
Read, remember, and observe each warning before
beginning actual system servicing.
NOTE: If the mine operates a fleet with some trucks
using R-12 and others using R-134a refrigerant, it is
essential that servicing tools that come into contact
with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one
type refrigerant only, to prevent cross contamination.
Federal regulations prohibit venting R-12 and

R134a refrigerant into the atmosphere. An SAE
and UL approved recovery/recycle station must
be used to remove refrigerant from the AC system. Refrigerant is stored in a container on the
unit for recycling, reclaiming, or transporting. In
addition, technicians servicing AC systems must
be certified they have been properly trained to
service the system.
Although accidental release of refrigerant is a
remote possibility when proper procedures are
followed, the following warnings must be
observed when servicing AC systems:
Provide appropriate protection for your eyes
(goggles or face shield) when working around
refrigerant.
A drop of the liquid refrigerant on your skin will
produce frostbite. Wear gloves and exercise
extreme care when handling refrigerant.
If even the slightest trace of refrigerant enters in
your eye, flood the eye immediately with cool
water and seek medical attention as soon as possible.
Ensure sufficient ventilation whenever refrigerant is being discharged from a system, keeping
in mind refrigerant is heavier than air and will
seek low areas of shop.
When exposed to flames or sparks, the components of refrigerant change and become deadly
phosgene gas. This poison gas will damage the
respiratory system if inhaled. NEVER smoke in
area where refrigerant is used or stored.
Never direct steam cleaning hose or torch in
direct contact with components in the air conditioning system. Localized heat can raise the
pressure to a dangerous level.
Do not heat or store refrigerant containers above
120 F (49 C).
Do not flush or pressure test the system using
shop air or another compressed air source. Certain mixtures of air and R-134a refrigerant are
combustible when slightly pressurized. Shop air
supplies also contain moisture and other contaminants that could damage system components.
N4-14
Operator Comfort
N04024
SYSTEM OIL
R-134a air conditioning systems require the use of
Polyalkylene Glycol (PAG) lubricating oil. This is the
only oil recommended for use in this system. At
present time, General Motors part number
(12345923) is the oil that is furnished in the system
on Komatsu trucks. This clear oil can be found at AC
Delco dealers. In some areas, it can be found from
other suppliers as U-Con 488. The only other alternative is General Motors part number (12356151)
which is now becoming more popular and is
expected to become the furnished oil in Komatsu AC
systems. This oil is light blue-green in color and may
be mixed with the other recommended oil.
REPLACING OIL
Component
Oil to add
Condenser
2-3 ounces
Evaporator
1 ounce
Receiver-Drier
2 ounces
Compressor
Compressors come with 10.5

ounces of oil in the sump. Refer to
"Setting Up a New Compressor"
Block Valve
(Expansion)
Adding oil is not necessary
Avoid skin contact and inhalation of PAG oil, as

these are normal precautions with any chemical.
Hoses
Drain and measure amount

removed
No PAG oil removed from new or old components

should be retained for re-use. It should be stored
in a marked container and properly sealed. PAG
oil is an environmental pollutant and should be
properly disposed of after use.
Setting Up a New Compressor
Handling and Reusing PAG Oil
PAG oil in containers or in an air conditioning

system should not be left exposed to the
atmosphere any longer than necessary. PAG oil
absorbs moisture very rapidly, and therefore, any
absorbed moisture could cause damage to an air
conditioning system.
Oil Quantity
It is critical to keep the correct amount of lubricant in
the air conditioning system at all times. Failure to do
so could result in damage to the compressor.
Damage to the compressor can be a result from not
only a lack of oil, but from too much oil, also. A lack
of oil will cause excess friction and wear on moving
parts. Excessive oil can result in slugging the compressor. This condition occurs when the compressor
attempts to compress liquid oil as opposed to vaporized refrigerant. Since liquid cannot be compressed,
damage to internal parts results.
Compressors come with 10.5 ounces of oil in the

sump. Compressors being replaced should have
been operating with 6 ounces of oil in the sump,
therefore, the new compressor should be adjusted,
accordingly.
Example: If a compressor is being replaced, the
receiver drier must also be replaced. (The receiverdrier should be replaced whenever the system is
opened.) Since the new compressor comes with 10.5
ounces of oil, 2.5 ounces of oil should be removed
from the compressor leaving 8 ounces. 8 ounces
accounts for the 6 ounces needed for the compressor, and the 2 ounces for the new receiver-drier.
Never run the system with more than 10.5 ounces

of oil in the compressor sump. Damage to the
compressor as well as other system components
may occur. It is important to have a good balance
of oil throughout the system.
Replacing Oil After Servicing the System

Replace oil that has been removed from the system
through recovery of refrigerant and replacement of
components. Refer to the chart below for adding oil.
N04024
Operator Comfort
N4-15
REFRIGERANT
Recycled Refrigerant
Recycled refrigerant has been extracted from a
mobile air conditioning system using a recovery unit.
The refrigerant is cleaned by the recovery unit as it
passes through filters located on the unit that meet
specifications stipulated by Society of Automotive
Engineers, SAE J2099. The refrigerant that has
passed through the filtering process has only been
cleaned of contaminants that are associated with
mobile systems. Therefore, recycled refrigerant from
mobile systems is only acceptable for reuse in mobile
systems.
An unclear sight glass on R-134a systems can

indicate that the system may be low on refrigerant. However, the sight glass should not be used
as a gauge for charging the system. Charging the
system must be done with a scale to ensure the
proper amount of refrigerant has been added.
Reclaimed Refrigerant
Reclaimed refrigerant has been filtered through a
more thorough filtering process and has been processed to the same standards of purity as virgin
refrigerant. Because of this, reclaimed refrigerant is
acceptable for use in all systems, not just mobile.
The reclaiming equipment used for this process is
expensive, and therefore, not common among normal maintenance shops. Equipment such as this is
more commonly found in air conditioning specialty
shops.
R-134a Refrigerant Containers

Two basic, readily available containers are used to
store R-134a: the 30 or 60 pound bulk canisters (Figure 4-6).
Always read the container label to verify the contents
are correct for the system being serviced. Note the
containers for R-134a are painted light blue.
Always use new, recycled, or reclaimed refrigerant when charging a system. Failure to adhere to
this recommendation may result in premature
wear or damage to air conditioning system components and poor cooling performance.
Refrigerant Quantity
If not enough refrigerant is charged into the system,
cooling ability will be diminished. If too much refrigerant is charged into the system, the system will operate at higher pressures, and in some cases, may
damage system components. Exceeding the specified refrigerant charge will not provide better cooling.
FIGURE 4-6. R-134a CONTAINERS

1. 30 lb. Cylinder
2. 60 lb. Cylinder
If an incorrect charge is suspected, recover the

refrigerant from the system, and charge the system
with the correct operating weight (6.9 lb, 3.13 kg).
This is not only the recommended procedure, but it is
also the best way to ensure that the system is operating with the proper charge and providing optimum
cooling. Using the sight glass to determine the
charge is not an accurate method.
N4-16
Operator Comfort
N04024
SERVICE TOOLS AND EQUIPMENT

Recovery/Recycle Station
Whenever refrigerant must be removed from the system, a dual purpose station as shown in Figure 4-7,
performs both recovery and recycle procedures
which follows the new guidelines for handling used
refrigerant. The recovered refrigerant is recycled to
reduce contaminants, and can then be reused in the
same machine or fleet.
Mixing different types of refrigerant will damage

equipment. Dedicate one recovery/recycle station to each type of refrigerant processing to
avoid equipment damage. DISPOSAL of the gas
removed requires laboratory or manufacturing
facilities.
To accomplish this, the recovery/recycle station separates the oil from the refrigerant and filters the
refrigerant multiple times to reduce moisture, acidity,
and particulate matter found in a used refrigerant.
Test equipment is available to confirm the refrigerant

in the system is actually the type intended for the
system and has not been contaminated by a mixture
of refrigerant types.
NOTE: To be re-sold, the gas must be reclaimed

which leaves it as pure as new, but requires
equipment normally too expensive for all but the
largest refrigeration shops.
Recycling equipment must meet certain standards as

published by the Society of Automotive Engineers
(SAE) and carry a UL approved label. The basic principals of operation remain the same for all machines,
even if the details of operation differ somewhat.
Equipment is also available to just remove or extract

the refrigerant. Extraction equipment does not clean
the refrigerant - it is used to recover the refrigerant
from an AC system prior to servicing.
Leak Detector
The electronic detector (Figure 4-8) is very accurate
and safe. It is a small hand-held device with a flexible
probe used to seek refrigerant leaks. A buzzer, alarm
or light will announce the presence of even the smallest leak.
Some leak detectors are only applicable to one type
of refrigerant. Ensure the leak detector being used
applies to the refrigerant in the system.
FIGURE 4-7. RECOVERY/RECYCLE STATION
N04024
FIGURE 4-8. TYPICAL ELECTRONIC LEAK

DETECTOR
Operator Comfort
N4-17
FIGURE 4-9. R-134a SERVICE VALVE

1. System Service Port
Fitting
2. Quick Connect
FIGURE 4-10. VACUUM PUMP
3. Service Hose
Connection
Vacuum Pump
Service Valves
Because an air conditioning system is a sealed system, two service valves are provided on the compressor to enable diagnostic tests, system charging
or evacuation. Connecting the applicable hoses from
the manifold gauge set to the compressor service
valves enables each of these to be readily performed.
The vacuum pump (Figure 4-10) is used to completely evacuate all of the refrigerant, air, and moisture from the system by deliberately lowering the
pressure within the system to the point where water
turns to a vapor (boils) and together with all air and
refrigerant is withdrawn (pumped) from the system.
New and unique service hose fittings (Figure 4-9)

have been specified for R-134a systems. Their purpose is to avoid accidental cross-mixing of refrigerants and lubricants with R-12 based systems. The
service ports on the system are quick disconnect
type with no external threads. They do contain a
Schrader type valve. The low side fitting has a
smaller diameter than the high side attachment.
Protective caps are provided for each service valve.
When not being used these caps should be in place
to prevent contamination or damage to the service
valves.
N4-18
Operator Comfort
N04024
Manifold Gauge Set

A typical manifold gauge set (Figure 4-11) has two
screw type hand valves to control access to the system, two gauges and three hoses. The gauges are
used to read system pressure or vacuum. The manifold and hoses are for access to the inside of an air
conditioner, to remove air and moisture, and to put in,
or remove, refrigerant from the system. Shutoff
valves are required within 12 inches of the hose
end(s) to minimize refrigerant loss.
A gauge set for R-134a will have a blue hose with a
black stripe for the low side, a red hose with a black
stripe for the high side, and a yellow hose with a
black stripe for the utility (center) hose. The hoses
use a 1/2 in. ACME female nut on the gauge end.
Special quick disconnect couplings are normally
combined with a shutoff valve on the high and low
side hoses. The free end of the center hose contains
a 1/2 in. ACME female nut and a shutoff device
within 12 inches of the hose end. These special
hoses and fittings are designed to minimize refrigerant loss and to preclude putting the wrong refrigerant
in a system.
FIGURE 4-11. MANIFOLD GAUGE SET
Low Side Gauge

NOTE: When hose replacement becomes necessary,
the new hoses must be marked SAE J2916 R134a.
The low side gauge, registers both vacuum and pressure. The vacuum side of the scale is calibrated from
0 to 30 inches of mercury (in. Hg). The pressure side
of the scale is calibrated to 150 psi.
Functions of the manifold gauge set are included in

many of the commercially available recovery or
recovery/recycle stations.
Never open the hand valve to the high side at
anytime when the air conditioning system is
operating. High side pressure, if allowed, may
rupture charging containers and potentially
cause personal injury.
High Side Gauge
The High Side Gauge is used to measure pressure
only on the discharge side of the compressor. The
scale is calibrated from 0 to 500 psi.
N04024
Operator Comfort
N4-19
Installing Manifold Gauge Set

Before attempting to service the air conditioning system, a visual inspection of both the engine and system components is recommended. Particular
attention should be given to the belts, hoses, tubing
and all attaching hardware plus the radiator cap, fan
clutch, and thermostat. Inspect both the condenser
and the radiator for any obstructions or potential contamination. Minimize all the possibilities for error or
malfunction of components in the air conditioning
system.
Shut off engine. DO NOT attempt to connect service equipment when the engine is running.
1. Be sure all valves on the manifold are closed all
the way (turn them clockwise).
2. Check the hose connections on the manifold for
tightness.
3. Locate the low and high side system service fittings and remove their protective caps.
4. Connect the two service hoses from the manifold to the correct service valves on the compressor as shown in Figure 4-12. (High side to
compressor discharge valve and low side to
compressor suction side.) Do not open service
valves at this time.
FIGURE 4-12. SERVICE HOSE HOOK-UP
This gauge hook-up process will be the same,

regardless of the gauge set being installed. Whether
it is a recovery station or individual gauges, the connections are the same. The procedures performed
next will vary depending what type of equipment is
being used. If a recovery/recycling station is being
used, complete servicing can be accomplished.
Using only a set of gauges will limit the servicing to
only adding refrigerant or observing pressures.
N4-20
Operator Comfort
N04024
Purging Air From Service Hoses

The purpose of this procedure is to remove all the
air trapped in the hoses prior to actual system testing. Environmental regulations require that all service hoses have a shutoff valve within 12 inches of
the service end. These valves are required to
ensure only a minimal amount of refrigerant is lost
to the atmosphere. R-134a gauge sets have a combination quick disconnect and shutoff valve on the
high and low sides. The center hose also requires a
valve.
The initial purging is best accomplished when connected to recovery or recycle equipment. With the
center hose connected to the recovery station, service hoses connected to the high and low sides of
the system, we can begin the purging. The manifold
valves and service valves should be closed. Activating the vacuum pump will now pull any air or moisture out of the center hose. This will require only a
few minutes of time. The hose is the only area that
is being placed in a vacuum and this will not require
a lengthy process. Closing the valve will then insure
the hose is purged. It is now safe to open the other
manifold valves.
FIGURE 4-13. PURGING SYSTEM
N04024
Operator Comfort
N4-21
SYSTEM PERFORMANCE TEST
Stabilizing the AC System
This test is performed to establish the condition of all

components in the system. Observe these conditions
during testing:
During this stabilization period, do not open
hand valves on manifold for any reason. Equipment damage and personal injury may result.
1. Start the engine and return to an idle speed of
1200 to 1500 RPM. Turn on the air conditioner.
2. After a performance check of the control functions, blower speeds and air flow, set the AC
system controls to maximum cooling and
blower speed on high. Open the cab to ensure
continuous operation of the compressor.
3. Run the engine and air conditioner about 5 minutes for the system to stabilize.
4. If the humidity is high it will be necessary to
place a fan in front of the AC condenser to help
the air flow across the condenser. This helps to
stabilize the system by simulating normal operating conditions.
5. It is then possible to observe the gauge readings and the temperature coming out of the air
ducts with a thermometer.
NOTE: If low refrigerant is indicated by lower than
normal pressure readings, recover and charge the
proper amount of refrigerant to enable adequate
system testing.
1. Start engine and operate at 1200 to 1500 RPM.

2. Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize.
3. Place a thermometer in air conditioning vent
closest to evaporator.
4. Evaluate the readings obtained from the
gauges to see if they match the readings for the
ambient temperature.
As preliminary steps to begin checkout of the system,
perform the following:
1. Close all windows and doors to the cab.
2. Set air conditioning system at maximum cooling
and blower speed operation.
3. Readings on the two manifold gauges should
be within normal range, adjust for ambient temperature.
4. Compare evaporator discharge air temperature
reading to see if it matches the recommended
temperature for the ambient temperature and
gauge readings obtained.
5. Carefully feel the hoses and components on the
high side. All should be warm-hot to the touch.
Check the inlet and outlet of receiver-drier for
even temperatures, if outlet is cooler than inlet,
a restriction is indicated.
Use extreme caution when placing hands on high

side components and hoses. Under certain conditions these items can be extremely hot.
6. Feel the hoses and components on the low
side. They should be cool to the touch. Check
connections near the expansion valve, inlet side
should be warm and cold-cool on the outlet
side.
7. If these conditions are met, the system is considered normal. Shut down engine. Remove
gauges and install the caps on the service
valves.
N4-22
Operator Comfort
N04024
SYSTEM LEAK TESTING
Electronic Leak Detector
Refrigerant leaks are probably the most common

cause of air conditioning problems, resulting from
improper or no cooling, to major internal component
damage. Leaks most commonly develop in two or
three places. The first is around the compressor shaft
seal, often accompanied by an indication of fresh
refrigerant oil. If a system is not operated for a while
(winter months), the shaft seal may dry out and leak
slightly. The centrifugal force of the clutch pulley
spinning can also cause the problem. When the system is operated and lubricant wets the seal, the leak
may stop. Such leaks can often be located visually,
or by feeling with your fingers around the shaft for
traces of oil. (The R-134a itself is invisible, odorless,
and leaves no trace when it leaks, but has a great
affinity for refrigerant oil.)
(Refer to Figure 4-8). As the test probe is moved into

an area where traces of refrigerant are present, a
visual or audible announcement indicates a leak.
Audible units usually change tone or speed as intensity changes.
A second common place for leaks is the nylon and

rubber hoses where they are crimped or clamped to
the fittings, or where routing allows abrasion. Other
threaded joints or areas where gaskets are used
should be visually and physically examined. Moving
your fingers along the bottom of the condenser and
evaporator, particularly near the drain hole for the
condensate will quickly indicate the condition of the
evaporator. Any trace of fresh oil here is a clear indication of a leak.
Soap and water can be mixed together and applied

to system components. Bubbles will appear to pinpoint the specific location of leaks.
Usually, a 50% charged system is enough to find

most leaks. If the system is empty, connect the manifold gauge set to the system and charge at least 3.5
lbs. of refrigerant into the system.
Tracer Dyes
Tracer dyes are available that can be added to the
system as refrigerant is added. The system is then
operated to thoroughly circulate the dye. As refrigerant escapes, it leaves a trace of the dye at the point
of leakage, which is then detected using an ultraviolet light (black light), revealing a bright fluorescent
glow.
Soap and Water
After determining the location or source of leak(s),

repair or replace leaking component(s).
NOTE: The length of the hose will affect the
refrigerant capacity. When replacing hoses, always
use the same hose length, if possible.
Before system assembly, check the compressor

oil level and fill to specifications.
Use extreme caution when leak testing a system

while the engine is running.
In its natural state, refrigerant is a harmless, colorless gas, but when combined with an open
flame, it will generate toxic fumes (phosgene
gas), which can cause serious injuries or death.
NOTE: The refrigerant is heavier than air and will
move downward when it leaks. Apply pickup hose or
test probe on the under-surface of all components to
locate leaks.
N04024
Operator Comfort
N4-23
SYSTEM REPAIR
Hoses and Fittings
The following service and repair procedures are not

any different than typical vehicle service work. However, AC system components are made of soft metals (copper, aluminum, brass, etc.). Comments and
tips that follow will make the job easier and reduce
unnecessary component replacement.
When replacing hoses, be sure to use the same type

and ID hose you removed. When hoses or fittings are
shielded or clamped to prevent vibration damage, be
sure these are in position or secured.
All of the service procedures described are only

performed after the system has been discharged.
Never use any lubricant or joint compound to
lubricate or seal any AC connections.
NOTE: To help prevent air, moisture or debris from
entering an open system, cap or plug open lines,
fittings, components and lubricant containers. Keep
all connections, caps, and plugs clean.
System Cleaning
When performing repairs on air conditioning components, a thorough inspection should be performed.
Inspect the parts that have been removed. If they
contain any loose or foreign material, the rest of the
system should be checked for the source of the
material.
Only SAE and/or Mobile Air Conditioning Society

(MACS) approved flushing methods with the
appropriate refrigerants are to be performed
when removing debris from the system. Other
methods may be harmful to the environment, as
well as air conditioning components.
Lines
Always use two wrenches when disconnecting or
connecting AC fittings attached to metal lines. You
are working with copper and aluminum tubing which
can kink or break easily. When grommets or clamps
are used to prevent line vibration, be certain these
are in place and secured.
It is important to always torque fittings to the

proper torque. Failure to do this may result in
improper contact between mating parts and leakage may occur. Refer to the following torque
chart for tightening specifications.
Fitting Size
Foot Pounds
Newton Meters
10 - 15 ft.lbs.
14 - 20 Nm
24 - 29 ft.lbs.
33 - 39 Nm
10
26 - 31 ft.lbs.
36 - 42 Nm
12
30 - 35 ft.lbs.
41 - 47 Nm
Installation torque for the single M10 or 3/8 in. capscrews securing the inlet and outlet fittings onto the
compressor ports is 11 - 25 ft.lbs. (15 - 34 Nm).
Expansion Valve
When removing the expansion valve from the system, remove the insulation, clean the area and disconnect the line from the receiver-drier. Detach the
capillary (bulb) and external equalizer tube (if
present) from their mounting locations. Remove the
expansion valve from the evaporator inlet. Expansion
valve service is limited to cleaning or replacing the filter screen. If this is not the problem, replace the
valve. Secure the capillary and equalizer, if used, to
clean surfaces and replace or attach any insulating
material.
N4-24
Operator Comfort
N04024
Receiver-Drier
Clutch
The receiver-drier can not be serviced or repaired. It

must be replaced whenever the system is opened
for any service. The receiver-drier has a pressure
switch to control the clutch, and should be removed
and installed onto the new unit.
Clutch problems include electrical failure in the clutch

coil or lead wire, clutch pulley bearing failure, worn or
warped clutch plate or loss of clutch plate spring temper. Defective clutch assembly parts may be
replaced or the whole assembly replaced. If the
clutch shows obvious signs of excessive heat damage, replace the whole assembly.
Thermostat
A thermostat can be stuck open or closed due to contact point wear or fusion. The thermostat temperature
sensing element (capillary tube) may be broken or
kinked closed and therefore unable to sense evaporator temperature.
When thermostat contact points are stuck open or
the sensing element can not sense temperature in
the evaporator, the clutch will not engage (no AC
system operation). Causes are a loss of charge in
the capillary tube or a kink, burned thermostat contact or just no contact. When troubleshooting, bypass
the thermostat by hot wiring the clutch coil with a
fused lead. If the clutch engages, replace the thermostat.
Thermostat contact points may be fused (burned)
closed and the clutch will not disengage. Causes are
a faulty switch that could be due to fatigue. The thermostat must be replaced. When the clutch will not
disengage you may also note that condensate has
frozen on the evaporator fins and blocked air flow.
There will also be below normal pressure on the low
side of the system. Side effects can be compressor
damage caused by oil accumulation (refrigeration oil
tends to accumulate at the coldest spot inside the
system) and lower than normal suction pressure that
can starve the compressor of oil.
Compressor
The compressor can fail due to shaft seal leaks (no
refrigerant in the system), defective valve plates,
bearings, or other internal parts or problems associated with high or low pressure, heat, or lack of lubrication. Be sure the compressor is securely mounted
and the clutch pulley is properly aligned with the
drive pulley.
Use a mechanic's stethoscope to listen for noises
inside the compressor.
N04024
The fast way to check electrical failure in the lead

wire or clutch coil is to hot wire the coil with a fused
lead. This procedure enables you to bypass clutch
circuit control devices.
Clutch pulley bearing failure is indicated by bearing
noise when the AC system is off or the clutch is not
engaged. Premature bearing failure may be caused
by poor alignment of the clutch and clutch drive pulley.
Sometimes it may be necessary to use shims or
enlarge the slots in the compressor mounting bracket
to achieve proper alignment.
Excessive clutch plate wear is caused by the plate
rubbing on the clutch pulley when the clutch is not
engaged or the clutch plate slipping when the clutch
coil is energized. A gap that is too small or too large
between the plate and clutch pulley or a loss of clutch
plate spring temper are possible causes. The ideal
air gap between the clutch pulley and the clutch plate
is 0.023 to 0.057 in. (1.02 0.043 mm). If the gap is
too wide, the magnetic field created when the clutch
coil is energized will not be strong enough to pull and
lock the clutch plate to the clutch pulley.
NOTE: Some compressors may be discarded

because it is suspected that internal components
within the compressor have seized. Ensure that
the compressor clutch is working properly before
discarding a compressor for internal seizure. The
normal compressor life span should be about
twice as long as the normal life span of the compressor clutch.
It is important to note that often times a weak clutch
coil may be mistaken for a seized compressor. When
a coils resistance has increased over time and the
magnetic field weakens, the coil may not be able to
pull the load of the compressor. Failure of the coil to
allow the compressor shaft to be turned, may appear
as though the compressor is locked up.
Operator Comfort
N4-25
Before a compressor is dismissed as being seized, a

check for proper voltage to the coil should be performed. In addition, the coil should be ohm checked
for proper electrical resistance. The coil should fall
within the following range:
1. Remove the belt guard from the front of the air

conditioning compressor.
12.0 0.37 Ohms @ 68 F (20 C)

16.1 0.62 Ohms @ 240 F (116 C)
The temperatures specified above are roughly typical
of a summer morning before first start-up and the
heat beside an engine on a hot day. At temperatures
in between those listed above, the correct resistance
is proportionate to the difference in temperature.
FIGURE 4-14.
Servicing the Compressor Clutch
* RECOMMENDED TOOLS FOR COMPRESSOR
CLUTCH REMOVAL AND INSTALLATION
J-9399
Thin Wall Socket
**J-9403
Spanner Wrench
**J-25030
Clutch Hub Holding Tool
J-9401
Clutch Plate and Hub Assembly

Remover
J-8433
Pulley Puller
J-9395
Puller Pilot
***J-24092
Puller Legs
J-8092
Universal Handle
J-9481
Pulley and Bearing Installer
J-9480-01
Drive Plate Installer
J-9480-02
Spacer, Drive Plate Installer
1. Belt Pulley
2. Clutch Hub/Drive
Plate
3. Shaft
4. Locknut
2. Remove the drive belt from compressor belt

pulley (1, Figure 4-14).
*Tools are available though your local Kent-Moore dealer.

** These tools are interchangeable.
***For use on multiple groove pulleys.
FIGURE 4-15.
Use the proper tools to remove and replace
clutch components. Using the recommended
tooling helps prevent damage to compressor
components during maintenance.
Do not drive or pound on the clutch plate, hub
assembly, or shaft. Internal damage to the compressor may result.
N4-26
1. Thin Wall Socket

2. Clutch Hub Holding
Tool
Operator Comfort
3. Clutch Hub
N04024
3. Remove locknut (4) using thin wall socket (1,

Figure 4-15) or the equivalent. Use clutch hub
holding tool (2), spanner wrench (J-9403), or
the equivalent to hold clutch hub (3) while
removing the locknut. It is recommended that
the locknut be replaced after it has been
removed.
5. Remove square key (1, Figure 4-17) from the

keyways.
FIGURE 4-18.
1. Clutch Hub
FIGURE 4-16.
1. Clutch Assembly
2. Clutch Plate & Hub

Assembly Remover
2. Pulley
6. Inspect the friction surface on the clutch hub

and the friction surface on the pulley. Scoring on
the friction surfaces is normal. DO NOT replace
these components for this condition only.
4. Thread clutch plate and hub assembly remover

(2, Figure 4-16) into the hub of clutch assembly
(1). Hold the body of the remover with a wrench
and tighten the center screw to pull the clutch
plate and hub assembly from the compressor.
Inspect the steel friction surface on the clutch
and ensure that it is not damaged by excessive
heat. Inspect the other components near the
clutch for damage due to heat. If signs of excessive heat are evident, it may be necessary to
replace the compressor. Excessive heat may
cause leakage in the seals and damage to internal components as well as external components.
FIGURE 4-17.
1. Square Key
N04024
2. Keyway in Shaft
Operator Comfort
N4-27
10. Tighten the center screw on the puller against

the shaft of the compressor to remove the pulley.
Pulley Removal
11. Clean the pulley and pulley bearing with solvent.

Inspect the assembly for damage. Check the
bearing for brinneling, excessive looseness,
noise, and lubricant leakage. Replace the
assembly if any of these warning signs are evident.
Clutch Coil Check
12. Use a multi-meter to ohm check the clutch coil.
The resistance should be as follows:
12 0.37 ohms @ 68 F (20 C)
16.1 0.62 ohms @ 239 F (115 C)
FIGURE 4-19.
1. Pulley Assembly
2. Pulley Retainer Ring
3. Retaining Ring Pliers
7. Use retaining ring pliers (3, Figure 4-19) to

remove pulley retainer ring (2) from pulley (1).
If the resistance of the coil is not within the specifications, the clutch will not operate properly. Remove
the retaining ring and replace the coil.
Pulley Installation
8. Pry the absorbent sleeve retainer from the neck

of the compressor, and remove the sleeve.
FIGURE 4-21.
1. Bearing Installer
2. Universal Handle
1. Pulley Puller
2. Pulley Assembly
1. Place the pulley assembly into position on the

compressor. Use bearing installer (1, Figure 421), universal handle (2), and a hammer to
lightly tap the pulley assembly onto the compressor until it seats. Use of the installer or the
equivalent ensures that the force driving the
bearing into position acts on the inner race of
the bearing. Applying force to the outer race of
the bearing will result in bearing damage.
FIGURE 4-20.
3. Puller Pilot
9. Install pulley puller (1, Figure 4-20) and puller

pilot (3) onto the compressor, as shown. If a
multiple groove pulley is used, install puller legs
(J-24092) onto the puller in place of the standard legs. Extend the puller legs to the back
side of the pulley. DO NOT use the belt grooves
to pull the pulley from the compressor.
N4-28
2. Ensure the pulley rotates freely. If the pulley

does not rotate freely, remove the pulley and
check for damaged components. Replace any
damaged components and reinstall the pulley.
3. Install the pulley retainer ring and ensure that
the ring is properly seated.
4. Install the absorbent sleeve into the neck of the
compressor. Install the sleeve retainer.
Operator Comfort
N04024
Clutch Assembly Installation

1. Insert square key (1, Figure 4-16) into the keyway in the clutch hub. Allow the key to protrude
about 4.5 mm (0.18 in.) from the outer edge of
the hub. Use petroleum jelly to hold the key in
place.
4. Press the clutch onto the compressor using

installer (1). Continue to press the clutch plate
until a 2 mm (0.079 in.) gap remains between
the clutch friction surface and the pulley friction
surface. Refer to Figure 4-23.
0.040 0.017 in.
FIGURE 4-23. CLUTCH GAP

FIGURE 4-22.
1. Drive Plate Installer
NOTE: The outer threads of installer (J-9480-01) are

left handed threads.
2. Spacer
2. Place the clutch assembly into position on the

compressor. Align the square key with the keyway on the shaft.
3. Thread drive plate installer (1, Figure 4-22) onto
the shaft of the compressor. Spacer (2) should
be in place under the hex nut on the tool.
5. Install locknut (4, Figure 4-14) and tighten the

nut until it seats. The gap should now measure
1.02 0.043 mm (0.040 0.017 in.). If the gap
is not within the specification, check for proper
installation of the square key.
6. Install the drive belt onto the compressor.
Ensure that the proper tension on the belt is
attained. Refer to the belt tension chart in the
appropriate engine manual for the proper specifications.
7. After assembly is complete, burnish the mating
parts of the clutch by operating the air conditioning system at maximum load conditions with
the engine at high idle. Turn the air conditioning
control ON and OFF at least 15 times for one
second intervals.
8. Install the belt guard if no further servicing is
required.
N04024
Operator Comfort
N4-29
RECOVERING AND RECYCLING THE

REFRIGERANT
Draining the Oil from the previous recovery cycle
1. Place the power switch and the controller on
the recovery unit in the OFF position.
2. Plug in the recovery station to the correct
power source.
3. Drain the recovered oil through the valve
marked oil drain on the front of the machine.
4. Place the controller knob in the ON position.
The low pressure gauge will show a rise.
5. Immediately switch to the OFF position and
allow the pressure to stabilize. If the pressure
does not rise to between 5 psi and 10 psi,
switch the controller ON and OFF again.
6. When the pressure reaches 5 to 10 psi, open
the oil drain valve, collect the oil in an appropriate container, and dispose of container as
indicated by local, state or federal regulation.
The oil is not reusable due to contaminants
absorbed during use.
Performing the Recovery Cycle
1. Be sure the equipment being used is designed
for the refrigerant you intend to recover.
2. Observe the sight glass oil level. Having
drained it, it should be zero.
3. Check the cylinder refrigerant level before
beginning recovery to make sure you have
enough capacity.
4. Confirm that all shut-off valves are closed
before connecting to the AC system.
5. Attach the appropriate hoses to the system
being recovered.
9. Check the system pressure after the recovery

equipment stops. After five minutes, system
pressure should not rise above 0 gauge pressure. If the pressure continues to rise, restart
and begin the recovery sequence again. This
cycle should continue until the system is void of
refrigerant.
10. Check the sight glass oil level to determine the
amount of oil that needs to be replaced. (The
amount of oil that was lost during the recovery
cycle must be replaced back into the system).
11. Mark the cylinder with a RECOVERED (red)
magnetic label to reduce the chance of charging
a system with contaminated refrigerant. Record
the amount of refrigerant recovered.
Performing the Recycling Procedure

The recovered refrigerant contained in the cylinder
must undergo the recycle procedure before it can be
reused. The recycle or clean mode is a continuous
loop design and cleans the refrigerant rapidly. Follow
equipment manufacturer's instructions for this procedure.
Evacuating and Charging the AC System

Evacuate the system once the air conditioner components are repaired or replacement parts are secured,
and the AC system is reassembled. Evacuation
removes air and moisture from the system. Then, the
AC system is ready for the charging process, which
adds new refrigerant to the system.
6. Start the recovery process by operating the

equipment as per the manufacturer's instructions.
7. Continue extraction until a vacuum exists in the
AC system.
8. If an abnormal amount of time elapses after the
system reaches 0 psi and does not drop
steadily into the vacuum range, close the manifold valves and check the system pressure. If it
rises to 0 psi and stops, there is a major leak.
N4-30
Operator Comfort
N04024
EVACUATING THE SYSTEM

Evacuating the complete air conditioning system is
required in all new system installations, and when
repairs are made on systems requiring a component
replacement (system opened), or a major loss of
refrigerant has occurred. All these conditions will
require that a vacuum be pulled using a vacuum
pump that completely removes any moisture from the
system. Once properly evacuated, the system can be
recharged again.
Using a pump to create a vacuum in the air conditioning system effectively vaporizes any moisture, allowing the water vapor to be easily drawn out by the
pump. The pump does this by reducing the point at
which water boils (212F at sea level with 14.7 psi).
In a vacuum, water will boil at a lower temperature
depending upon how much of a vacuum is created.
As an example, if the ambient air outside the truck is
75F at sea level, by creating a vacuum in the system
so that the pressure is below that of the outside air
(in this case, at least 29.5 inches of vacuum is
needed), the boiling point of water will be lowered to
72F. Thus any moisture in the system will vaporize
and be drawn out by the pump if the pump is run for
approximately an hour. The following steps indicate
the proper procedure for evacuating all moisture from
the heavy duty air conditioning systems.
Do not use the air conditioning compressor as a vacuum pump or the compressor will be damaged.
FIGURE 4-24. VACUUM PUMP HOOKUP

1. Low Pressure Hand
Valve
NOTE: Lower the vacuum requirement one inch for

every 1000 feet above sea level at your location.
1. With the manifold gauge set still connected
(after discharging the system), connect the center hose to the inlet fitting of the vacuum pump
as shown in Figure 4-24. Then open the low
side hand valves to maximum.
2. Open the discharge valve on the vacuum pump
or remove the dust cap from the discharge outlet. Turn the pump on and watch the low side
gauge. The pump should pull the system into a
vacuum (if not, the system has a leak).
3. Run the pump for five minutes and close the
hand valves and shut off the pump.
2. High Pressure Hand

Valve
3. Vacuum Pump
4. Observe gauge reading and wait 10 minutes.

Reading should not vary more than 1-2 in. hg.
After waiting, if more vacuum is lost than this, a
serious leak is indicated and the system must
be recharged, leak tested, repaired and evacuated.
5. Turn on pump, open hand valves and continue
evacuation for at least one hour.
NOTE: If system has excessive amounts of moisture,
60 minutes evacuation may not be sufficient since
the water must turn to a vapor to be drawn out of the
system. If it has been verified that no system leaks
exist and gauge readings increase after 1 hour,
extend the evacuation time to ensure total moisture
removal.
6. Close the manifold hand valves and turn off
vacuum pump, watching the low side gauge
reading. If vacuum remains for a few minutes,
the system is ready for charging.
N04024
Operator Comfort
N4-31
The moisture must turn to gas before the pump can

pull it out. The moisture takes time to boil away, so
that it can be drawn out of the system. The vacuum
pump can draw most of the air out quickly, but a deep
vacuum requires more time; the deeper the vacuum
the more time required.
The most important factor is the ability for the

system to hold the deepest vacuum the pump
can pull, and hold it for 15 minutes after the
pump has stopped. This may take several tries
depending on how long the system was held in a
vacuum.
CHARGING THE AC SYSTEM

When charging the system, it is possible to put it in
as a gas or as a liquid. Adding refrigerant as a liquid
is faster but can damage the compressor if not done
correctly. The procedure used, and where the refrigerant is added in the AC system makes a difference.
When using refrigerant as a liquid, never add more
than two thirds of system requirements as a liquid.
Finish charging the system using gas.
The proper method for charging refrigerant into a R134a system is to first, recover all of the refrigerant
from the system. The charging refrigerant should
then be weighed on a scale to ensure the proper
amount is charged into the system. Most recovery
units include a scale within the apparatus, thus making it very easy to charge the correct amount every
time. If equipment such as this is not available, a
common scale can be used to determine the weight
of charge. Simply weigh the charging tank, subtract
the weight of the proper charge, and charge the system until the difference is shown on the scale. On
certain types of equipment, it is also possible to add
any necessary lubricant when charging the system.
If a scale is not used when charging R-134a into a
system, it is difficult to tell if the correct charge has
been achieved. The sight glass can provide some
indication, but it is not a reliable tool for determining
proper charge.
N4-32
Operator Comfort
N04024
TROUBLESHOOTING
Pre-Diagnosis Checks
If the system indicates Insufficient cooling, or no
cooling, the following points should be checked
before proceeding with the system diagnosis procedures.
NOTE: If the truck being serviced is a model 930E,
be certain the rest switch in the cab is ON. Place the
GF cutout switch in the CUTOUT position.
Preparing For Diagnosis
Successfully servicing an air conditioning system,
beyond the basic procedures outlined in the previous
section, requires additional knowledge of system
testing and diagnosis.
A good working knowledge of the manifold gauge set
is required to correctly test and diagnose an air conditioning system. An accurate testing sequence is
usually the quickest way to diagnose an internal
problem. When correctly done, diagnosis becomes
an accurate procedure rather than guesswork.
Refrigerant charge - Make sure system is

properly charged with the correct amount of
refrigerant.
Preliminary Steps
The following steps outline the correct procedures
necessary to prepare the truck and the system for
testing and diagnosis:
1. Correctly connect the manifold gauge set to the
system. Refer to the connection and purging
procedures outlined in this section.
2. Run the engine with the air conditioning system
on for five to ten minutes to stabilize the system.
3. With the engine and the system at normal operating temperature, conduct a Performance Test
as outlined in this section.
Compressor belt - Must be tight, and aligned.
System Performance Test
Compressor clutch - The clutch must engage. If it

does not, check fuses, wiring, and switches.
This test is performed to establish the condition of all

components in the system. Observe these conditions
during testing:
Oil leaks - Inspect all connection or components

for refrigeration oil leaks (especially in the area of
the compressor shaft). A leak indicates a
refrigerant leak.
Electrical check - Check all wires and
connections for possible open circuits or shorts.
Check all system fuses.
Note: Some systems use different safety devices in
the compressor circuit to protect the compressor.
Check the thermal fuse, the low pressure cutout
switch, high pressure cutout switch or trinary
pressure switch if equipped.
Cooling system - Check for correct cooling
system operation. Inspect the radiator hoses,
heater hoses, clamps, belts, water pump,
thermostat and radiator for condition or proper
operation.
Radiator shutters - Inspect for correct operation
and controls, if equipped.
Fan and shroud - Check for proper operation of
fan clutch. Check installation of fan and shroud.
Heater/water valve - Check for malfunction or
leaking.
System ducts and doors - Check the ducts and
doors for proper function.
N04024
1. Start engine and operate at 1200 to 1500 RPM.

2. Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize.
3. Place a thermometer in air conditioning vent
closest to evaporator.
4. Evaluate the readings obtained from the
gauges to see if they match the readings for the
ambient temperature.
As preliminary steps to begin checkout of the system,
perform the following:
1. Close all windows and doors to the cab.
2. Set air conditioning system at maximum cooling
and blower speed operation.
3. Readings on the two manifold gauges should
be within normal range, adjust for ambient temperature.
4. Compare evaporator discharge air temperature
reading to see if it matches the recommended
temperature for the ambient temperature and
gauge readings obtained.
5. Carefully feel the hoses and components on the
high side. All should be warm-hot to the touch.
Check the inlet and outlet of receiver-drier for
Operator Comfort
N4-33
even temperatures, if outlet is cooler than inlet,

a restriction is indicated.
Use extreme caution when placing hands on high

side components and hoses. Under certain conditions these items can be extremely hot.
6. Feel the hoses and components on the low
side. They should be cool to the touch. Check
connections near the expansion valve, inlet side
should be warm and cold-cool on the outlet
side.
Diagnosis Of Gauge Readings And System

Performance
The following Troubleshooting Chart lists typical malfunctions encountered in air conditioning systems.
Indications and or problems may differ from one system to the next. Read all applicable situations, service procedures, and explanations to gain a full
understanding of the system malfunction. Refer to
information listed under Suggested Corrective
Action for service procedures.
7. If these conditions are met, the system is considered normal. Shut down engine. Remove
gauges and install the caps on the service
valves.
N4-34
Operator Comfort
N04024
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PROBLEM: Insufficient Cooling

Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is only slightly cool.
Possible Causes
Suggested Corrective Actions
- Low refrigerant charge, causing pressures to be

slightly lower than normal.
Check for leaks by performing leak test.

If No Leaks Are Found:
Recover the refrigerant and use a scale to
charge the proper amount into the system.
Check system performance.
If Leaks Are Found:
After locating the source of the leak, recover the
refrigerant, and repair the leak. Evacuate the
system and recharge using a scale. Add oil as
necessary. Check AC operation and performance test the system.
PROBLEM: Little or No Cooling

Indications:
Low side pressure - VERY LOW
High side pressure - VERY LOW
Discharge air is warm.
No bubbles observed in sight glass, may show oil
streaks.
Possible Causes
- Pressure sensing switch may have compressor

clutch disengaged.
- Refrigerant excessively low; leak in system.
N04024
Add refrigerant (make sure system has at least

50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable
the compressor to operate, if the compressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
Operator Comfort
N4-35
PROBLEM: Extremely Low Refrigerant Charge in the System

Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is warm.
The low pressure switch may have
shut off the compressor clutch.
Possible Causes
- Extremely low or no refrigerant in the system.
Possible leak in the system.

Check for leaks by performing leak test.
No Leaks Found:
Recover refrigerant from the system. Recharge
using a scale to ensure correct charge. Check
AC operation and performance.
Leaks Found:
Add refrigerant (make sure system has at least
50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable the compressor to operate, if the compressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
PROBLEM: Air and/or Moisture in the System

Indications:
Low side pressure - Normal
High side pressure - Normal
(In a cycling type system with a
thermostatic switch, the switch may not cycle
the clutch on and off, so the low pressure
gauge will not fluctuate.)
Possible Causes
Leaks in the system.
N4-36

Test for leaks, especially around the compressor shaft
seal area. When the leak is found, recover refrigerant
from the system and repair the leak. Replace the
receiver-drier or accumulator because the desiccant
may be saturated with moisture. Check the compressor
and replace any refrigerant oil lost due to leakage.
Evacuate and recharge the system with refrigerant
using a scale. Check AC operation and performance.
Operator Comfort
N04024
PROBLEM: Air and/or Moisture in the System

Indications:
Low side pressure - HIGH
High side pressure - HIGH
Possible Causes
- Leaks in system.
Test for leaks, especially around the compressor

shaft seal area. After leaks are found, recover
refrigerant from the system and repair leaks. Replace the receiver-drier. Check the compressor
and replace any oil lost due to leakage. Evacuate
and recharge the system using a scale to ensure
proper quantity. Check AC operation and performance.
PROBLEM: Expansion Valve Stuck or Plugged

Indications:
Low side pressure - VERY LOW or in a Vacuum
High side pressure - HIGH
Discharge air only slightly cool.
Expansion valve body is frosted or sweaty.
Possible Causes
An expansion valve malfunction could mean

the valve is stuck in the closed position, the filter
screen is clogged (block expansion valves do not
have filter screens), moisture in the system has
frozen at the expansion valve orifice, or the
sensing bulb is not operating. If the sensing bulb
is accessible, perform the following test. If not,
proceed to the Repair Procedure.
Test: Warm diaphragm and valve body with your

hand, or very carefully with a heat gun. Activate
the system and watch to see if the low pressure
gauge rises. Next, carefully spray a little nitrogen,
or any substance below 32 F, on the capillary coil
(bulb) or valve diaphragm. The low side gauge
needle should drop and read at a lower (suction)
pressure on the gauge. This indicates the valve was
partially open and that your action closed it. Repeat
the test, but first warm the valve diaphragm or
capillary with your hand. If the low side gauge
drops again, the valve is not stuck.
Repair Procedure: Inspect the expansion valve
screen (except block type valves). To do this,
remove all refrigerant from the system. Disconnect
the inlet hose fitting from the expansion valve.
Remove, clean, and replace the screen. Reconnect
the hose and replace the receiver-drier. Evacuate
and recharge the system with refrigerant using a
scale. Check AC operation and performance. If the
expansion valve tests did not cause the low pressure gauge needle to rise and drop, and if the other
procedure described did not correct the problem,
the expansion valve is defective. Replace the valve.
N04024
Operator Comfort
N4-37
PROBLEM: Expansion Valve Stuck Open

Indications:
Air from vents in the cab seems warm
or only slightly cool.
Possible Causes
The expansion valve is stuck open and/or the
capillary tube (bulb) is not making proper contact
with the evaporator outlet tube. Liquid refrigerant
may be flooding the evaporator making it impossible for the refrigerant to vaporize and absorb
heat normally. In vehicles where the expansion
valve sensing bulb is accessible, check the
capillary tube for proper mounting and contact
with the evaporator outlet tube. Then perform the
following test if the valve is accessible. If it is not,
proceed to the Repair Procedure.

Test: Operate the AC system on it's coldest
setting for a few minutes. Carefully spray
nitrogen or another cold substance on the capillary tube coil (bulb) or head of the valve. The low
pressure (suction) side gauge needle should now
drop on the gauge. This indicates the valve has
closed and is not stuck open. Repeat the test,
but first warm the valve diaphragm by warming
with hands. If the low side gauge shows a drop
again, the valve is not stuck. Clean the surfaces of
the evaporator outlet and the capillary coil or bulb.
Make sure the coil or bulb is securely fastened to
the evaporator outlet and covered with insulation
material. Operate the system and check performance.
Repair Procedure: If the test did not result in
proper operation of the expansion valve, the valve
is defective and must be replaced. Recover all
refrigerant from the system and replace the expansion valve and the receiver-drier. Evacuate and
recharge the system with refrigerant using a
scale. Check AC operation and performance.
PROBLEM: High Pressure Side Restriction

Indications:
Low side pressure - LOW
High side pressure - Normal to HIGH
Look for sweat or frost on high side hoses
and tubing. The line will be cool to the touch
near the restriction.
Possible Causes
Kink in a line, collapsed hose liners, plugged
receiver-drier or condenser, etc.
N4-38
Repair Procedure: After you locate the defective

component containing the restriction, recover all
of the refrigerant. Replace the defective component and the receiver-drier. Evacuate and recharge
the system with refrigerant, then check AC
operation and performance.
Operator Comfort
N04024
PROBLEM: Compressor Malfunction

Indications:
High side pressure - LOW
Compressor operates noisily.
Possible Causes

Repair Procedure: If the belt is worn or loose,
replace or tighten it and recheck system performance and gauge readings. If inspection of the
compressor is required, all of the refrigerant must
be recovered and the compressor disassembled
to the point that inspection can be performed.
Replace defective components or replace the
compressor. If particles of desiccant are found in
the compressor, flushing of the system will be
required. It will also be necessary to replace the
receiver-drier. Always check the oil level in the
compressor, even if a new unit has been installed.
Rotary compressors have a limited oil reservoir.
Extra oil must be added for all truck installations.
Tighten all connections and evacuate the system.
Recharge the system with refrigerant using a scale.
Check system operation and performance.
- Defective reed valves or other internal

components.
PROBLEM: Thermostatic Switch Malfunction

Indications:
Low side pressure - Normal
Low side pressure may cycle within a smaller
range as the compressor clutch cycles
more frequently than normal. This may indicate
the thermostat is set too high.
Possible Causes
- Thermostat malfunctioning possibly due to
incorrect installation.

Replace the thermostatic switch. When removing
the old thermostat, replace it with one of the same
type. Take care in removing and handling the
thermostat and the capillary tube that is attached
to it. Use care not to kink or break the tube.
Position the new thermostat capillary tube at or
close to the same location and seating depth
between the evaporator coil fins as the old one.
Connect the electrical leads
N04024
Operator Comfort
N4-39
PROBLEM: Condenser Malfunction or System Overcharge

Indications:
Low Side High
High Side High
Discharge air may be warm.
High pressure hoses and lines are very hot.
Possible Causes
- Lack of air flow through the condenser fins
N4-40
Repair Procedure: Check the engine cooling

system components, fan and drive belt, fan clutch
operation, and the radiator shutter. Inspect
condenser for dirt, bugs, or other debris, and
clean if necessary. Be sure the condenser
is securely mounted and there is adequate
clearance (about 38 mm) between it and
the radiator. Check the radiator pressure cap and
cooling system, including the fan, fan clutch, drive
belts and radiator shutter assembly. Replace any
defective parts and then recheck AC system
operation, gauge readings, and performance.
If the problem continues, the system may be overcharged. Recover the system refrigerant. Use a
scale to recharge the system using the correct
amount. Recheck AC system operation, gauge
readings and performance. If the gauge readings
do not change, all of the refrigerant should be
recovered and the system flushed. The condenser
may be partially blocked -replace condenser. The
receiver-drier must also be replaced. Evacuate the
system, recharge, and check operation and
performance.
Operator Comfort
N04024
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM

Truck Serial Number_________________________
Last Maintenance Check:_____________________
Site Unit Number____________________________
Name of Service Technician________________
Date:____________Hour Meter:________________
Maintenance Interval
COMPONENT
NOTE: Compressor should be run at least 5 minutes

(40F minimum ambient temperature) every month,
in order to circulate oil and lubricate components.
(months)
3
12
Done
Maintenance Interval
COMPONENT
1. Compressor
Check noise level
Check clutch pulley
Check oil level
Run system 5 minutes
Check belt tension
(80-100) lbs; V-belt
3
4. Expansion Valve
Check mounting bracket

(tighten bolts)
Check solder joints on inlet/

outlet tubes (leakage)
Check clutch alignment w/

crankshaft pulley (within
0.06 in.)
Inspect condensation drain
2. Condenser
Clean dirt, bugs, leaves, etc.
from coils (w/compressed air)
Verify engine fan clutch is
engaging (if installed)
Check inlet/outlet for
obstructions or damage
3. Receiver-Drier
12
Done
5. Evaporator
Clean dirt, bugs, leaves, etc.
from fins (w/ compressed air)
Verify clutch is engaging
Inspect capillary tube (if

used) for leakage, damage,
looseness
Inspect shaft seal for leakage
Perform manifold gauge

check
(months)
6. Other Components
Check discharge lines
(hot to touch)
Check suction lines
(cold to touch)
Inspect fittings/clamps/hoses
Check thermostatic switch for
proper operation
Outlets in cab: 40F to 50 F
Inspect all wiring connections
Operate all manual controls
through full functions
Check inlet line from

condenser (should be hot to
touch)
Replace, if system is opened
N04024
Operator Comfort
N4-41
NOTES:
N4-42
Operator Comfort
N04024
SECTION N5
OPERATOR CAB CONTROLS
INDEX
OPERATOR CAB CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
Steering Column Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
Telescope Lock Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
Tilt Wheel Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
Turn Signal/Headlight Dimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
DYNAMIC RETARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
Retarder Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
Dynamic Retarder/Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
Accelerator (Throttle) Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
Starting on a Grade With a Loaded Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
GRADE/SPEED RETARD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . N5-8
Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-9
OVERHEAD PANEL AND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-9
CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
F-N-R Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Lowering The Dump Body: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Ash Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
L.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
R.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Engine Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Override/Fault Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-12
Retard Speed Control (RSC) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-12
Retard Speed Control (RSC) Adjust Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-12
PSC Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
Engine Diagnostics Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
TCI Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
N05055
Operator Cab Controls
N5-1
Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13

PAYLOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
Payload Meter Download Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
INSTRUMENT PANEL AND INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
CONTROL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
PANEL GAUGES, INDICATORS, AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
Normal Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
Engine Shutdown Switch with 5 Minute Idle Timer Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
Fog Lights (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
Manual Backup Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
Panel Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Cab/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Rotating Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Heated Mirror Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Wheel Brake Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
High Beam Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
AC Drive System Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21
Rest Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22
Windshield Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22
Panel Light Dimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22
OVERHEAD STATUS / WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23
STATUS / WARNING INDICATOR LIGHT SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-24
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-29
Lamp Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-29
Link-On Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-29
N5-2
N05055
OPERATOR CAB CONTROLS

STEERING COLUMN
Steering Column Inspection
Removal
1. Shut off engine by turning the key switch OFF.
Allow at least 90 seconds for the steering accumulators to bleed down. Turn the steering
wheel to be certain no pressure remains.
2. Open the battery disconnect switch.
3. Remove access cover (15, Figure 5-1) from the
front of the cab. Do not remove hydraulic lines
from steering control unit unless necessary.
4. Loosen capscrews (10) on steering control unit
(7) and move it out of the way.
5. Disconnect steering column wire harness(s).
6. Remove screws retaining trim cover (14) where
steering column enters the instrument panel
and remove cover.
7. Remove capscrews (12) and brackets (8 & 9).
8. Remove four capscrews (4). Access to these
screws is from the front of the cab through the
access opening.
9. Lift the steering column from instrument panel.
Whenever the steering column or steering control

unit is removed for service, the steering column shaft
splines should be inspected for excessive wear.
1. With the column assembly removed from the
truck, thoroughly clean splines on steering column shaft and inspect for damage or excessive
wear.
2. Using an outside micrometer or dial caliper,
measure the outside diameter of the male
splines on the steering column shaft.
Minimum diameter: 0.950 in. (24.13 mm)
3. If splines are smaller than minimum diameter
specification, replace steering column.
Installation
1. Insert capscrew (10), lockwashers (11), and
flatwashers (5) through brackets (8 & 9) and
then through steering column flange. Add second flatwasher (5) and nut (13) to each capscrew to hold parts together. Tighten nuts
securely.
2. Slide the entire assembly down the tapered
blocks until brackets (8 & 9) contact the mounting surface in the cab. Install capscrews (4) and
(12) with washers (5) and (6). Only tighten capscrews (4).
3. Inspect brackets (8 & 9) to see if they contact
the mounting surface evenly, and are flat and
inline with the surface. If so, tighten capscrews
(12). If brackets are not quite parallel, install flat
washers (as needed) between brackets and
mounting surface to eliminate any gaps.
Tighten capscrews (12) to standard torque.
4. After capscrews (4 & 12) are tightened to standard torque, remove nuts (13) and flatwashers
(5) that were holding the steering column to the
two brackets. Do not remove capscrews (10)
from the brackets.
FIGURE 5-1. STEERING COLUMN INSTALLATION

9. Bracket R.H.
1. Steering Wheel
10. Capscrew
2. Button Horn
11. Lock Washer
3. Steering Column
12. Capscrew
4. Capscrew
13. Nut
5. Flat Washer
14. Trim Cover
6. Lock Washer
7. Steering Control Unit 15. Access Cover
8. Bracket L.H.
N05055
5. Lubricate the male splines on the end of the

steering column shaft.
Note: There is no lower end bearing in this new
steering column assembly, therefore the male end of
the shaft will have to be guided into the mating
female part of the steering control unit (7).
6. Without removing capscrews (10) from the
holes, move the steering control unit (7) into
place and start each of the capscrews.
N5-3
7. Tighten the four capscrews (10) to standard

torque.
9. If disconnected, re-connect the hoses to the

steering control unit.
8. Check for proper steering wheel rotation without binding. Be certain wheel returns to neutral
after rotating 1/4 turn left and right.
10. Connect the steering column wire harness(es)

to the harness(es) in the cab.
11. Install access and trim covers.
FIGURE 5-2. CAB INTERIOR - OPERATOR VIEW

6. Heater/Air Conditioner Controls 11. Radio, AM/FM Stereo
1. Steering Wheel
12. Warning Lights Dimmer Control
7. Instrument Panel
2. Retarder Control Lever
13. Warning/Status Indicator Lights
8. Grade/Speed Retard Chart
3. Retarder/Service Brake Pedal
14. Air Cleaner Vacuum Gauges
9. Radio Speakers
4. Throttle/Accelerator Pedal
15. Windshield Wipers
10. Warning Alarm Buzzer
5. Heater/Air Conditioner Vents
N5-4
N05055
STEERING WHEEL AND CONTROLS

Steering wheel (1, Figure 5-3) will telescope "in" and
"out" and adjust through a tilt angle to provide a comfortable wheel position for most operators.
Horn Button
Horn (2, Figure 5-3) is actuated by pushing the button in the center of the steering wheel. Operation of
the horn should be verified before moving the truck.
Observe all local safety rules regarding the use of the
horn as a warning signal device before starting
engine and moving the vehicle.
Telescope Lock Ring
Telescope lock ring (3, Figure 5-3) around the horn
button locks/unlocks the telescoping function of the
steering column. Rotating the ring 90 - 180 counterclockwise (L.H. rotation), releases the column to
move "in" or "out". Rotating the ring clockwise (R.H.
rotation), locks the column in the adjusted position.
DYNAMIC RETARDING
Tilt Wheel Lever

Adjust the tilt of the steering wheel by pulling tilt
adjustment lever (4, Figure 5-3) toward the steering
wheel and moving the wheel to the desired angle.
Releasing the lever will lock the wheel in the desired
location.
Turn Signal/Headlight Dimmer
Turn signal lever (5, Figure 5- 3) is used to activate
the turn signal lights and to select either high or low
headlight beams.
Move the lever upward to signal a turn to
the right.
An indicator in the top, center of the instrument
panel will illuminate to indicate turn direction
selected. Refer to Instrument Panel and Indicator
Lights in this section.
Move the lever downward to signal a
turn to the left.
Moving the lever toward the steering
wheel changes headlight beam. When
high beams are selected, the indicator
in the top, center of the instrument panel will illuminate.
N05055
FIGURE 5-3. STEERING WHEEL AND CONTROLS
Dynamic retarding is a braking torque (not a brake)

produced through electrical generation by the wheelmotors when the truck motion (momentum) is the
propelling force.
For normal truck operation, dynamic retarding should
be used to slow and control truck speed.
Dynamic retarding is available in FORWARD/
REVERSE at all truck speeds above 0 mph/kph;
however, as the truck speed slows below 3 mph (4.8
kph), the available retarding force may not be effective. Use the service brakes to bring the truck to a
complete stop.
Dynamic retarding will not hold a stationary truck on
an incline; use the parking brake or wheel brake lock
for this purpose.
Dynamic retarding is available in NEUTRAL only
when truck speed is above 3 mph (4.8 kph).
When dynamic retarding is in operation, engine rpm
will automatically go to an advance retard speed setting. This rpm will vary depending on temperature of
several electrical system components.
Dynamic retarding will be applied automatically, if the
speed of the truck obtains the maximum speed setting programmed in the control system software.
When dynamic retarding is activated, an indicator
light in the overhead display will illuminate. The
grade/speed retard chart should always be used to
determine safe downhill speeds. Refer to grade/
speed retard chart in this chapter.
N5-5
Retarder Control Lever

Retarder control lever (6, Figure 5-3), mounted on
the right side of the steering column, can be used to
modulate retarding effort. The lever will command
the full range of retarding and will remain at a fixed
position when released.
a. When the lever is rotated to full up (counterclockwise) position, it is in the OFF/no
retard position. An adjustable detent holds
the lever in the OFF position. Refer to Section J, Brake Circuit Component Service for
adjustment procedures.
b. When the lever is rotated to full "down"
(clockwise) position, it is in the full ON/retard
position.
c. For long downhill hauls, the lever may be
positioned to provide a desired retarding
effort. It will remain where it is positioned.
NOTE: The retarder control lever must be rotated
back to the OFF position before the truck will resume
the propel mode of operation.
The lever and foot-operated retarder/service brake
pedal can be used simultaneously or independently.
The Propulsion System Controller (PSC) will determine which device is requesting the most retarding
effort and apply that amount.
Dynamic Retarder/Service Brake Pedal

Dynamic retarder/service brake pedal (3, Figure 5-2)
is a single, foot-operated pedal which controls both
retarding and service brake functions. The first portion of pedal travel commands retarding effort
through a rotary potentiometer. The second portion
of pedal travel modulates service brake pressure
directly through a hydraulic valve. Thus, the operator
must first apply, and maintain, full dynamic retarding
in order to apply the service brakes. Releasing the
pedal returns the brake and retarder to the OFF position.
When the pedal is partially depressed, dynamic
retarding is actuated. As the pedal is further
depressed, to where dynamic retarding is fully
applied; the service brakes (while maintaining full
retarding) are actuated through a hydraulic valve
which modulates pressure to the service brakes.
Completely depressing the pedal causes full application of both dynamic retarding and the service
brakes. An indicator light in the overhead panel (B3,
Figure 5-7) will illuminate), and an increase in pedal
N5-6
resistance will be felt when the service brakes are

applied.
For normal truck operation, dynamic retarding (lever
or foot-operated pedal) should be used to slow and
control the speed of the truck.
The service brakes should be applied only when
dynamic retarding requires additional braking force to
slow the truck speed quickly, or when bringing the
truck to a complete stop.
Accelerator (Throttle) Pedal

Accelerator (throttle) pedal (4, Figure 5-2) is a footoperated pedal which allows the operator to control
engine rpm, depending on pedal depression.
It is used by the operator to request torque from the
motors when in forward or reverse. In this mode, the
propulsion system controller commands the correct
engine speed for the power required. In NEUTRAL,
this pedal controls engine speed directly.
Starting on a Grade With a Loaded Truck

Initial propulsion with a loaded truck should begin
from a level surface whenever possible, but when
there are circumstances where starting on a hill or
grade cannot be avoided, use the following procedure:
1. Fully depress the foot-operated retarder/service brake pedal (Do Not use retarder lever) to
hold the truck on the grade. With service brakes
fully applied, move the selector switch to a drive
position (FORWARD/REVERSE) and increase
engine rpm with throttle pedal.
2. As engine rpm approaches maximum, and
operator senses propulsion effort working
against the brakes, release the brakes and let
truck movement start. Be sure to completely
release the foot-operated retarder/service brake
pedal. As truck speed increases above 3-5 mph
(5-8 kph) the Propulsion System Control (PSC)
will drop propulsion if the retarder is still applied.
Releasing and reapplying dynamic retarding
during a hill start operation will result in loss of
propulsion and, if truck speed is above 1-2 mph,
application of retarding effort.
N05055
GRADE/SPEED RETARD CHART

The grade/speed retard chart (8, Figure 5-2 & shown
below) provides the recommended MAXIMUM
retarding limits at various truck speeds and grades
with a fully loaded truck.
This decal in the truck may differ from the decal
below due to optional truck equipment such as:
wheel motor drive train ratios, retarder grids, tire
sizes, etc. Always refer to this decal in the operator's cab, and follow these recommendations for
truck operation.
The operator should reference this chart before
descending any grade with a loaded truck. Proper
use of dynamic retarding will maintain a safe speed.
The "short term" numbers listed on the chart indicate

the combination of speeds and grades which the
vehicle can safely negotiate for a short duration
before system components reach the maximum
allowable temperature during retarding. These
speeds are faster than the "continuous" values,
reflecting the thermal capacity of various system
components. System components can accept heating at a higher-than-continuous rate for a short period
of time. Beyond this short duration of time, the system would become overheated.
If the vehicle is operated at "short term" grade and
speed limits for a period of time exceeding thermal
capacity, the Propulsion System Controller (PSC)
gradually reduces retarding effort from "short term" to
"continuous". The "retard @ continuous" indicator
light will illuminate alerting the operator of the retarding reduction and the need for a reduction in speed.
The operator must use the service brakes to quickly
slow the truck to maximum "continuous" retarding
limits or less.
Do Not LIGHTLY apply the service brakes when

attempting to slow the truck on a downhill grade.
Overheating of the brakes will result. Fully apply
the brakes (within safe limits for road conditions)
in order to quickly slow the truck to maximum
"continuous" retarding limits or less.
NOTE: The "three minute" curve is a minimum and
the actual time limit could be greater. Ambient
temperature, barometric pressure and recent motor
power levels can affect this number.
The "short term" rating will successfully accommodate most downhill loaded hauls. It is necessary to
divide haul road grade segment length by allowable
speed to determine actual time on grade. If actual
time on the grade exceeds the allowable limits, the
grade will need to be negotiated at the "continuous"
speed.
Two speed lists are provided, one for continuous
retarding, and the second, for short term (approx. 3minute) retarding. Both lists are matched to the truck
at maximum Gross Vehicle Weight (GVW). The two
ratings are guidelines for proper usage of the retard
function on downhill grades.
N05055
The "continuous" numbers on the chart indicate the

combination of speeds and grades which the vehicle
can safely negotiate for unlimited time or distance
during retarding.
DO NOT exceed these recommended MAXIMUM
speeds when descending grades with a loaded truck.
N5-7
HEATER / AIR CONDITIONER

COMPARTMENT AND CONTROLS
The heater/air conditioner compartment contains the
heater/air conditioner controls (6, Figure 5-2) and
some of the heater/air conditioner components, such
as the blower motor assembly and heater coils. Optimum cab air climate can be selected by using the following controls in various combinations.
Heater/Air Conditioner Vents
Each heater/air conditioner vent (6, Figure 5-4) is a
flapper type which may be opened or closed or
rotated 360 for optimum air flow. There are four
(three not shown) across the top of the panel, one
each in the right and left panel modules, and four
below the panel.
Heater/Air Conditioner Selector Switch

Selector switch (5, Figure 5-4) allows the operator to
select heat, A/C, or neither. The left position of the
switch activates the air conditioning and the right side
of the switch activates the heater. The middle position is OFF. Neither the heat nor the air conditioning
can be activated in this position.
NOTE: The air conditioner will not operate unless the
fan control knob is turned ON.
Defroster Control Switch

Defroster control switch (1, Figure 5-4) directs
heated air for windshield defrosting. "Down" position
of the toggle switch is OFF. "Up" position of the toggle switch is ON.
Heat Control Switch
Heater control 2, Figure 5-4) directs heated air to the
cab floor for heating of the cab. "Down" position of
the toggle switch is OFF. "Up" position of the toggle
switch is ON.
Temperature Control Knob
Temperature control knob (3, Figure 5-4) allows the
operator to select a comfortable temperature.
Rotating the knob counter-clockwise (blue arrow) will
select cooler temperatures. Full counter-clockwise
position is the coldest air setting. Rotating the knob
clockwise (red arrow) will select warmer temperatures. Full clockwise position is the warmest heater
setting.
Fan Control Knob
Fan control knob (4, Figure 5-4) controls the cab air
fan motor. The fan motor is a 3-speed motor: low
(setting 1), medium (setting 2), and high (setting 3).
Speeds are selected by rotating the control knob
clockwise to the desired position. OFF is full counterclockwise position (setting 0).
FIGURE 5-4. A/C & HEATER CONTROLS
N5-8
N05055
INSTRUMENT PANEL
Instrument panel (7, Figure 5-2) includes a wide variety of switches, gauges, and indicators. Refer to Instrument
Panel and Indicator Lights, in this chapter for a detailed description of function and location of these components.
OVERHEAD PANEL AND DISPLAYS

The items listed below are located on the overhead panel. Refer to Figure 5-2 for the location of each item. A brief
description of each component is documented below.
Radio Speakers
Status/Warning Indicator Light Panel
Radio speakers (9, Figure 5-2) for the AM/FM Stereo

radio are located at the far left and right of the overhead panel.
Panel (13, Figure 5-2) contains an array of indicator

lights to provide the operator with important status
messages concerning selected truck functions. Refer
to Instrument Panel and Indicator Lights, in this chapter for a detailed description of these indicators.
Warning Alarm Buzzer

Warning alarm buzzer (10, Figure 5-2) will sound
when activated by any one of several truck functions.
Refer to Instrument Panel and Indicator Lights, in this
chapter for a detailed description of functions and
indicators that will activate this alarm.
Cab Radio (Optional)

This panel will normally contain AM/FM stereo radio
(11, Figure 5-2). Refer to Section 7 in the Operation
and Maintenance Manual for a more complete
description of the radio and its functions. Individual
customers may use this area for other purposes,
such as a two-way communications radio.
Air Cleaner Vacuum Gauges

Air cleaner vacuum gauges
(14, Figure 5-2) provide a continuous reading of maximum
air cleaner restriction reached
during operation. The air
cleaner(s) should be serviced
when the gauge(s) shows the
following maximum recommended restriction:
Komatsu SSDA16V160 Engine: 25 inches of H2O
vacuum.
NOTE: After service, push the reset button on face of
gauge to allow the gauge to return to zero.
Warning Indicator Light Dimmer Control

Dimmer control (12, Figure 5-2) permits the operator
to adjust the brightness of warning indicator lights
(13).
Windshield Wipers
Windshield wipers (15, Figure 5-2) are powered by
an electric motor. Refer to Instrument Panel and Indicator Lights, in this chapter for a location and
description of the windshield wiper and washer controls.
N05055
N5-9
CENTER CONSOLE
The center console (1, Figure 5-5) contains:
(1) Center Console
(2) F-N-R Selector Switch
(3) Hoist Control Lever
(4) Ash Tray
(5) Cigar/Cigarette Lighter
(6) L.H. Window Control Switch
(7) R.H. Window Control Switch
(8) Engine Shutdown Switch
(9) Override/Fault Reset Switch
(10) Blank - Not Used on this truck
(11) RSC Switch
(12) Retarder Speed Control Dial
(13) Propulsion System Controller (PSC)
Diagnostic Port
(14) Engine Diagnostic Port (CENSE)
(15) Truck Control Interface (TCI)
(16) Passenger Seat
(mounted on top of the right hand
portion of the Console structure)
(17) Engine Diagnostic Port (QUANTAM)
(18) Modular Mining Port (Optional)
(19) Data Store Button
FIGURE 5-5. CENTER CONSOLE
F-N-R Selector Switch

Selector switch (2, Figure 5-5) is mounted on a console to the right of the operator's seat. It is a three
position switch that controls the forward-neutralreverse motion of the truck. When the selector switch
handle is in the center "N" position, it is in NEUTRAL.
The handle must be in NEUTRAL to start the engine.
The operator can select FORWARD drive
by moving the handle forward.
REVERSE drive can be selected by moving

the handle to the rear.
The truck must be stopped before the selector handle is moved to a drive position.
N5-10
N05055
Hoist Control Lever
Ash Tray
Hoist control (3, Figure 5-5) is a four position handoperated lever located between the operator seat
and the center console (see illustration below).
Ash tray (4, Figure 5-5) is used for extinguishing and

depositing smoking materials. Do Not use for flammable materials, such as paper wrappers, etc. Be
certain that all fire ash is extinguished!
Lighter
Lighter (5, Figure 5-5) may be used for lighting
cigars/cigarettes. Always use caution with smoking
materials!
This socket may also be used for a 12 VDC power
supply.
L.H. Window Control Switch

LH window control switch (6, Figure 5-5) is springloaded to the OFF position.
Raising The Dump Body

1. Pull the lever to the rear to actuate the hoist circuit. (Releasing the lever anywhere during
"hoist up" will place the body in HOLD at that
position.)
2. Raise engine rpm to increase hoist speed.
3. Reduce engine rpm as the last stage of the
hoist cylinders begin to extend and then let the
engine go to low idle as the last stage reaches
half-extension.
4. Release the hoist lever as the last stage
reaches full extension.
5. After material being dumped clears the body,
lower the body to frame.
Pushing the front of the switch raises the left side

cab window.
Pushing the rear of the switch lowers the window.
R.H. Window Control Switch

RH window control switch (7, Figure 5-5) is springloaded to the OFF position.
Pushing the front of the switch raises the right

side cab window.
Pushing the rear of the switch lowers the window.
Refer to Operating Instructions - Dumping, Section 3,

of the Operation and Maintenance Manual for more
complete details concerning this control
Engine Shutdown Switch
Lowering The Dump Body:
Use this switch to shutdown the engine if the engine

does not shutdown by turning off the keyswitch, or to
shutdown the engine without turning off the 24 VDC
electric circuits.
Move the hoist lever forward to DOWN position and

release. Releasing the lever places the hoist control
valve in the FLOAT position allowing the body to
return to the frame.
N05055
Engine shutdown switch (8, Figure 5-5) is

used for engine shutdown by depressing
this button and holding it until engine
stops.
There is also a ground level engine shutdown switch

on the left front frame rail behind the ladder.
N5-11
Override/Fault Reset Switch
Retard Speed Control (RSC) Adjust Dial
Override/Fault reset
switch (9, Figure 55) is spring-loaded
to the OFF position.
When pushed in
and
held,
this
switch may be used for several functions.
RSC adjust dial (12, Figure 5-5) allows the operator

to vary the downhill truck speed that the retard speed
control system will maintain when descending a
grade. This function can be overridden by the accelerator, retard lever, or retard pedal.
1. This switch permits the operator to override the

body-up limit switch and move the truck forward
when the selector switch is in FORWARD, the
dump body is raised, and the brakes are
released.
Use of the override switch for this purpose is
intended for emergency situations only!
2. The push button deactivates the retard pedal
function when speed of truck is below 3 mph
(4.8 kph).
3. The override switch is also used to reset an
electric system fault when indicated by a red
warning light (Refer to Overhead Status/Warning Indicators in this section.
10, Figure 5-5 - Blank
This position is not used for the
930E.
When the dial is rotated clockwise toward

this symbol, the truck speed will increase.
ALWAYS refer to the grade/speed retard chart in the
operator's cab, and follow the recommendations for
truck operation. DO NOT exceed these recommended MAXIMUM speeds when descending
grades with a loaded truck.
Throttle pedal position will override the RSC setting.
If the operator depresses the throttle pedal to
increase truck speed, dynamic retarding will not
come activate unless the truck overspeed setting is
reached or the foot operated retard pedal is used.
When the throttle pedal is released and the RSC
switch is on, dynamic retarding will activate at, or
above, the RSC dialed speed and will adjust truck
speed to, and maintain, the dialed speed.
To adjust the RSC control, pull switch (11) ON and
start with dial (12) rotated toward fastest speed while
driving the truck at the desired maximum speed.
Relax the throttle pedal to let the truck coast and
slowly turn the RSC adjusting dial counterclockwise
until dynamic retarding is activated. Dynamic retarding will now be activated automatically anytime the
"set" speed is reached, the RSC switch is on, and the
throttle pedal is released.
In some other truck models, this position is used for an engine idle switch.
Retard Speed Control (RSC) Switch

Retard speed control switch (11, Figure 5-5) turns
the system off or on. Push the knob in to turn off and
pull the knob out to turn the system on.
IN
OFF
OUT
When the dial is rotated counterclockwise

toward this symbol, the truck will descend
a grade at lower speeds.
ON
With the RSC switch on and dial adjusted, the system will function as follows: As truck speed increases
to the "set" speed and throttle pedal released,
dynamic retarding will apply. As truck speed tries to
increase, the amount of retarding effort will automatically adjust to keep the selected speed. When truck
speed decreases, the retarding effort is reduced to
maintain the selected speed. If truck speed continues
to decrease to approximately 3 mph (4.8 kph) below
"set" speed, dynamic retarding will turn off automatically. If truck speed must be reduced further, the
operator can turn the adjust dial to a new setting or
depress the foot operated retard pedal.
If the operator depresses the foot operated retard
pedal and the retard effort called for is greater than
that from the automatic system, the foot pedal retard
will override RSC.
N5-12
N05055
PSC Download Port
PAYLOAD METER
PSC download port (13, Figure 5-5) is for use by

qualified personnel to access diagnostic information
from the Propulsion System Controller (PSC).
Payload meter (1, Figure 5-6) and download connector (2) are used to provide management with operational data such as tonnage hauled and cycle times.
The payload meter is located on the back wall inside
of the cab.
Engine Diagnostics Download Port
Refer to Section M, Payload Meter, for a more complete description of the payload meter and its functions.
Engine diagnostics download port (14, Figure 5-5) is

for use by qualified personnel to access the diagnostic information for the engine control system.
(CENSE)
Payload Meter Download Connector

Engine Control System
Engine control system port (17, Figure 5-5) is for use
by qualified personnel. This 9-PIN connector is used
to access diagnostic information for the engine control system. (QUANTUM)
Connector (2, Figure 5-6) is used with a special cable

to allow the payload meter to communicate with a
portable computer.
TCI Download Port

TCI download port (15, Figure 5-5) is for use by qualified personnel to access the Truck Control Interface
(TCI) diagnostic information and data.
Passenger Seat
Passenger seat (16, Figure 5-5) is mounted on top of
the right hand portion of the center console structure.
The area beneath the passenger seat provides a
cabinet for various 24 VDC electrical components.
FIGURE 5-6. PAYLOAD METER
Modular Mining System (Optional)
1. Payload Meter III
2. Download Connector
Modular mining system connector (18, Figure 5-5) is

for use by qualified personnel to access the Modular
Mining System for diagnostic information and data.
N05055
N5-13
NOTES
N5-14
N05055
INSTRUMENT PANEL AND INDICATOR LIGHTS

CONTROL SYMBOLS
Many control functions are identified with "International" symbols that the operator should learn to recognize immediately. The operator must understand the function and operation of each instrument and control. This knowledge
is essential for proper and safe operation of the machine.
The following symbols are general indicators and may appear in multiple locations and combinations on the instrument panel.
This symbol may be used alone
or with another symbol. This
symbol identifies the OFF position of a switch or control.
This symbol when it appears on

an indicator or control identifies
that this indicator or control is
NOT used.
This symbol may be used alone

or with another symbol. This
symbol identifies the ON position
of a switch or control.
This symbol identifies a rotary

control or switch. Rotate the knob
clockwise or counterclockwise for
functions.
This symbol identifies the

"Pushed-In" position of a pushpull switch or control.
This symbol identifies a switch

used to test or check a function.
Press the switch on the side near
the symbol to perform the test.
This symbol identifies the

"Pulled-Out" position of a pushpull switch or control.
INSTRUMENT PANEL
(Figure 5-7)
The operator must understand the function and operation of each instrument and control. Control functions are identified with "International" symbols that
the operator should learn to recognize immediately.
This knowledge is essential for proper and safe operation.
Items that are marked optional do not apply to
every truck.
N05055
N5-15
FIGURE 5-7. PANEL GAUGES, INDICATORS, AND CONTROLS

1. Keyswitch
2. Engine Shutdown Switch with Timer Delay
3. Backup Light Switch (N./O.)
4. Ladder Light Switch (3 - Way)
5. Fog Light Switch (N./O.)
6. Panel Illumination Light(s)
7. Vent(s) - Cab Air Conditioner/Heater
8. Not used on 930E
9. Rotating Beacon Light Switch (N./O.) (Optional)
10. Heated Mirror Switch (N./O.) (Optional)
11. Not used on 930E
12. Wheel Brake Lock Switch (N./O.)
13. Parking Brake Switch (N./O.)
14. Digital Tachometer
15. Right Turn Signal Indicator Light

16. High Beam Headlight Indicator Light
17. Left Turn Signal Indicator Light
18. Digital Speedometer
19. Voltmeter Gauge
20. Engine Oil Pressure Gauge
21. Engine Water Temperature Gauge
22. Fuel Gauge
23. AC Drive System Temperature
24. Engine Hourmeter
25. Hydraulic/Brake Oil Temperature
26. AC REST Switch
27. Headlights Switch (N./O.)
28. Wiper / Washer Switch
29. Panel Illumination Lights Dimmer Rheostat
WIRE NUMBERS
1. 712/21PB/11S
2. 11S/11TD/11R
3. 712/47S/47L/710
4. 11L/48A/48B
5. 11L/48F
6. 49/710
7. N/A
8. 712/28E
9. 11L/11RB
10. 712/69M/SPR56/SPR57/
SPR58
N5-16
11. 71/79M/SPR55/79H/72F/
SPR54
12. 712BL/52B/39H/710/SPR59
13. 71/52C/21PB/21
14. 41TS/74X/74Z/710
15. 45R/710
16. 41H/710
17. 45L/710
18. 41TS/77/77A/710
19. 712D/710/49
20. 712D/31PS/710/49
21. 712D/31TS/710/49
22. 712D/38G/710/49
23. 15V/72MT/49/710
24. 11L/36
25. 15V/34BT/710/49
26. 710/72RQ
27. 11D/41L/41TS
28. High 66S/Low 66L/710/66P
Park/712W / Washer 66
29. 49/41TS
N05055
PANEL GAUGES, INDICATORS, AND CONTROLS

(Figure 5-7)
Normal Engine Shutdown
Key Switch
Key switch (1, Figure 5-7) is a three position (OFF,
RUN, START) switch.
1. Stop the truck. Reduce engine rpm to low idle.

Place selector switch in NEUTRAL and apply
parking brake switch.
2. Place rest switch in ON position (put drive system in "rest" mode of operation). Refer to discussion of rest switch (26, Figure 5-7).
3. Allow engine to cool gradually by running at low
idle for 3 to 5 minutes or use the engine shutdown with timer delay as described on the following page.
4. With truck stopped and engine cooled down,
turn keyswitch counterclockwise to OFF for normal shutdown of engine. If engine does not
shutdown with keyswitch, use engine shutdown
switch on center console (see Center Console)
and hold this switch down until engine stops.
at least 90 seconds. Insure steering circuit is
completely bled down by turning steering wheel
back and forth several times. No front wheel
movement will occur when hydraulic pressure is
relieved.
Starting
When the switch is rotated one position clockwise, it
is in the RUN position and all electrical circuits
(except START are activated.
1. With the selector switch in NEUTRAL, rotate
the keyswitch fully clockwise to the START
position, and hold this position until the engine
starts. The START position is spring-loaded to
return to RUN when the key is released.
2. After the engine has started, place the rest
switch in the OFF position (de-activate the
"rest" mode of operation). Refer to discussion of
rest switch (26, Figure 5-7).
6. Verify all the link voltage lights turn off within 5

minutes after the engine is shut down. (One is
located in cab, behind the operator seat, two
others are located in the access panel at the left
front corner of the electrical cabinet.) If lights
remain on, refer to Section E for additional
instructions and information.
unauthorized truck operation. Dismount truck
properly.
NOTE: A ground level shutdown switch is located on
lower front left side of truck.
Cold Weather Starting

Do not crank an electric starter for more than 30
seconds at a time. Allow two minutes for cooling
before attempting to start engine again. Severe
damage to starter motor can result from overheating.
N05055
N5-17
Engine Shutdown Switch with

5 Minute Idle Timer Delay
The timer delayed, engine shutdown switch (2, Figure 5-7) is a
3-position, rocker type switch
with OFF, ON and MOMENTARY positions. When used, the
engine is allowed to idle for approximately 5 minutes
before actual shutdown occurs. The delayed shutdown feature allows the engine to cool down slowly,
reducing internal temperatures as coolant is circulated through the engine.
5. Verify all the link voltage lights turn off within 5

minutes after the engine is shut down. (One is
located in the cab behind the operator seat, two
others are located in the access panel at the left
front corner of the electrical cabinet. If the lights
remain on, refer to Section E for additional
instructions and information.
unauthorized truck operation. Dismount the
truck properly.
Operation
1. Stop the truck, and reduce engine rpm to low
idle. Place the selector switch in NEUTRAL and
apply the parking brake switch. Place the rest
switch in ON position (put drive system in "rest"
mode of operation). Refer to the discussion of
the rest switch later in this chapter.
2. Press the top of the engine shutdown switch to
select the ON (center) position. Press the top of
the switch again to activate the timer delay
(momentary position). Release the switch and
allow it to return to the ON position.
When the engine shutdown timer has been
activated, the timer delay indicator light (C4,
Figure 5-8) in the overhead status panel will
illuminate to indicate that the shutdown timing
sequence has started. The engine will continue
to idle for approximately 5 minutes to allow for
proper engine cool-down before stopping.
3. Turn the keyswitch counterclockwise to the
OFF position to cause the engine to shutdown
when the timing sequence is complete. When
the engine stops, this will activate the hydraulic
bleeddown timer and turn off the 24 VDC electric circuits controlled by the keyswitch.
NOTE: To cancel the 5 minute idle timer sequence,
press the timer delay shutdown switch to the OFF
(lower) position. If the keyswitch is in the OFF
position, the engine will stop. If the keyswitch is in the
ON position, the engine will continue to run.
at least 90 seconds. Ensure the steering circuit
is completely bled down by turning the steering
wheel back and forth several times. No front
wheel movement will occur when hydraulic
pressure is relieved.
N5-18
Fog Lights (Optional)

Fog lights (5, Figure 5-7) are
optional equipment that are useful in foggy conditions and heavy
rain. Pressing the top of the
rocker switch turns the lights on.
Pressing the bottom of the switch
turns the lights off.
Ladder Light Switch

The switch (4, Figure 5-7) turns
the ladder lights on or off after or
before using ladder. Pressing
the top of the rocker switch turns
the lights on. Pressing the bottom of the switch turns the lights
off. Another switch is mounted at
the front left of truck near the
base of ladder.
Manual Backup Switch

The manual backup switch (3,
Figure 5-7) allows backup lights
to be turned on providing added
visibility and safety when the
selector switch (see Operator
Controls) is not in REVERSE
position. When the switch is
pressed toward the ON position, the manual back up
light indicator (B4, overhead panel, Figure 5-7) will
be illuminated.
N05055
Panel Illumination Lights
Wheel Brake Lock Control
These lights (6, Figure 5-7) provide illumination for

the instrument panel. Brightness is controlled by the
panel light dimmer switch (28).
The wheel brake lock (12, Figure 5-7)

should be used with engine running for
dumping and loading operations only. The
brake lock switch actuates the hydraulic
brake system which locks the rear wheel service
brakes only. When pulling into shovel or dump area,
stop the truck using the foot-operated service brake
pedal. When truck is completely stopped and in loading position, apply the brake lock by pressing the
rocker switch toward the ON symbol. To release,
press the rocker switch toward the OFF symbol.
Cab/Air Conditioner Vents

These Vents (7, Figure 5-7) are spherically mounted
and may be directed by the operator to provide the
most comfortable cabin air flow.
Use at shovel and dump only to hold truck in

position.
(8, Figure 5-6) Not Used
Rotating Beacon Light Switch (Optional)

The optional rotating beacon light
(9, Figure 5-7), is activated by
this
rocker-type
switch
(if
equipped) when it is pressed
toward the ON position.
Heated Mirror Switch (Optional)

The optional heated mirror (10,
Figure 5-7), is activated by this
rocker-type switch (if equipped)
when it is pressed toward the ON
position.
(11, Figure 5-7) Not Used
Do not use this switch to stop truck, unless footoperated treadle valve is inoperative. Use of this
switch applies rear service brakes at full, unmodulated pressure!
Do not use brake lock for parking. With engine
stopped, hydraulic pressure will bleed down,
allowing brakes to release!
Parking Brake Control
The parking brake (13, Figure 5-7) is
spring applied and hydraulically released.
It is designed to hold a stationary truck
when the engine is shutdown and keyswitch is turned OFF. The truck must be completely
stopped before applying the parking brake, or damage may occur to parking brake.To apply the parking
brake, press the rocker switch toward the ON symbol. To release the parking brake, press the rocker
switch toward the OFF symbol. When the keyswitch
is ON and parking brake switch is applied, the parking brake indicator light (A3, overhead panel, Figure
5-8) will be illuminated.
NOTE: Do not use the parking brake at shovel or
dump. With keyswitch ON and engine running,
sudden shock caused by loading or dumping could
cause the system's motion sensor to release the park
brake.
N05055
N5-19
Tachometer
Voltmeter
The tachometer (14, Figure 5-7) registers engine

crankshaft speed in hundreds of revolutions per
minute (rpm).
Governed rpm
The voltmeter (19, Figure 5-7)

indicates the voltage of the 24V
battery system. Normal indicated
voltage at high rpm is 27 to 28
volts with batteries in fully
charged condition. When keyswitch (10) is ON and engine is
not running, voltmeter indicates
battery charge condition.
Low Idle - 750 rpm

High Idle - 1910 rpm
Full Load - 1900 rpm
Right Turn Signal Indicator

Engine Oil Pressure Gauge
This light (15, Figure 5-7) illuminates to indicate the right turn
signals are operating when the
turn signal lever on the steering
column is moved upward. Moving the lever to its center position
will turn indicator off.
The engine oil pressure gauge

(20, Figure 5-7) indicates pressure in the engine lubrication
system in pounds per square
inch (psi).
Normal operating pressure after
engine warm up should be:
Idle - 20 psi (138 kPa) Minimum
Rated Speed - 45 to 70 psi (310 - 483 kPa)
High Beam Indicator

The high beam indicator (16, Figure 5-7) when lit, indicates that
the truck headlights are on high
beam. To switch headlights to
high beam, push the turn indicator lever away from steering
wheel. For low beam, pull lever
toward the steering wheel.
Water Temperature Gauge

The water temperature gauge
(21, Figure 5-7) indicates the
temperature of the coolant in the
engine cooling system. The temperature range after engine
warm-up and truck operating
under normal conditions should
be:
Left Turn Signal Indicator

This light (17, Figure 5-7) illuminates to indicate the left turn signals are operating when the turn
signal lever on the steering column is moved downward. Moving the lever to its center position
will turn indicator off.
185-207F (85-97C)
Fuel Gauge
The fuel gauge (22, Figure 5-7)
indicates how much diesel fuel is
in the fuel tank.
The fuel tank capacity is 1200
gallons (4542 liters).
Speedometer
The speedometer (18, Figure 5-7) indicates the truck
speed in miles per hour (mph), or with optional
speedometer, it may indicate truck speed in kilometers per hour (kph). The display also shows payload
meter information. For more information, see section
M, Payload Meter
N5-20
N05055
AC Drive System Temperature Gauge
Hourmeter
The AC drive system temperature gauge (23, Figure 5-7) indicates

the
drive
system
temperature. There are three
colored bands: green; yellow;
and red. Green indicates "normal" operation.
The hourmeter (24, Figure 5-7)

registers the total number of
hours the engine has been in
operation.
Yellow indicates the system temperature is rising.

There is also an amber (yellow) "temperature warning" light in the overhead panel (C5, Figure 5-8) that
will illuminate when the temperature exceeds a certain level. When this condition occurs, the operator
should consider changing truck operation in order to
reduce system temperature.
If the AC drive system temperature should reach the
red band, continued operation could damage components in the system.
Safely stop truck, shutdown engine, and notify
maintenance personnel immediately.
Hydraulic Oil Temperature Gauge

The hydraulic oil temperature
gauge (25, Figure 5-7) indicates
oil temperature in the hydraulic
tank. There are two colored
bands: green, and red. Green
indicates "normal" operation.
The rest switch (26,

Figure 5-7) is a
"rocker" type switch
with a locking device
for the OFF (left side)
position. When in this
position, a small black
tab must be pushed to the left to unlock the switch
before it can be depressed to switch to the ON (right
side) position. When in the ON position, an internal
amber lamp will illuminate. It should be activated to
de-energize the AC drive system whenever the
engine is to be shutdown, or the truck parked for a
length of time with the engine running.
The selector switch must be in NEUTRAL and the
vehicle not moving to enable this function. This will
allow the engine to continue running while the AC
drive system is de-energized.
As the needle gets close to the

red zone, the minimum engine idle speed will
increase to help cool the oil.
Red indicates high oil temperature in the hydraulic
tank. Continued operation could damage components in the hydraulic system. There is also a red
"temperature warning" light in the overhead panel
(D5, Figure 5-8) that will illuminate when the temperature exceeds a certain level (when the needle
enters the red zone). If this condition occurs, the
operator should safely stop the truck, move selector
switch to NEUTRAL, apply the park brake, and operate engine at 1200 - 1500 rpm to reduce system temperature.
If temperature gauge does not move into the
green range after a few minutes, and the red
overhead indicator light does not go out, shutdown truck and notify maintenance personnel
immediately.
N05055
Rest Switch
Activation of the rest switch alone does NOT

completely ensure that the drive system is safe
to work on.
Refer to Safety Procedures, and check all "linkon", or "link energized", indicator lights to verify
the AC drive system is de-engergized before performing any maintenance on the drive system.
DO NOT activate the rest switch while the truck is
moving! The truck may unintentionally enter the
rest mode after stopping.
An amber (yellow) indicator light
in the overhead panel (B6, Figure 5-8) will illuminate when the
"rest" state has been requested
and entered.
N5-21
Light Switch
Panel Light Dimmer
The instrument panel lights,

clearance lights, and the headlights are controlled by this three
position rocker type switch (27,
Figure 5-7). OFF is selected by
pressing the bottom of the
switch. Press the top of the
switch until it reaches the first
detent to select the panel, clearance, and tail lights
only. Press the top of the switch again, until it
reaches the second detent to select headlights, as
well as panel, clearance, and tail lights.
The panel light dimmer control

(29, Figure 5-7) is a rheostat
which allows the operator to vary
the brightness of the instruments
and panel lights.
Rotating knob to the full

counterclockwise position turns panel lights on to
brightest condition.
Rotating knob clockwise continually dims lights

until OFF position is reached at full clockwise
rotation.
Windshield Wiper and Washer

The windshield wiper control
switch (28, Figure 5-7) is a four
position rotary switch with
intermittent wiper delay and
wash feature.
OFF position is the detented
position when the knob is
rotated fully counterclockwise against the stop. The
intermittent wiper position is located between OFF
and the first detent position, when rotating the knob
clockwise.
Rotating the knob closer to the first detent

position decreases the time interval between
wiper strokes.
Rotate the knob clockwise to the first detent

position for slow speed.
Rotate the knob to the second detent position for

fast speed.
To use the windshield washer,

press and hold the knob "in" to
activate the windshield washer
system.
N5-22
N05055
OVERHEAD STATUS / WARNING INDICATORS
FIGURE 5-8. OVERHEAD STATUS / WARNING INDICATOR

Row /
Column
Indicator
Description
Indicator Color
Wire Index
Row /
Column
Indicator
Description
Indicator Color
Wire Index
A1*
Not Used
12FD/34TL
A5
No Power
Red-12M/75-6PI
B5
Propulsion System
Warning
Amber-12F/79WI
C5
Propulsion System
Temperature
Amber -12F/34TW
D5
Hydraulic Oil Temperature

High
Red-12F/34TGI
E5
Stop Engine
Red-12M/528A
A6
NO PROPEL
Red-12M/75NPI
B6
Propulsion System @ Rest Amber-12M/72PR
C6*
Propulsion System Not

Ready
Amber-12MD/72NR
D6*
Reduced Propulsion
System
Amber-12MD/72LP
E6*
Retard @ Continuous
Level
Amber-12MD/76LR
B1*
Red-12FD/33A
C1
Low Accumulator Pr.
Red-12F/33K
D1
Not Used
Red-12F/79V
E1
Low Brake Pressure
Red-12F/33L
A2*
Hydraulic Tank Level
Red-12FD4/34LL
B2*
Low Automatic
Lubrication Pressure
Amber-12FD8/
68LLP
C2*
Circuit Breaker Tripped
Amber-12FD/31CB
D2*
Hydraulic Oil Filter
Amber-12MD/39
E2*
Low Fuel
Amber-12MD/38
A3*
Park Brake Applied
Amber-12MD/52A
B3*
Service Brake Applied
Amber-12MD/44L
C3*
Body Up
Amber-12MD6/63L
D3*
Dynamic Retarding
Amber-12MD/44DL
E3
Stop Engine
Red-12M/509MA
A4*
Not Used
Amber-12MD/SPR2
B4*
Manual Back-Up Lights
Amber-12MD/47L
C4*
5 Min. Shutdown Timer
Amber-12MD/23L1
D4*
Amber-12MD/31R
E4*
Check Engine
Amber-12MD7/419
N05055
-Switches7
Hazard Lights Switch N/O
11L/45L/45R
Lamp Check Switch N/O

(Mom.)
33H/528/710/712
* NOTE: Brightness for these Indicator Lamps can be

adjusted by using dimmer control (12, Figure 5-2).
N5-23
STATUS / WARNING INDICATOR LIGHT SYMBOLS

Amber (Yellow) color indicator lights alert the operator that the indicated truck function requires some
precaution when lighted.
Red color indicator lights alert the operator that the
indicated truck function requires immediate action
by the operator. Safely stop the truck and shut down
the engine.
DO NOT OPERATE THE TRUCK WITH A RED
WARNING LIGHT ILLUMINATED.
Refer to Figure 5-8 and the descriptions below for
explanations of the symbols.
Location of the symbols is described by rows (A-E)
and columns (1 - 6).
A1
Not Used
B1
RED
C1
Low Accumulator
Precharge Pressure
RED
D1
Not Used
E1
Low Brake Pressure
considered "normal", and truck operation may

continue.
If the indicator light illuminates at higher truck

speed and high engine rpm, DO NOT operate
the truck.
If the low steering
warning light continues to illuminate and the alarm
continues to sound, low steering pressure is
indicated. The remaining pressure in the accumulators allows the operator to control the truck
to a stop. Do not attempt further operation until
the malfunction is located and corrected.
C1.
LOW
PRESSURE
ACCUMULATOR
PRECHARGE
Not currently used. Reserved for future use or

options.
The low accumulator precharge warning light, if illuminated, indicates low nitrogen precharge for the
steering accumulator(s). To check for proper accumulator nitrogen precharge, engine must be stopped
and hydraulic system completely bled down; then
turn keyswitch to RUN position. Warning light will
NOT illuminate if system is properly charged. The
warning light will flash if the nitrogen precharge
within the accumulator(s) is below 1100 45 psi
(7585 310 kPa).
If low accumulator
precharge warning
light flashes, notify
maintenance personnel. Do not attempt further operation until the
accumulators have been recharged with nitrogen
to 1400 psi (9653 kPa). Sufficient energy for
emergency steering may not be available, if system is not properly charged.
B1. LOW STEERING PRESSURE
D1. NOT USED
When the keyswitch is turned ON, the low steering

pressure warning light will illuminate until the steering
system hydraulic pressure reaches 2100 psi (14.7
MPa). The warning horn will also turn on, and both
will remain on, until the accumulator has been
charged.
Not currently used. Reserved for future use or

options.
RED
A1. NOT USED
During truck operation, the low steering pressure

warning light and warning horn will turn sound if
steering system hydraulic pressure drops below
2100 psi (14.7 MPa).
E1. LOW BRAKE PRESSURE

This red indicator light indicates a malfunction within
the hydraulic brake circuit. If this light comes on and
buzzer sounds, shut down truck operation and
notify maintenance personnel.
NOTE: Adequate hydraulic fluid is stored to allow the
operator to safely stop the truck.
If the light illuminates momentarily ("flickers")

while turning the steering wheel at low truck
speed and low engine rpm, this may be
N5-24
N05055
A2
Low Hydraulic Tank

Level
RED
A3
Parking Brake
AMBER
B2
Low Automatic Lube

System Pressure
AMBER
B3
Service Brake
AMBER
C2
Circuit Breaker
Tripped
AMBER
C3
Body Up
AMBER
D2
Hydraulic Oil Filter

Monitor
AMBER
D3
Dynamic Retarding
AMBER
E2
Low Fuel
AMBER
E3
Stop Engine
RED
E2. LOW FUEL
A2. LOW HYDRAULIC TANK LEVEL

This warning light indicates the oil level in the
hydraulic tank is below recommended level. Damage
to hydraulic pumps may occur if operation continues.
Shut truck down and notify maintenance personnel
immediately.
B2. LOW AUTO LUBE SYSTEM PRESSURE
The amber light will illuminate if the automatic lubrication system fails to reach 2,300 psi (at the junction
block on the rear axle) within one minute after the
lube timer initiates a grease cycle. To turn the light
off, turn the key switch off, then back on again. Notify
maintenance personnel at earliest opportunity.
C2. CIRCUIT BREAKER TRIPPED
This light will illuminate if any of the circuit breakers
in the relay circuit control boards are tripped. The
relay circuit boards are located in the electrical interface cabinet.
NOTE: Additional circuit breakers are in the operator
cab behind the center console, however tripping of
these circuit breakers should not activate this light.
A3. PARKING BRAKE

This amber parking brake indicator will illuminate
when the parking brake is applied. Do not attempt to
drive truck with parking brake applied.
B3. SERVICE BRAKE
This amber service brake indicator will illuminate
when the service brake pedal is applied or when
wheel brake lock or emergency brake is applied. Do
not attempt to drive the truck from stopped position
with service brakes applied, except as noted in Section 3, Operating Instructions, Starting On a Grade
With a Loaded Truck, in the O&M.
C3. BODY UP
This amber indicator, when illuminated, shows that
the body is not resting on the frame. The truck should
not be driven until body is down and light is off.
D3. DYNAMIC RETARDING
D2. HYDRAULIC OIL FILTER MONITOR

This light indicates a restriction in the high pressure
filter assembly for either the steering or hoist circuit.
This light will come on before filters start to bypass.
Notify maintenance personnel at earliest opportunity
after light comes on.
NOTE: The filter monitor warning light may also
illuminate after the engine is initially started if the oil
is cold. If the light turns off after the oil is warmed,
filter maintenance is not required.
N05055
This amber low fuel indicator will illuminate when the

usable fuel remaining in the tank is approximately 25
gallons (95 liters). A warning buzzer will also sound.
This amber indicator illuminates whenever the

retarder pedal or lever is operated, RSC (Retard
Speed Control) is activated, or the automatic overspeed retarding circuit is energized, indicating the
dynamic retarding function of the truck is operating.
E3. STOP ENGINE
This red warning light will illuminate if a serious
engine malfunction is detected in the electronic
engine control system. (Continued on next page.)
N5-25
E3. STOP ENGINE (Continued)
Electric propulsion to the wheel motors will be

discontinued.
A4
Not Used
Dynamic retarding will still be available if needed

to slow or stop the truck.
B4
Stop the truck as quickly as possible in a safe

area and apply parking brake.
SHUT DOWN THE ENGINE IMMEDIATELY. Additional engine damage is likely to occur if operation is continued.
Low Oil Pressure - Red warning light will

illuminate, but engine does not shut down.
Low Coolant Level - Red warning light will

Low Coolant Pressure - Red warning light will

High Coolant Temperature - Red warning light

will illuminate, but engine does not shut down.
C4
Engine Shutdown
Timer - 5 Minute Idle
D4
Retard Speed Control AMBER

Indicator
E4
A few conditions that would cause the Stop Engine

light to illuminate are listed below:
Manual Backup Lights AMBER
Check Engine
AMBER
AMBER
A4. NOT USED

Reserved for future use or options.
B4. MANUAL BACKUP LIGHTS
This amber indicator will illuminate when the manually operated manual backup switch (3, Figure 5-7,
Instrument Panel) is turned ON.
C4. ENGINE SHUTDOWN TIMER - 5 Minute Idle
When the engine shutdown timer switch (2, Figure 57, Instrument Panel) has been activated, this indicator light will illuminate to indicate that the shutdown
timing sequence has started. Refer to "Instrument
Panel" for operation of this switch.
D4. RETARD SPEED CONTROL INDICATOR
This amber light is illuminated when the RSC switch
mounted on the console is pulled out to the ON position. The light indicates the retarder is active. It is for
feedback only and does not signal a problem.
E4. CHECK ENGINE
This amber "check engine" indicator will illuminate if
a malfunction is detected by the engine electronic
control system. If this indicator illuminates, truck
operation may continue, but maintenance personnel should be alerted as soon as possible.
N5-26
N05055
A5
No Power
RED
B5
Propulsion System
Warning
AMBER
C5
Propulsion System
Temperature
AMBER
D5
High Hydraulic Oil

Temperature
RED
E5
Stop Engine
RED
A5. NO POWER
This red "no propel/no retard" indicator light indicates
a fault has occurred which has eliminated the retarding and propulsion capability. A warning buzzer will
also sound.
If this condition occurs, the operator should
safely stop the truck, move selector switch to
NEUTRAL, apply the park brake, shutdown
engine, and notify maintenance personnel immediately.
B5. PROPULSION SYSTEM WARNING
When this amber indicator is illuminated, the light
indicates a "no propel" or "no retard" event may be
about to occur. It is intended to provide advance
notice of these events when possible. It does not
require the operator to stop the truck, but may suggest that truck operation be appropriately modified, in
case a red alarm does occur.
C5. PROPULSION SYSTEM TEMPERATURE

This amber AC drive system "temperature warning"
light indicates the drive system temperature is above
a certain level. When this condition occurs, the operator should consider modifying truck operation in
order to reduce system temperature. The operator is
not required to stop the truck at this time.
D5. HIGH HYDRAULIC OIL TEMPERATURE
This red warning light indicates high oil temperature
in the hydraulic tank. Several things occur before the
red light illuminates:
N05055
If the truck is moving, and the oil temperature

exceeds 221 F (105 C), the minimum idle
speed will be 1200 rpm (normally 1050).
If the truck is moving, and the oil temperature

goes above 230 F (110 C), the minimum idle
If the truck is stopped, and the oil temperature

goes above 212 F (100 C) the minimum idle
NOTE: Once the oil cools down to the normal

operating range, the engine rpm will return to normal
speed.
The red warning light will illuminate if the oil

temperature rises above 248 F (120 C).
Continued operation could damage components
in the hydraulic system.
If this condition occurs, the operator should safely

stop the truck, move selector switch to NEUTRAL,
apply the park brake, and operate engine at 1200 1500 rpm to reduce system temperature.
If temperature gauge (25, Figure 5-7) does not
move into the green range after a few minutes,
and the red overhead indictor light does not go
out, notify maintenance personnel immediately.
E5. STOP ENGINE
This red engine monitor warning light will illuminate if
a serious engine malfunction is detected in the electronic engine control system.
Electric propulsion to the wheel motors will still be

available.
Dynamic retarding will still be available if needed

to slow the truck.
Stop the truck as soon as possible in a safe area

and apply the parking brake.
SHUT DOWN THE ENGINE immediately. Additional engine damage is likely to occur if operation is continued.
An example of a condition that could cause the stop
engine light to illuminate:
If the governor senses an overspeed condition,

the ECM will close the fuel solenoid and stop the
flow of fuel to the engine until engine speed is
back within normal operating range.
N5-27
D6. REDUCED PROPULSION
B6
Propulsion System @ AMBER

Rest
The amber "reduced propulsion" light is used to indicate that the full AC drive system performance in propulsion is not available. At this time, the only event
that should activate this light is the use of "limp home
mode". This mode of operation requires a technician
to enable.
C6
Propulsion System Not AMBER

Ready
E6. RETARD AT CONTINUOUS LEVEL
A6
D6
E6
No Propel
Reduced Propulsion
RED
AMBER
Retard @ Continuous AMBER

Level
The amber "retard continuous" light indicates the

retarding effort is at a reduced level. The operator
should control the speed of the truck in accordance
to the "continuous" speeds on the grade/speed
retard chart. The chart is shown on page N5-5 in this
module.
A6. NO PROPEL
The red "no propel" light indicates a fault has
occurred which has eliminated the propulsion capability.
If this condition occurs, the operator should
safely stop the truck, move selector switch to
NEUTRAL, apply the park brake, shutdown
engine, and notify maintenance personnel immediately.
B6. PROPEL SYSTEM @ REST

The amber "propel system @ rest" light is used to
indicate that the AC drive system is de-energized
and propulsion is not available. This light is activated
when the instrument panel rest switch is turned ON
and the AC drive system is de-energized. The three
"link energized" lights (one on rear wall of operator
cab, and two on the deck-mounted control cabinets)
should NOT be illuminated at this time.
C6. PROPEL SYSTEM NOT READY

The amber "propel system not ready" indicator light
functions during start-up much like the hourglass
icon on a computer screen. This light indicates the
computer is in the process of performing the selfdiagnostics and set-up functions at start-up. Propulsion will not be available at this time.
N5-28
N05055
Hazard Warning Lights
Link-On Warning Light
The hazard warning light

switch (7, Figure 5-8) flashes
all the turn signal lights.
Pressing the bottom side of
the rocker switch (toward the
triangle) activates these
lights. Pressing the top side
of the rocker switch (toward
the OFF symbol) turns these
lights off.
The "link-on", or "link energized",

indicator light is located next to
the D.I.D. display panel behind
the passenger seat and indicates
the AC drive system is energized.
The D.I.D. display panel is for use
by maintenance personnel only,
and is located out of the operator's field of vision for
that reason.
Lamp Test Switch

The lamp test switch (8, Figure 5-8) is provided to allow
the operator to test the indicator lamps prior to starting
the engine. To test the
lamps, and the warning horn,
turn the key switch (1, Figure
5-7) to the RUN position and
press the bottom side of the
rocker switch for the CHECK position. All lamps
should illuminate, except those which are for optional
equipment that may not be installed. The warning
horn should also sound. Any lamp bulbs which do not
illuminate should be replaced before operating the
truck. Releasing the spring-loaded switch will allow
the switch to return to the OFF position.
N05055
N5-29
NOTES
N5-30
N05055
SECTION P
LUBRICATION AND SERVICE
INDEX
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-1
AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-1
P01024
Index
P1-1
NOTES
P1-2
Index
P01024
SECTION P2
INDEX
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3

930E SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
WHEEL MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
RADIATOR FILLING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
Reserve Oil Tank Filling Procedure (Remote fill) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-5
10 HOUR (DAILY) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-6
50 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-9
100 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-10
250 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P2-11
500 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-14
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . P2-15
2500 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-16
5000 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-16
P02036 11/02
Lubrication and Service
P2-1
NOTES
P2-2
11/02 P02036

Recommended preventive maintenance will contribute to the long life and dependability of the truck and
its components. The use of proper lubricants and the
performance of checks and adjustments at the recommended intervals is most important.
Lubrication requirements are referenced to the lube
key found in the Lubrication Chart (page 2-5). For
detailed service requirements for specific components, refer to the service manual section for that
component (i.e. Section H for suspensions, Section L
for hydraulic system, etc.).
Refer to manufacturer's service manual when servicing any components of the General Electric system.
Refer to engine manufacturer's service manual when
servicing the engine or any of its components.
The service intervals presented here are in hours of
operation. These intervals are recommended in
lieu of an oil analysis program which may determine different intervals. However, if the truck is
being operated under extreme conditions, some or
all, of the intervals may need to be shortened and the
service performed more frequently.
The 930E truck is equipped with a Lincoln Automatic
Lubrication System. The initial setup for this system
provides for nominal amounts of lubricant to be delivered to each serviced point. The lubrication injectors
can be adjusted to vary the amount of lubricant delivered. In addition, the timer for lubrication intervals is
normally adjustable. For adjustments to these
devices, refer to Automatic Lubrication System later
in this manual.
930E SERVICE CAPACITIES

Liters
U.S.
Gallons
280
74
Cooling System:
Komatsu SSDA16V160 Engine
594
157
Hydraulic System:
Refer to Hydraulic Tank Service
1325
350
76
20
4542
1200
Fuel Tank (Diesel Fuel Only)
P02036 11/02
There are two sight gauges on the side of the

hydraulic tank. With engine stopped, keyswitch OFF,
hydraulic system bled down and body down, oil
should be visible in the top sight gauge. If hydraulic
oil is not visible in the top sight gauge, follow Adding
Oil instructions below.
Adding Oil
Keep the system open to the atmosphere only as
long as absolutely necessary to lessen chances of
system contamination.
Service the tank with clean Type C-4 hydraulic oil
only. All oil being put into the hydraulic tank should
be filtered through 3 micron filters.
1. With engine stopped, keyswitch OFF, hydraulic
system bled down and body down, check to
see that hydraulic oil is visible in the top sight
gauge.
2. If hydraulic oil is not visible in the top sight
gauge, remove the tank fill cap and add clean,
filtered C-4 hydraulic oil (Lubrication Chart,
Lube Key B) until oil is visible in the top sight
gauge.
3. Replace fill cap.
4. Start engine. Raise and lower the dump body
three times.
5. Repeat Steps 1 through 4 until oil is maintained
in the top sight gauge with engine stopped,
body down, and hydraulic system bled down.
WHEEL MOTOR SERVICE
Crankcase:
(including 4 oil filters)
Komatsu SSDA16V160 Engine
Wheel Motor Gear Box

(each side)
HYDRAULIC TANK SERVICE
Due to differences in gear ratio and component evolution/design, wheel motor service intervals may be
unit number and/or mine specific. Because of the
wide variety of factors involved, it is necessary to
consult your area Komatsu representative for all
wheel motor service intervals and instructions. General intervals for oil service and sampling are listed in
the interval charts.
P2-3
COOLANT LEVEL CHECK

Inspect the coolant sight gauge. If coolant cannot be
seen in the sight gauge, it is necessary to add coolant to the system before truck operation. Refer to the
procedure below for the proper filling procedure.
RADIATOR FILLING PROCEDURE
Cooling system is pressurized due to thermal

expansion of coolant. Do Not remove radiator
cap while engine and coolant are hot. Severe
burns may result.
1. With engine and coolant at ambient temperature, remove radiator cap.
Note: If coolant is added using the Wiggins quick fill
system, the radiator cap MUST be removed prior to
adding coolant.
2. Fill radiator with proper coolant mixture (as
specified by the engine manufacturer) until
coolant is visible in the sight gauge.
3. Install radiator cap.
4. Run engine for 5 minutes, check coolant level.
5. If coolant is not visible in the sight gauge,
repeat Steps 1 - 4. Any excess coolant will be
discharged through the vent hose after the
engine reaches normal operating temperature.
Engine coolant must always be visible in the sight
gauge before truck operation.

(Optional)
The reserve oil tank for the engine is designed to add
more oil capacity to the engine to reduce the frequent
servicing of the engine oil. The engine oil level must
still be checked every shift using the dipstick. If
engine oil level is not correct, check for proper operation of reserve oil system. Never add oil to engine
unless it has been drained.
If the engine oil has been drained from the oil pan,
the new oil must be added to the engine oil pan
before starting. Do Not use the oil in the reserve tank
to fill an empty engine with oil. After an oil change,
both engine and reserve tank must be full of oil
before starting the engine.
Reserve Oil Tank Filling Procedure (Remote fill)
1. Connect the pressure supply hose from the
new oil supply to the quick coupler on the truck.
Open valve on supply hose to apply pressure.
2. Pull out on switch (2, Figure 2-1) to turn the system on.
3. Push start switch (3). The "VALVE OPEN" light
(5) should illuminate and the filling process will
begin.
4. When tank is full, the "VALVE OPEN" light will
turn off and the FULL light (4) will illuminate.
5. Close the oil supply valve in the fill hose.
6. Press and hold start switch (3) for a couple of
7. Disconnect the new oil supply hose.
8. Push switch (2) in to turn system power OFF.
COOLING SYSTEM
ANTI-FREEZE RECOMMENDATIONS
(Ethylene Glycol Permanent Type Anti-Freeze)
Percentage of
Anti-Freeze
Protection
To:
10
+ 23 F
- 5 C
20
+ 16 F
- 9 C
25
+ 11 F
- 11 C
30
+ 4 F
- 16 C
35
- 3 F
- 19 C
40
- 12 F
- 24 C
45
- 23 F
- 30 C
50
- 34 F
- 36 C
55
- 48 F
- 44 C
60
- 62 F
- 52 C
Use only anti-freeze that is compatible with engine as

specified by engine manufacturer.
P2-4
FIGURE 2-1.
1. Remote Control Box
2. System Switch
3. Start Switch
4. FULL Light
5. VALVE OPEN
Light
11/02 P02036
LUBRICATION CHART
P02036 11/02
P2-5
10 HOUR (DAILY) INSPECTION

Truck Serial Number______________________ Site Unit Number_______________
Date_______________
Hourmeter_____________
Name of Service Technician___________________________________
TASK
COMMENTS
CHECKED INITIALS
1. MACHINE - Inspect the entire machine for leaks,

worn parts, and damage. Repair as necessary.
2. FAN DRIVE AND TURBOCHARGERS - Check for
leaks, vibration or unusual noise. Check alternator
and fan belt condition and alignment.
3. RADIATOR - Check the coolant level and fill with the
proper mixture as shown in the Cooling System Recommendation Chart in this chapter. Refer to the
engine manual for proper coolant additives.
4. ENGINE a. Check the oil level on the dipstick. Refer to
the engine manual for oil recommendations.
(Lube Key A).
NOTE: If the truck is equipped with a reserve engine
oil tank, the oil should be visible in the center (middle)
sight gauge. If not, add oil to the reserve tank until oil
is visible in the top sight gauge. Also, with the engine
running, check operation of the LED indicator light.
See below for description of LED light signals. Refer
to Figure 2-1.
LED Light Signals:
Steady - Pump 1 is withdrawing oil from the
engine sump and bringing down the oil level.
Regular pulsing - Pump 2 is returning oil to the
engine sump and raising the oil level.
Irregular pulsing - Oil is at the correct running
level.
b. Inspect exhaust piping for security.
c. Check for abnormal noises and fluid leaks.
5. HYDRAULIC TANK - Check the oil level in the tank;
add oil if necessary. Refer to Section L, Hydraulic
Tank - Filling Instructions. Oil should be visible in the
sight glass. - Do Not overfill. Lube Key B.
6. BATTERIES - Check the electrolyte level and add
water if necessary.
7. WHEELS AND TIRES a. Inspect tires for proper inflation and wear.
b. Check for embedded debris in tread and remove.
c. Inspect for damaged, loose, or missing wheel
mounting nuts and studs.
8. COOLING AIR DUCTWORK - Inspect ductwork from
the blower to the rear drive case. Ensure that ductwork is secure, free of damage, and unrestricted.
P2-6
11/02 P02036
10 HOUR (DAILY) INSPECTION (Continued)

Date_______________
TASK
COMMENTS
CHECKED INITIALS
9. AIR INTAKE PIPING - Check all mounting hardware,

joints, and connections. Ensure no air leaks exist and
all hardware is properly tightened. Figure 2-2.
10. AIR CLEANERS - Check the air cleaner vacuum
gauges in the operator cab, Figure 2-3. The air
cleaner(s) should be serviced if the gauge(s) shows
the following maximum restriction:
Komatsu SSDA16V160 Engine:
. . . . . . . . . . . . . . . . . . . . . . . . 25 in. of H2O vacuum.
Refer to Section C in the service manual for servicing
instructions for the air cleaner elements. Empty the air
cleaner dust caps.
NOTE: After service, push the reset button on face of
gauge to allow the gauge to return to zero.
11. BODY-UP & HOIST LIMIT SWITCHES - Clean the
sensing areas of any dirt accumulation and inspect
the wiring for any signs of damage.
12. CAB AIR FILTER - Under normal operating conditions, clean every 250 hours. In extremely dusty conditions, service as frequently as required. Clean the
filter element with mild soap and water. Rinse completely clean and air dry with a maximum of 40 psi
(275 kPa). Reinstall the filter. Refer to Figure 2-4.
FIGURE 2-2.
FIGURE 2-3.
FIGURE 2-4.
1. Filter Cover
P02036 11/02
2. Cab Filter
P2-7
10 HOUR (DAILY) INSPECTION (Continued)

Date_______________
TASK
COMMENTS
CHECKED INITIALS
13. FUEL FILTERS (Fuel Separators) - Drain water from

the bottom drain valve on each fuel separator.
14. AUTOMATIC LUBE SYSTEM Check the grease reservoir; fill as required. Lube
Key D.
When filling the reservoir, check the grease filter
indicator. Clean or replace the grease filter if the
indicator detects a problem.
Inspect the system and check for proper
operation. Be certain the following important
areas are receiving adequate amounts of grease.
Lube Key D.
Steering Linkage
Final Drive Pivot Pin Rear Suspension Pin Joints - Upper & Lower
Body Hinge Pins Hoist Cylinders Pins - Upper & Lower
Anti-sway Bar - Both Ends
P2-8
11/02 P02036
50 HOUR LUBRICATION AND MAINTENANCE CHECKS

Date_______________
TASK
COMMENTS
CHECKED INITIALS
*1. FUEL FILTERS - Change the fuel filters, (fuel

separators).
Refer to engine manufacturer's maintenance manual
for fuel filter replacement instructions.
*2. HYDRAULIC SYSTEM FILTERS - Replace filter elements only, after the initial 50, 100, and 250 hours of
operation; then at each 500 hours of operation thereafter.
*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation).
P02036 11/02
P2-9
*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:

Date_______________
TASK
COMMENTS
CHECKED INITIALS
*1. HYDRAULIC SYSTEM FILTERS - Replace filter elements only, after the initial 100 and 250 hours of
operation; then at each 500 hours of operation thereafter.
P2-10
11/02 P02036

The 10 hour lubrication and maintenance checks should also be performed at this time.
NOTE: Lube Key references are to the Lubrication Chart.
Date_______________
TASK
COMMENTS
CHECKED INITIALS
1. ENGINE - Refer to Cummins Operation & Maintenance manual for complete specifications regarding
engine lube oil specifications.
NOTE: If the engine is equipped with the *Centinel
oil system and/or the Eliminator filter system,
engine oil and filter change intervals are extended
beyond 250 hours. Refer to Cummins Operation &
Maintenance manual for specific oil and filter change
intervals.
* The Centinel system is a duty-cycle-dependent
lubrication management system whereby oil is
blended with the fuel and burned and an extension of
oil change intervals can occur.
a. Change engine oil. Lube Key A.
b. Replace lube oil filters.
NOTE: When installing spin-on filter elements, follow
the instructions as specified by the filter manufacturer.
The tightening instructions are normally printed on the
outside of the filter. Do not use a wrench or strap to
tighten filter elements.
c. If the truck is equipped with a reserve engine
oil tank, change the reserve tank oil filter.
d. Check belt tension and condition of each
accessory belt. Refer to Cummins Operation
& Maintenance manual for specific adjustment instructions.
e. Check the torque on the mounting capscrews
on cooling fan (1, Figure 2-5). Tighten eight
capscrews (2) to 175 ft.lbs. (237 Nm).
2. COOLING SYSTEM a. COOLANT MIXTURE - Check for proper
coolant mixture. Add coolant as required.
b. COOLANT FILTERS - Change coolant filters.
c. COOLING SYSTEM HOSES - Check cooling
system hoses for damage and signs of deterioration.
Refer to the Cummins maintenance manual for coolant filter replacement instructions and proper coolant
mixture instructions.
(CONTINUED NEXT PAGE)
P02036 11/02
P2-11
250 HOUR LUBRICATION AND MAINTENANCE (Continued)

TASK
COMMENTS
3.
FUEL FILTERS - Change the fuel filters (fuel separators). Refer to Cummins Operation & Maintenance
manual for specific filter replacement instructions.
4.
FUEL TANK - Drain water and sediment from the fuel

tank. Refer to Section B, Fuel Tank - Cleaning.
5.
STEERING LINKAGE - Check the torque on pin

retaining nuts (1, Figure 2-6) on the steering linkage.
(525 ft.lbs. (712 N.m) Check the torque on tie rod
retaining nuts (2). (310 ft.lbs. (420 N.m)
6.
HYDRAULIC PUMP DRIVESHAFT & U-JOINTS Add one or two applications of grease to each grease
fitting. Check that each bearing of the cross & bearing
assembly is receiving grease. Lube Key D.
7.
REAR WHEEL MOUNTING - Using a mirror on a long

rod and a flashlight, inspect all inner and outer wheel
mounting nuts/studs for any evidence of looseness,
damage, or missing hardware.
CHECKED INITIALS
If wheel mounting nuts/studs must be secured or

replaced, the outer wheel must be removed for
access. Refer to the Shop manual, Section G, for
these procedures.
FIGURE 2-5.
P2-12
FIGURE 2-6.
11/02 P02036
250 HOUR LUBRICATION AND MAINTENANCE (Continued)

TASK
COMMENTS
8.
REAR AXLE HOUSING - Check the rear axle housing

for fluid leaks by removing the two drain plugs on the
bottom of the axle housing. If fluid is present, the
cause must be found and corrected before releasing
the truck to operation.
9.
MAGNETIC PLUG - Remove the magnetic plugs from

the front wheel hub covers and inspect for debris.
Clean the plugs and perform any necessary repairs.
CHECKED INITIALS
10. MOTORIZED WHEELS - Check for the correct oil

level. Rotate a magnetic plug to the 6 oclock position
and remove the plug. The oil level should be even
with the bottom of the plug opening. Inspect the magnetic plugs for ferrous materials. Service the wheel
motor as necessary. Refer to Figure 2-8.
11. WHEEL MOTOR OIL SAMPLING - Refer to Section
G5, Wheel Motor, for oil sampling information.
*12. HYDRAULIC SYSTEM FILTERS - Replace filter elements only after the initial 250 hours of operation;
then at each 500 hours of operation thereafter. Check
oil level. Add oil as necessary. Lube Key B.
*This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:
FIGURE 2-7.
1. Magnetic Plug
2. Cover
FIGURE 2-8.
P02036 11/02
P2-13

Maintenance requirements for every 10, 50, & 250 hour Lubrication and Maintenance Checks should also be carried out at this time.
Date_______________
TASK
COMMENTS
CHECKED INITIALS
1. FINAL DRIVE CASE BREATHERS - Remove the

breather elements for the motorized wheels. Clean or
replace the elements.
2. HYDRAULIC SYSTEM FILTERS - Replace the tank
breathers and high pressure filter elements. Check
the oil level. Add oil as necessary. Lube Key B.
3. HYDRAIR SUSPENSION - Check for proper piston
extension (front and rear).
4. THROTTLE AND BRAKE PEDAL - Lubricate the treadle roller and hinge pins with lubricating oil. Lift the
boot from the mounting plate and apply a few drops of
lubricating oil between the mounting plate and the
plunger.
5. BODY-UP & HOIST LIMIT SWITCHES - Check operation of the switches. Clean and adjust as necessary.
6. HOIST ACTUATOR LINKAGE - Check operation.
Clean, lubricate, and adjust as necessary.
7. PARKING BRAKE - Refer to Section J, Parking Brake
Maintenance. Perform the recommended inspections.
8. RESERVE ENGINE OIL SYSTEM (OPTIONAL)
a. Check electrical system connections for tightness, corrosion and physical damage. Check
the battery, oil pressure switch, junction
boxes, remote control fill box and the circuit
breakers.
b. Examine all electrical cables over their entire
length for possible damage.
c. Examine all hoses, including those on the
reserve tank and the ones leading to and
from the engine. Check for leaks, cracks or
other damage. Check all fittings for tightness,
leakage or damage.
9. WHEEL MOTOR OIL (Initial 500 hours only) Change or filter wheel motor gear oil only after initial
500 hours or operation. Wheel motor gear oil must be
filtered or changed every 2500 hours of operation
thereafter.
P2-14
11/02 P02036
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should be performed at this time.
Date_______________
TASK
COMMENTS
1.
HYDRAULIC TANK - Drain the hydraulic tank and

clean the inlet strainer. Refill the tank with oil; approximate capacity 250 gal. (947 l). Use Lube Key B.
2.
RADIATOR - Clean the cooling system with a quality

cleaning compound. Flush with water. Refill the system with anti-freeze and water solution. Check the
Cooling System Recommendation Chart in this section for the correct mixture. Refer to the Cummins
Operation and Maintenance Manual for the correct
additive mixture.
3.
FUEL TANK - Remove the breather and clean in solvent. Dry with pressurized air and reinstall.
4.
OPERATOR'S SEAT - Apply grease to the slide rails.

Lube Key D.
5.
AUTOMATIC BRAKE APPLICATION - Ensure the

brakes are automatically applied when brake pressure decreases below the specified limit. Refer to
Section J, Brake Check-out Procedure.
6.
AUXILIARY BLOWER - Apply a few applications of

grease to the auxiliary blower bearings. Two grease
zerks (1, Figure 2-9) are located on blower (2).
CHECKED INITIALS
FIGURE 2-9. AUXILIARY BLOWER

1. Grease Zerk
P02036 11/02
2. Auxiliary Blower
P2-15
2500 HOUR MAINTENANCE CHECKS

Date_______________
TASK
COMMENTS
CHECKED INITIALS
WHEEL MOTOR GEAR OIL - Wheel motor gear oil

must be filtered or changed every 2500 hours of operation.
5000 HOUR MAINTENANCE CHECKS

Date_______________
TASK
COMMENTS
CHECKED INITIALS
AIR CLEANERS - Clean the Donaclone tubes in the

pre-cleaner section of the air filter. Use low pressure
cold water or low pressure air to clean the tubes.
Refer to Section C, Air Cleaners.
NOTE: Do not use a hot pressure washer or high
pressure air to clean the tubes. Hot water/high pressure causes the pre-cleaner tubes to distort.
P2-16
11/02 P02036
SECTION P3
AUTOMATIC LUBRICATION SYSTEM
INDEX
AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-3
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-3
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-6
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-6
Pressure Failure Detection Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-7
INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-8
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
LUBRICANT REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
LUBRICANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
Pump Housing Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
Pump Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
Pressure Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
INJECTORS (SL-1 Series H)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-10
Injector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-10
Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-10
SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-10
Lubrication Cycle Timer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P3-11
Lubrication Cycle Timer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P3-11
FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P3-11
PUMP REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-14
P03018 04/00
Automatic Lubrication System
P3-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-15

PREVENTATIVE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
Daily Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
1000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
P3-2
04/00
P03018
AUTOMATIC LUBRICATION SYSTEM

GENERAL DESCRIPTION
The Lincoln automatic lubrication system is a pressurized lubricant delivery system which delivers a
controlled amount of lubricant to designated lube
points. The system is controlled by an electric timer
which signals a solenoid valve to operate a hydraulic
motor powered grease pump. Hydraulic oil for pump
operation is supplied by the truck steering circuit.
Grease output is proportional to the hydraulic motor
input flow. A pump control manifold, mounted on top
of the hydraulic motor, controls input flow and pressure. A 24VDC solenoid mounted on the manifold
turns the pump on and off.
The pump is driven by the rotary motion of the
hydraulic motor, which is then converted to reciprocating motion through an eccentric crank mechanism. The reciprocating action causes the pump
cylinder to move up and down. The pump is a positive displacement, double-acting type as grease output occurs on both the up and the down stroke.
FIGURE 3-1. PUMP AND RESERVOIR

COMPONENTS
1. Hose from Filter
2. Outlet to Injectors
3. Hydraulic Motor
4. Pressure
Reducing Valve
5. Solenoid Valve
6. Vent Valve
P03018 04/00
7. Pressure Gauge
8. Pump Assembly
10. Pressure Switch
11. Relay Box
12. Grease Reservoir
13. Vent Hose
During the down stroke, the pump cylinder is

extended into the grease. Through the combination
of shovel action and vacuum generated in the pump
cylinder chamber, the grease is forced into the pump
cylinder. Simultaneously, grease is discharged
through the outlet of the pump. The volume of grease
during intake is twice the amount of grease output
during one cycle. During the upstroke, the inlet check
valve closes, and one half the grease taken in during
the previous stroke is transferred through the outlet
check and discharged to the outlet port.
Over-pressurizing of the system, modifying

parts, using incompatible chemicals and fluids,
or using worn or damaged parts, may result in
equipment damage and/or serious personal
injury.
DO NOT exceed the stated maximum working

pressure of the pump, or of the lowest rated
component in the system.
Do not alter or modify any part of this system

unless approved by factory authorization.
Do not attempt to repair or disassemble the

equipment while the system is pressurized.
Make sure all fluid connections are securely

tightened before using this equipment.
Always
read
and
follow
the
fluid
manufacturer's recommendations regarding
fluid compatibility, and the use of protective
clothing and equipment.
Check all equipment regularly and repair, or

replace, worn or damaged parts immediately.
This equipment generates very high grease pressure. Extreme caution should be used when
operating this equipment as material leaks from
loose or ruptured components can inject fluid
through the skin and into the body causing serious bodily injury including possible need for
amputation. Adequate protection is recommended to prevent splashing of material onto the
skin or into the eyes.
If any fluid appears to penetrate the skin, get
emergency medical care immediately! Do not
treat as a simple cut. Tell attending physician
exactly what fluid was injected.
P3-3
FIGURE 3-2. AUTO LUBE SYSTEM INSTALLATION

NOTE: The above illustration shows the standard location for the lube pump & reservoir (right platform). This
assembly may be located on left platform on some models.
1. L.H. Suspension, Top Bearing
2. L.H. Suspension, Bottom Bearing
3. L.H. Body Pivot Pin
4. L.H. Hoist Cylinder, Top Bearing
5. L.H. Hoist Cylinder, Bottom Bearing
6. L.H. Anti-Sway Bar Bearing
7. Rear Axle Pivot Pin
8. Grease Supply From Pump
9. Pressure Switch, N.O., 2000 psi (13 790 kPa)
10. R.H. Suspension, Top Bearing
11. R.H. Suspension, Bottom Bearing
12. R.H. Body Pivot Pin
P3-4
13. R.H. Hoist Cylinder, Top Bearing

14. R.H. Hoist Cylinder, Bottom Bearing
15. R.H. Anti-Sway Bar Bearing
16. Vent Hose
17. Junction Box
18. Pressure Switch, N.O., 2500 psi (17 237 kPa)
19. Grease Pump
20. Vent Valve
21. Filter
22. Grease Supply to Injectors
23. Truck Frame
24. Injector
04/00
P03018
SYSTEM COMPONENTS
Filter (21, Figure 3-2)
Vent Valve (6, Figure 3-1)
A filter assembly mounted on the grease reservoir filters the grease prior to refilling the reservoir from the
shop supply. A bypass indicator alerts service personnel when the filter requires replacement.
With the vent valve closed, the pump continues to

operate until maximum grease pressure is achieved.
As this occurs, the vent valve opens and allows the
grease pressure to drop to 0, so the injectors can
recharge for their next output cycle.
Hydraulic Motor and Pump (3 & 8, Figure 3-1)

The rotary hydraulic pump is a fully hydraulically
operated grease pump. An integrated pump control
manifold is incorporated with the motor to control
input flow and pressure.
Note: The pump crankcase oil level must be
maintained to the level of the pipe plug port. If
necessary, refill with 10W-30 motor oil.
Hydraulic oil supply inlet pressure must not

exceed 3000 psi (20 685 kPa). Exceeding the
rated pressure may result in damage to the system components and personal injury.
Grease Reservoir (12, Figure 3-1)
Lubrication Cycle Timer (1, Figure 3-4)

The solid state lubrication cycle timer provides a 24
VDC timed-interval signal to energize the solenoid
valve (5, Figure 3-1), providing oil flow to operate the
grease pump motor. This timer is mounted in the
Electrical Interface Cabinet.
Delay Timer (11, Figure 3-4)
The delay timer, located in the electrical interface
cabinet, provides a one minute delay in the low pressure warning lamp circuit to allow a normally operating system to attain full grease system pressure
without activating the warning lamp. If the system
fails to reach 2000 psi (13 789 kPa) within this time
period, the timer will apply 24VDC to several relays
which will illuminate the low pressure warning lamp in
the overhead display. An external 604K ohm resistor
determines the delay period.
Pump Cutoff Pressure Switch (N.O. 2500 psi [17
237 kPa]) (10, Figure 3-1)
The reservoir has an approximate capacity of 60 lbs.

(27 kg) of grease. When the grease supply is replenished by filling the system at the service center, the
grease is passed through the filter to remove contaminants before it flows into the reservoir.
This pressure switch de-energizes the pump solenoid relay when the grease line pressure reaches the
switch pressure setting, turning off the motor and
pump.
Pressure Reducing Valve (4, Figure 3-1)
Grease Pressure Failure Switch (N.O. 2000 psi

[13 789 kPa]) (9, Figure 3-2)
The pressure reducing valve, located on the manifold

reduces the hydraulic supply pressure (from the truck
steering circuit) to a suitable operating pressure,
[325-350 psi (2 240 to 2 415 kPa)] for the hydraulic
motor used to drive the lubricant pump.
Flow Control Valve (9, Figure 3-1)
This pressure switch monitors grease pressure in the

injector bank on the rear axle housing. If the proper
pressure is not sensed within 60 seconds (switch
contacts do not close), several relays energize, actuating a warning lamp circuit to notify the operator a
problem exists in the lube system.
The flow control valve mounted on the manifold, controls the amount of oil flow to the hydraulic motor.
The flow control valve has been factory adjusted
and the setting should not be disturbed.
Pressure Gauge (7, Figure 3-1)
Solenoid Valve (5, Figure 3-1)
Injectors (24, Figure 3-2)
The solenoid valve, when energized, allows oil to

flow to the hydraulic motor.
Each injector delivers a controlled amount of pressurized lubricant to a designated lube point. Refer to
Figure 3-2 for locations.
P03018 04/00
The pressure gauge monitors hydraulic oil pressure

to the inlet of the hydraulic motor.
P3-5
SYSTEM OPERATION
Normal Operation
1. During truck operation, the lubrication cycle
timer (1, Figure 3-4) will energize the system at a
preset time interval.
2. The timer provides 24 VDC through the normally
closed relay, RB7K5 (4) used to energize the
pump solenoid valve (5), allowing hydraulic oil
provided by the truck steering pump circuit to
flow to the pump motor and initiate a pumping
cycle.
3. The hydraulic oil pressure from the steering circuit is reduced to 325 to 350 psi (2 240 to 2 413
kPa) by the pressure reducing valve (4, Figure 33) before entering the motor. In addition, the
amount of oil supplied to the pump is limited by
the flow control valve (6). Pump pressure can be
read using the gauge (5) mounted on the manifold.
4. With oil flowing into the hydraulic motor, the
grease pump will operate, pumping grease from
the reservoir to the injectors (13), through a
check valve (10) and to the vent valve (11).
5. During this period, the injectors will meter the

appropriate amount of grease to each lubrication
point.
6. When grease pressure reaches the pressure
switch (3, Figure 3-4) setting, the switch contacts
will close and energize the relay RB7K5, removing power from the hydraulic motor/pump solenoid and the pump will stop. The relay will remain
energized until grease pressure drops and the
pressure switch opens again or until the timer
turns off.
7. After the pump solenoid valve is de-energized,
hydraulic pressure in the manifold drops and the
vent valve will open, releasing grease pressure
in the lines to the injector banks. When this
occurs, the injectors are then able to recharge for
the next lubrication cycle.
8. The system will remain at rest until the lubrication cycle timer turns on and initiates a new
grease cycle.
FIGURE 3-3. HYDRAULIC SCHEMATIC

1. Hydraulic Oil Return
2. Hydraulic Oil Supply
3. Pump Solenoid Valve
4. Pressure Reducing Valve
P3-6
5. Motor Pressure Gauge

7. Hydraulic Motor
8. Grease Pump
9. Pressure Switch (N.O.)

10. Check Valve
11. Vent Valve
12. Orifice
13. Injector Bank
04/00
P03018
Pressure Failure Detection Circuits

1. When the lubrication cycle is initiated, 24VDC
flows through relay RB7K1 (7, Figure 3-4) N.C.
contacts to a 1 minute delay timer (11).
2. If the system is operating normally, grease pressure at the rear axle injector bank will rise to
pressure switch (6) setting of 2000 psi (13.8
MPa) and energize relay RB7K1 (7), removing
24VDC from the delay timer.
3. If a problem occurs and the system is not able to
attain 2000 psi (13.8 MPa), the delay timer (11)
will energize relay RB7K4 (12) after 60 seconds,

turning on the low lube system pressure warning
lamp on the overhead display. After RB7K4 relay
energizes, it will energize relay RB7K3 (10).
4. Once RB7K3 is energized, it will latch and
remain energized as long as the keyswitch is on.
In addition, RB7K4 will also remain energized
and the low lube pressure warning lamp will
remain on to notify the operator a problem exists
and the system requires service.
FIGURE 3-4. ELECTRICAL SCHEMATIC

1. Lubrication Cycle Timer
2. Circuit Breaker CB7 (In Electrical Interface Cabinet)
3. Pressure Switch; N.O., 2500 psi (17 237)
4. Relay K5 (On Relay Board RB7)
5. Grease Pump Motor Solenoid Valve
6. Pressure Switch; N.O. 2000 psi (13 790)
8. Lube System Manual Test Switch
P03018 04/00
9. Circuit Breaker CB9 (In Electrical Interface Cabinet)

11. Circuit Time Delay Module
13. Low Grease Pressure Warning Lamp (On Overhead
Display Panel)
14. Warning & Caution Lamp Test Switch (On Overhead
Display Panel)
P3-7
INJECTOR OPERATION
STAGE 1.
The injector piston (2) is in its normal or
rest position. The discharge chamber (3) is
filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant (6),
the slide valve (5) is about to open the passage (4) leading to the measuring chamber
(1) above the injector piston (2).
STAGE 2.
When the slide valve (5) uncovers the passage (4), lubricant (6) is admitted to the measuring chamber (1) above the injector piston
(2) which forces lubricant from the discharge
chamber (3) through the outlet port (7) to the
bearing.
STAGE 3.
As the injector piston (2) completes its
stroke, it pushes the slide valve (5) past the
passage (4), cutting off further admission of
lubricant (6) to the passage (4) and measuring chamber (1). The injector piston (2) and
slide valve (5) remain in this position until
lubricant pressure in the supply line (6) is
vented.
STAGE 4.
After venting, the injector spring expands,
causing the slide valve (5) to move, so that
the passage (4) and discharge chamber (3)
are connected by a valve port (8). Further
expansion of the spring causes the piston to
move upward, forcing the lubricant in the
measuring chamber (1) through the passage
(4) and valve port (8) to refill the discharge
chamber (3).
The injector is now ready for the next cycle.
P3-8
04/00
P03018
GENERAL INSTRUCTIONS
LUBRICANT REQUIREMENTS
Pump Pressure Control
Grease requirements will depend on ambient temperatures encountered during truck operation:
Above 90F (32C) - Use

multipurpose grease (MPG).
-25 to 90F (-32 to 32C) - Use NLGI No. 1

multipurpose grease (MPG).
High pressure hydraulic fluid from the truck steering

system is reduced to 325 to 350 psi (2 240 to 2 413
kPa) by the pressure reducing valve located on the
manifold on top of the pump motor. This pressure
can be read on the gauge installed on the manifold
and should be checked occasionally to verify pressure is within the above limits.
Below -25F (-32C) - Refer to local supplier for

extreme cold weather lubricant requirements.
Pressure Control Valve Adjustment
NLGI
No.2
System Priming
The system must be full of grease and free of air
pockets to function properly. After maintenance, if the
primary or secondary lubrication lines were replaced,
it will be necessary to prime the system to eject all
entrapped air.
1. Fill lube reservoir with lubricant, if necessary.
2. To purge air from the main supply line, remove
the main supply line at the canister and connect
an external grease supply to the line.
3. Remove plugs from each injector group in
sequence (right front, left front, and rear axle).
4. Using the external grease source, pump grease
until grease appears at the group of injectors
and re-install the pipe plug. Repeat for remaining injector groups.
5. Remove the caps from each injector and connect an external grease supply to the zerk on
the injector and pump until grease appears at
the far end of the individual grease hose or the
joint being greased.
1. With the truck engine running, activate the lube

system manual test switch to start the hydraulic
motor and pump.
2. Loosen the locknut on the pressure control (1,
Figure 3-5) by turning the nut counterclockwise.
3. Turn the valve stem counterclockwise until it no
longer turns. (The valve stem will unscrew until
it reaches the stop - it will not come off.)
Note: This is the minimum pressure setting, which is
about 170 psi (1 172 kPa).
4. With the pump stalled against pressure, turn the
pressure control valve stem clockwise until 325
to 350 psi (2 240 to 2 413 kPa) is attained on
the manifold pressure gauge (2).
5. Tighten the locknut to lock the stem in position.
Note: The flow control valve (4) is factory adjusted to
2.5 gpm (9.5 L/min.). Do not change this setting.
LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Oil level should be
checked at 1000 hour intervals. To add oil, remove
pipe plug (3, Figure 3-5) and fill housing to bottom of
plug hole.
FIGURE 3-5. PUMP CONTROLS

1. Pump Pressure Control 3. Oil Level Plug
2. Pressure Gauge
P03018 04/00
P3-9
INJECTORS (SL-1 Series H))

Injector Specifications
Each lube injector services only one grease

point. In case of pump malfunction, each injector
is equipped with a covered grease fitting to allow
the use of external lubricating equipment.
Injector output is adjustable:

Maximum output = 0.08 in3 (1.31 cc).
Minimum output = 0.008 in3 (0.13 cc).
Operating Pressure:
Minimum - 1850 psi (12 755 kPa)
Maximum - 3500 psi (24 133 kPa)
Recommended - 2500 psi (17 238 kPa)
Maximum Vent Pressure - (Recharge)
600 psi (4 137 kPa)
Injector Adjustment
The injectors may be adjusted to supply from 0.008
in3 to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per
injection cycle. The injector piston travel distance
determines the amount of lubricant supplied. This
travel is in turn controlled by an adjusting screw in
the top of the injector housing.
Turn the adjusting screw (1, Figure 4-9) counterclockwise to increase lubricant amount delivered and
clockwise to decrease the lubricant amount.
When the injector is not pressurized, maximum injector delivery volume is attained by turning the adjusting screw (1) fully counterclockwise until the
indicating pin (8) just touches the adjusting screw. At
the maximum delivery point, about 0.38 inch (9.7
mm) adjusting screw threads should be showing.
Decrease the delivered lubricant amount by turning
the adjusting screw clockwise to limit injector piston
travel. If only half the lubricant is needed, turn the
adjusting screw to the point where about 0.19 inch
(4.8 mm) threads are showing. The injector will be
set at minimum delivery point with about 0.009 inch
(0.22 mm) thread showing.
FIGURE 3-6. TYPE SL-1 INJECTOR

1. Adjusting Screw
2. Locknut
3. Piston Stop Plug
4. Gasket
5. Washer
6. Viton O-Ring
7. Injector Body Assy.
8. Piston Assembly
9. Fitting Assembly
10. Plunger Spring
11. Spring Seat

12. Plunger
13. Viton Packing
14. Inlet Disc
15. Viton Packing
16. Washer
17. Gasket
18. Adapter Bolt
19. Adapter
20. Viton Packing
SYSTEM CHECKOUT
To check system operation (not including timer), proceed as follows:
1. Turn keyswitch ON and start the engine.
2. Actuate the lube system test switch at the reservoir/pump assembly on the front bumper.
3. The motor and pump should operate until the
system attains 2500 psi (17 237 kPa).
NOTE: The above information concerns adjustment

of injector delivery volume. The timer adjustment
should also be changed, if overall lubricant delivery is
too little or too much. Injector output should NOT be
adjusted to less than one-fourth capacity.
4. Once the required pressure is achieved, the

pump motor should turn off and the system
should vent.
NOTE: The piston assembly (8) has a visible indicator pin at the top of the assembly to verify the injector
operation.
6. After checking system, shutdown engine,

observing normal precautions regarding high
voltage present in the propulsion system before
attempting to repair lube system.
P3-10
5. Check for pump, hose or injector damage or

leakage with the system under pressure.
04/00
P03018
Lubrication Cycle Timer Check
Lubrication Cycle Timer Adjustment
To check the solid state timer operation without waiting for the normal timer setting, proceed as follows:
The timer is factory set for a nominal 2.5 minute (off

time) interval. Dwell time is approximately 1 minute,
15 seconds. A longer interval (off time) is obtained by
turning the Selector knob (3, Figure 3-7) to the
desired position.
1. Remove timer dust cover.

NOTE: The timer incorporates a liquid and dust tight
cover which must be in place and secured at all times
during truck operation.
2. Adjust timer selector (3, Figure 3-7) to 5 minute
interval setting.
3. The timer should cycle in five minutes if the
truck is operating.
NOTE: If the timer check is being made on a cold
start, the first cycle will be approximately double the
nominal setting. All subsequent cycles should be
within the selected time tolerance.
4. Voltage checks at the timer should be accomplished if the above checks do not identify the
problem.
NOTE: Set timer by turning the selector knob (3) to

the 2.5 minute setting point. Then, turn the Selector
clockwise, one detent at a time, to the desired
setting, or until the maximum limit of eighty minutes
is reached.
The timer is a sealed unit, do not attempt disassembly.
FILTER ASSEMBLY
The filter assembly element (5, Figure 3-8) should be
replaced if the bypass indicator (2) shows excessive
element restriction.
a. Insure timer ground connection is clean and

tight.
b. Using a volt-ohm meter, read the voltage
between positive and negative posts on the
solid state timer with the truck keyswitch
ON.
Normal reading should be 18-26 VDC,
depending upon whether or not the engine
is running.
FIGURE 3-7. TIMER (TOP COVER REMOVED)

1. Timer Enclosure
2. Red LED (Light Emitting Diode)
3. Timer Selector
P03018 04/00
FIGURE 3-8. FILTER ASSEMBLY

6. Spring
1. Housing
7. Bowl
2. Bypass Indicator
8. O-Ring
3. O-Ring
9. Plug
4. Backup RIng
5. Element
P3-11
PUMP REBUILD
13. Using a 0.50 in. (13 mm) diameter wooden or

plastic rod, push the cup seal (22) and the
pump cylinder (24) from the reciprocating tube.
14. Remove the pump plunger (20) from the
plunger link rod (17). (A spanner wrench, which
uses the holes in the pump plunger, is
required.)
Be certain to bleed steering accumulators to

relieve hydraulic pressure and to relieve pump
outlet grease pressure before removing any
hoses or fittings.
15. Unscrew the plunger link rod (17) from the

plunger tube (11) and slide off the cup seal (16)
backup washer (15) and wrist pin anchor (14).
16. Unscrew the plunger tube (11) from the outlet
pin (9).
Disassembly
1. Remove the four socket head screws (33, Figure 3-9) and separate the manifold (37) from
the hydraulic motor (42).
17. To dismantle the crankrod assembly (1 through

8), remove flat head screws (1) and the inner
and outer weights (2 & 3).
2. Remove pipe plug (45) and drain the crankcase

oil from pump housing (46).
18. Remove the small retaining rings (6) and press

the crank eccentric (7) out of the ball bearing
(8). Be sure to support the ball bearing on the
inner race.
3. Remove the six screws (29) and remove the

housing cover (30) and cover gasket (31).
4. Remove retaining ring (57) and pull the shovel
plug (56) from the housing tube (55).
5. Remove two socket head screws (44) and separate hydraulic motor (42) from the pump housing (46).

1. Discard all seals and gaskets. Repair kits are
available containing all the necessary seals and
gaskets for reassembly. Refer to the appropriate truck parts book.
6. Remove two outlet pin nuts (50) from pump

housing.
7. Remove the pump subassembly (1 through 28)
from the pump housing. Pushing the subassembly up with a 0.75 in. (19 mm) diameter wooden
or plastic rod against the check seat housing
(28) is helpful.
8. Remove the housing tube (55) from the pump
housing by inserting a 0.75 in. (19 mm) diameter rod through the inlet holes at the bottom of
the housing tube and unscrewing it.
9. Remove the bronze bearing (51), O-ring (52),
backup washer (53), and O-ring (54) from the
housing tube.
2. Clean and inspect the following parts. Replace

if excessive wear is evident:
Ball bearing (8)
Crank eccentric (7)
Crankrod (5)
Wrist pin bushings (13)
Plunger tube (11)
Pump plunger & upper check parts (20, 19 & 18)
Pump cylinder (24)
10. Remove the crankrod assembly (1 through 8)

from the pump by unscrewing the button head
screws (12) and then pulling out the wrist pin
bushings (13).
Check seat housing/lower check ball (28, 26)
Upper bronze bushing (51)
Housing tube (55)
11. Remove the check seat housing (28) from the

reciprocating tube (21).
Shovel plug (56)
Reciprocating tube (21)
Note: There is a 3/8 in. allen head socket in the

throat of the check seat housing to facilitate removal.
12. Unscrew the wrist pin anchor (14) from the
reciprocating tube (21) and pull the plunger
assembly (9 through 20) from the tube.
P3-12
04/00
P03018
1. Screw
2. Outer Weight
3. Inner Weight
4. Retaining Ring
5. Crankrod
6. Retaining Ring
7. Eccentric Crank
8. Ball Bearing
9. Outlet Pin
10. O-Ring
11. Plunger Tube
12. Screw
13. Wrist Pin Bushing
14. Wrist Pin Anchor
15. Backup Washer
P03018 04/00
FIGURE 3-9. LUBE PUMP ASSEMBLY

31. Cover Gasket
16. Cup Seal
32. Gauge
17. Plunger Rod
33. Screw
18. Spring
34. Valve Cartridge
19. Steel Ball
35. Solenoid Valve
20. Plunger
36. Connector
21. Reciprocating Tube
37. Manifold
22. Cup Seal
38. Press. Reducing Valve
23. O-Ring
24. Cylinder
40. O-Ring
25. Ball Cage
41. Gasket
26. Steel Ball
42. Hydraulic Motor
27. O-Ring
43. Washer
28. Check Seat
44. Screw
29. Screw
45. Pipe Plug
30. Housing Cover
46. Pump Housing

47. Backup Ring
48. O-Ring
49. O-Ring
50. Nut
51. Bronze Bearing
52. O-Ring
53. Backup Washer
54. O-Ring
55. Housing Tube
56. Shovel Plug
57. Retaining Ring
58. Orifice Fitting
P3-13
Assembly
Note: Use Loctite 242 (or equivalent) thread locker
on all torqued, threaded connections. Use extreme
care to prevent thread locker from flowing into
adjacent areas such as clearance fits and ball check.
Allow a minimum of 30 minutes cure time before
operating pump.
1. Support ball bearing (8, Figure 3-9) inner race
and press eccentric (7) into bore. Install small
retaining rings (6).
2. Assemble crankrod assembly parts; large
retaining rings (4), inner weights (3), outer
weights (2) and install flat head screws (1).
Tighten to 100 - 110 in. lbs. (11.3 - 12.4 N.m)
torque.
3. Using a new O-ring (10), install plunger tube
(11) on outlet pin (9). Tighten to 100 - 110 in.
lbs. (11.3 - 12.4 N.m) torque.
4. Assemble the wrist pin anchor (14), backup
washer (15), cup seal (16) and plunger link rod
(17) onto plunger tube (11). Tighten to 100 - 110
in. lbs. (11.3 - 12.4 N.m) torque.
5. Assemble spring (18), ball (19), and plunger
(20) on plunger link rod (17). Tighten plunger to
100 - 110 in. lbs. (11.3 - 12.4 N.m) torque.
6. Install reciprocating tube (21) onto wrist pin
anchor (14). Tighten to 20 - 25 ft. lbs. (27.1 33.9 N.m) torque.
7. Install cup seal (22), O-ring (23), cylinder (24),
ball cage (25), ball (26), O-ring (27) and check
seat (28) into reciprocating tube (21). Tighten
check seat housing to 20 - 25 ft. lbs. (27.1 33.9 N.m) torque.
P3-14
8. Assemble crank rod assembly, to pump with

bushings (13) and button head screws (12).
Tighten screws to 100 - 110 in. lbs. (11.3 - 12.4
N.m) torque.
9. Place pump subassembly (parts 1 through 28)
into pump housing (46).
10. Install new O-ring (54), backup washer (53) and
O-ring (52) and bronze bushing (51) into housing tube (55).
11. Install housing tube assembly onto pump housing (46). Be certain reciprocating tube (21) is
inserted through both bushings. Using a 0.75 in.
(19 mm) diameter rod through the inlet holes at
bottom of tube, tighten to 20 - 25 ft. lbs. (27.1 33.9 N.m) torque.
12. Install shovel plug (56) and retainer (57).
13. Install new backup rings (47), O-rings (48 & 49),
and outlet pin nuts (50). Tighten to 30 - 35 ft.
lbs. (40.7 - 47.5 N.m) torque.
14. Install gasket (41) and motor (42) on pump
housing (46). Install washers (43) and socket
head screws (44).
15. Install shovel plug (56) in housing tube (55).
Install retaining ring (57).
16. Install gasket (31), cover (30) and six self-tapping screws (29), on pump housing.
17. Using new O-rings (40), install manifold (37) on
motor (42). Install socket head screws (33).
18. With the pump assembly in its normal operating
position, add SAE 10W-30 motor oil to pump
housing until oil is level with bottom of pipe plug
(45) hole. Install pipe plug.
04/00
P03018
SYSTEM TROUBLESHOOTING CHART

If the following procedures do not correct the problem, contact a factory authorized service center.
POSSIBLE CAUSES
TROUBLE: Pump Does Not Operate

Lube system not grounded.
Correct grounding connections to pump assembly

and truck chassis.
Electrical power loss.
Locate cause of power loss and repair. Check circuit

breaker CB7. Be sure keyswitch is ON.
Timer malfunction.
Replace timer assembly.
Solenoid valve malfunctioning.
Replace the solenoid valve assembly.
RB7K5 Relay malfunctioning
Replace relay.
Motor or pump malfunction.
Replace motor and/or pump assembly.
Pressure switch defective
Replace pressure switch.
NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing
cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as
specified.
TROUBLE: Pump Will Not Prime

Low lubricant supply.
Dirt in reservoir, pump inlet clogged, filter clogged.
TROUBLE: Pump Will Not Build Pressure

Air trapped in lubricant supply line.
Prime system to remove trapped air.
Lubricant supply line leaking.
Check lines and connections to repair leakage.
Vent valve leaking.
Clean or replace vent valve.
Pump worn or scored.
Repair or replace pump assembly.
TROUBLE: Injector Indicator Stem Does Not Operate

NOTE: Normally, during operation, the injector indicator stem will move into the body of the injector when pressure
builds properly. When the system vents (pressure release) the indicator stem will again move out into the adjusting
yoke.
Malfunctioning injector - usually indicated by
the pump building pressure and then venting.
Replace individual injector assembly.
All injectors inoperative - pump build up not

sufficient to cycle injectors.
Service and/or replace pump assembly.
P03018 04/00
P3-15
POSSIBLE CAUSES
TROUBLE: Pressure Gauge Does Not Register Pressure

No system pressure to the pump motor.
Check hydraulic hose from steering system.
No 24 VDC signal at pump solenoid.
Determine problem in 24 VDC electric system.
Pressure reducing valve set too low.
Refer to Pressure Control Valve Adjustment.
Relay (RB7K5) may be defective.
Replace relay.
TROUBLE: Pump Pressure Builds Very Slowly Or Not At All

No signal at RB7K5 relay.
Check timer and CB7.
Pressure switch may be defective.
Replace pressure switch.
Pressure reducing valve may be set too low.
Refer to Pressure Control Valve Adjustment.
Grease viscosity may be too high for temperature

at which pump is operating.
Replace grease with a lower viscosity lubricant.
Pump inlet check or outlet check may have foreign

matter trapped causing leakage.
Remove, inspect and clean, if necessary.Inspect

sealing surfaces between checks. Replace if rough
or pitted.
Lubricant supply line leaks or is broken.
Repair lubricant supply line.
Insufficient hydraulic oil supply.
Check oil pressure and flow to motor.
TROUBLE: Lube Cycle Timer Not Operating

Timer BAT (-) connection is not on grounded member.
Connect to good ground.
Timer BAT (+) connection not on circuit continuously connected to BAT (+) terminal during operation of vehicle.
Establish direct connection between Timer BAT (+)

connection and 24 V BAT (+) terminal.
Loose wire connections at any of the timer terminals.
Secure wire connections.
TROUBLE: Timer Stays Timed Out

Commutation failure in timer caused by damaged
component.
Replace timer.
Output relay contacts welded shut caused by

extended short to ground.
Replace timer.
Solenoid valve connected to "IGN" terminal of

timer instead of terminal marked "SOL".
Correct wiring hook-up.
P3-16
04/00
P03018
POSSIBLE CAUSES
TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) Times More Often Than Set Time Interval
Electrical noise is being introduced into the power
supply to the timer overcoming suppressor capacitor causing uncontrolled turn-on of its output relay.
IMPORTANT: In some instances, electrical noise

may be generated into vehicle electrical system
which may cause timer to turn on at random
intervals, independent of timer setting.
If this occurs, a 250 to 1,000 MFD capacitor rated
150 to 350 VDC should be added across BAT (+)
and BAT (-) terminals to suppress this noise and
improve timer performance.
TROUBLE: Timer Turns On At Intervals Faster Than Allowable Tolerances Of Settings

Timer out of adjustment or damaged component.
P03018 04/00
Refer to Timer Adjustment and re-adjust timer or

replace timer.
P3-17
PREVENTATIVE MAINTENANCE PROCEDURES

The following maintenance procedures should be
used to insure proper system operation.
Daily Lubrication System Inspection
1. Check grease reservoir level.
Inspect grease level height after each shift of operation. Grease usage should be consistent from day-today operations.
Lack of lubricant usage would indicate an

inoperative system. Excessive usage would
indicate a broken supply line.
2. Check filter bypass indicator when filling reservoir. Replace element if bypassing.
3. Check all grease feed line hoses from the SL-1
Injectors to the lubrication points.
a. Repair or replace all damaged feed line
hoses.
b. Make sure that all air is purged and all new
feed line hoses are filled with grease before
sending the truck back into service.
4. Inspect key lubrication points for a bead of lubricant around seal. If a lubrication point appears
dry, troubleshoot and repair problem.
250 Hour Inspection

1. Check all grease feed line hoses from the SL-1
Injectors to the lubrication points (see, Figure 31).
a. Repair or replace all worn / broken feed line
hoses.
feed line hoses are filled with grease before
sending the truck back into service.
2. Check all grease supply line hoses from the
pump to the SL-1 injectors.
a. Repair or replace all worn / broken supply
lines.
supply line hoses are filled with grease
before sending the truck back into service.
4. Inspect all bearing points for a bead of lubricant

around the bearing seal.
It is good practice to manually lube each bearing
point at the grease fitting provided on each Injector.
This will indicate if there are any frozen or plugged
bearings, and will help flush the bearings of contaminants.
5. System Checkout
a. Remove all SL-1 injector cover caps to allow
visual inspection of the injector cycle indicator pins during system operation.
b. Start truck engine.
c. Actuate the lube system test switch. The
hydraulic motor and grease pump should
operate.
d. With the grease under pressure, check each
SL-1 injector assembly. The cycle indicator
pin should be retracted inside the injector
body.
e. When the system attains 2500 psi (17 237
kPa), the pump should shut off and the pressure in the system should drop to zero, venting back to the grease reservoir.
f. With the system vented, check all of the SL-1
injector indicator pins; all of the pins should
be visible. Replace or repair injectors, if
defective.
g. Reinstall all injector cover caps.
h. Check timer operation.
Note: With engine running, lube system should
activate within 5 minutes. The system should build
2000 to 2500 psi within 25-40 seconds.
a. If the system is working properly, the truck is
ready for operation.
b. If the system is malfunctioning, refer to the
troubleshooting chart.
3. Check grease reservoir level.

a. Fill reservoir if low.
1000 Hour Inspection
b. Check reservoir for contaminants. Clean, if

required.
1. Check pump housing oil level and correct if

necessary.
c. Check that all filler plugs, covers and

breather vents on the reservoir are intact and
free of contaminants.
P3-18
04/00
P03018
SECTION Q
ALPHABETICAL INDEX
A
Accumulator, Brake . . . . . . . . . . . . . . . . . . . . . . . J3-24
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . J4-3

Failure Modes Checkout Procedure . . . . . . . . . . J4-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . J4-11
AC Drive System Electrical Checkout . . . . . . . . . . E3-3
Brake Disc Wear Indicator . . . . . . . . . . . . . . . . . . J5-4
AID System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
Brake, Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Air Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
Brake Seal Assembly, Rear . . . . . . . . . . . . . . . . . J5-13
Air Conditioning System . . . . . . . . . . . . . . . . . . . . N4-7

Component Service . . . . . . . . . . . . . . . . . . . . . N4-14
Brake Seal Gap Adjustment (Rear) . . . . . . . . . . . J5-12
Alarm Indicating Device (AID) . . . . . . . . . . . . . . . . D3-5
Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3

Test and Adjustment . . . . . . . . . . . . . . . . . . . . . J3-12
Accelerator Pedal, Electronic . . . . . . . . . . . . . . . E2-54

Accumulator, Steering . . . . . . . . . . . . . . . . . . . . . L6-21
Alternator, 24VDC . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Brakes, Wet Disc . . . . . . . . . . . . . . . . . . . . . . . . . . J5-3
Alternator, Propulsion . . . . . . . . . . . . . . . . . . . . . . C4-3

Antifreeze Recommendations . . . . . . . . . . . . . . . . P2-4
Anti-sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Automatic Lubrication System . . . . . . . . . . . . . . . . P3-3
Axle, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
C
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Capacities, Service . . . . . . . . . . . . . . . . . . . . . . . . P2-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Maintenance and Service . . . . . . . . . . . . . . . . . . D2-3
Charging Procedure
Brake Accumulators (Hydraulic Cabinet) . . . . . J3-27
Brake Accumulators (Frame Cabinet). . . . . . . . J3-31
Steering Accumulators . . . . . . . . . . . . . . . . . . . L6-24
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
Battery Charging System. . . . . . . . . . . . . . . . . . . D10-3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Battery Control Box . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Battery Disconnect Switches . . . . . . . . . . . . . . . . . D2-6
Battery Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6
Bearing, Wheel
Front, Installation . . . . . . . . . . . . . . . . . . . . . . . . G3-9
Front, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . G3-9
Bleeddown Manifold Valve . . . . . . . . . . . . . . . . . . L6-3
Body, Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Body Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Body Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Body Up Retention Cable . . . . . . . . . . . . . . . . . . . B3-6
Body-Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . J3-24
Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
Bleeding Procedures
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . J5-16
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-8
Q01046
Checkout Procedures
Brake Apply Circuit . . . . . . . . . . . . . . . . . . . . . . . J4-3
Brake Cooling Circuit . . . . . . . . . . . . . . . . . . . . L10-8
Data Sheet (Hydraulic System). . . . . . . . . . . . L10-15
Electrical Propulsion System . . . . . . . . . . . . . . . E3-3
Hoist Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-8
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . L10-3
Circuit Breaker Chart . . . . . . . . . . . . . . . . . . . . . . D3-17
Center Console . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
Control Cabinet, Electrical . . . . . . . . . . . . . . . . . . E2-50
Cooling System (Engine) . . . . . . . . . . . . . . . . . . . . C3-3
Cooling System (Disc Brakes) . . . . . . . . . . . . . . . . L2-8
Cylinders
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-14
Steering
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G3-13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-8
Alphabetical Index
Q1-1
Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Diode Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10
Heater/Air Conditioner . . . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil, Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Motor and Speed Control . . . . . . . . . . . . . .
Differenatial Pressure Switch . . . . . . . . . . . . . . . . J3-20
Hoist Circuit Operation . . . . . . . . . . . . . . . . . . . . . .L7-3
Dual Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . J3-17
Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . D3-16
Dump Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Hoist Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . L8-11
Dump Procedure, Disabled Truck. . . . . . . . . . . . .L8-23
Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-14
Diagnostic Information Display . . . . . . . . . . . . . . . E2-7

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-7
N4-3
N4-5
N4-4
N4-5
Hoist Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . .L10-9

Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Electrical Interface Cabinet. . . . . . . . . . . . . . . . . . D3-8
Hub, Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Electrical Propulsion Components . . . . . . . . . . . . E2-3
HYDRAIR II Suspensions
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Electrical System Schematic . . . . . . . . . . . . . . . . R1-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Engine/Alternator Mating . . . . . . . . . . . . . . . . . . C4-5
Engine Specifications. . . . . . . . . . . . . . . . . . . . . A2-3
F
Fan, Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
Filters
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-4
Hoist Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-5
5 Minute Idle Timer . . . . . . . . . . . . . . . . . . . . . . . D3-3
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-4
Flushing, Hydraulic System . . . . . . . . . . . . . . . .L10-12
Oil and Nitrogen Specifications . . . . . . . . . . . H4-10

Hydraulic System
Disc Brake Cooling System . . . . . . . . . . . . . . . . .L2-8
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
Hoist Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1-1
Strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-17
Steering and Brake Pump . . . . . . . . . . . . . . . . .L6-10
System Flushing . . . . . . . . . . . . . . . . . . . . . . .L10-12
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-16
Troubleshooting
Hoist Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-15
Steering System. . . . . . . . . . . . . . . . . . . . . . . . .L6-25
Front Suspension, HYDRAIR II . . . . . . . . . . . . . H2-3

Front Tires and Rims . . . . . . . . . . . . . . . . . . . . . . G2-4
Front Wheel Hub and Spindle. . . . . . . . . . . . . . . . G3-3

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . N5-15
G
Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-32
Lubrication and Service . . . . . . . . . . . . . . . . . . . . P2-3
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Lubrication System, Automatic . . . . . . . . . . . . . . . P3-3
Q1-2
Alphabetical Index
Q01046
Manifold,
Bleeddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-3
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
Metric Capscrews, Torque Chart . . . . . . . . . . . . . . A5-2
Rear HYDRAIR II Suspension. . . . . . . . . . . . . . . H3-3
Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . A5-6
Rear Tire and Rim . . . . . . . . . . . . . . . . . . . . . . . . .G2-5
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G4-3
Relay Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11

Retarder Pedal, Electronic. . . . . . . . . . . . . . . . . . E2-54
Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G2-8
Nitrogen Specifications . . . . . . . . . . . . . . . . . . . . H4-10
Rock Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Oiling and Charging Procedure, Suspension . . . . H4-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Operator Cab Controls . . . . . . . . . . . . . . . . . . . . . N5-3

Optional Equipment
Fire Control System . . . . . . . . . . . . . . . . . . . . . .M2-3
Payload Meter II . . . . . . . . . . . . . . . . . . . . . . . .M20-1
Overhead Display Panel . . . . . . . . . . . . . . . . . . . N5-23
Software Functions, PSC. . . . . . . . . . . . . . . . . . . E2-32

Starter, 24VDC (Refer to Engine Manual)
Seal Assemblies, Gap Adjustment
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-11
Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-13
Seat, Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
P
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Pedal
Accelerator, Electronic . . . . . . . . . . . . . . . . . . . E2-54
Retarder, Electronic . . . . . . . . . . . . . . . . . . . . . E2-54
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5
Plates, Warning and Caution . . . . . . . . . . . . . . . . . A4-1
Portable Test Unit (PTU) . . . . . . . . . . . . . . . . . . . . E3-6
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3
Solenoid
Bleeddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M8-1
Specifications
HYDRAIR II Oil . . . . . . . . . . . . . . . . . . . . . . . H4-10
HYDRAIR II Nitrogen . . . . . . . . . . . . . . . . . . . H4-10
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . P2-5
Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Engine/Alternator Mating . . . . . . . . . . . . . . . . . . C4-5
Spindle, Front Wheel Hub . . . . . . . . . . . . . . . . . . .G3-3
Pressure Control Adjustment, Pump . . . . . . . . . . L10-4
Steering
Accumulator Charging Procedure . . . . . . . . . . . L6-24
Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3
Hydraulic Check-Out Procedure . . . . . . . . . . . . L10-3
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-3
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . L6-25
Propulsion System Controller (PSC) . . . . . . . . . . . E2-5

Checkout Procedure . . . . . . . . . . . . . . . . . . . . . E3-22
Pump, Hoist System . . . . . . . . . . . . . . . . . . . . . . . L3-3
Pump, Steering/Brake System. . . . . . . . . . . . . . . L6-10
Starter Isolation Diode . . . . . . . . . . . . . . . . . . . . . . D2-5

Status/Warning Indicator Lights . . . . . . . . . . . . . . N5-24
Strainer, Hydraulic Tank. . . . . . . . . . . . . . . . . . . . L3-17

Suspension, HYDRAIR II
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Q01046
Alphabetical Index
Q1-3
V
Switch
Accumulator Pressure . . . . . . . . . . . . . . . . . . . . .L4-7
Body-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Differential Pressure . . . . . . . . . . . . . . . . . . . . . J3-20
Hoist Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16
Low Steering Pressure. . . . . . . . . . . . . . . . . . . . .L4-5
T
Tank
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-16
Valves
Bleeddown Solenoid . . . . . . . . . . . . . . . . . . . . . .L4-5
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Dual Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-17
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-8
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Hoist Pilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-11
Hoist Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-8
Pressure Compensator, Adjustment . . . . . . . . .L10-4
Steering Control . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Unloader Adjustment . . . . . . . . . . . . . . . . . . . . L10-4
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-12

Tires and Rims
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-4
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
Toe-In Adjustment. . . . . . . . . . . . . . . . . . . . . . . . G3-15
Tools, Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8-1
Torque Table
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-2
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1
Troubleshooting
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7
Alternator, 24VDC . . . . . . . . . . . . . . . . . . . . . . D10-3
Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . J4-11
Hoist Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-15
Steering Circuit. . . . . . . . . . . . . . . . . . . . . . . . . .L6-25
Truck Control Interface (TCI) . . . . . . . . . . . . . . . . E2-6
Checkout Procedure . . . . . . . . . . . . . . . . . . . . E3-14
W
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . A4-1
Weights (Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4
Wheel Bearing Adjustment
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-9
Front Wheel Bearing Seal Adjustment. . . . . . . G3-11
Wheel Hub and Spindle . . . . . . . . . . . . . . . . . . . . G3-3
Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Wheels and Tires
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-4
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
Window, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-9
Windshield Washer. . . . . . . . . . . . . . . . . . . . . . . . N3-5
Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
U
Unloader Valve, adjustment . . . . . . . . . . . . . . . . .L10-4
Q1-4
Alphabetical Index
Q01046
SECTION R
SYSTEM SCHEMATICS
INDEX
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HH347
HYDRAULIC BRAKE SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HH352
PLM III ELECTRICAL SYSTEM SCHEMATIC (930E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE479
PLM III HOOK-UP WIRING (730E, 830E, 930E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE480
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XS0500
R01061
Index
R1-1
NOTES
R1-2
Index
R01061

Shop Manual 930E-2 A30296, A30297, A30300

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Shop Manual 930E-2 A30296, A30297, A30300

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A30296, A30297, A30300

This ALERT symbol is used with the signal words,

DANGER identifies a specific potential hazard WHICH WILL

WARNING identifies a specific potential hazard WHICH MAY

CAUTION is used for general reminders of proper safety

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

KOMATSU MODEL 930E DUMP TRUCK

TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1

GENERAL SAFETY AND TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1

WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1

CHARTS AND TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1

STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-1

MAJOR COMPONENT DESCRIPTION

The 930E Dump Truck is an off-highway, rear dump

The operator cab has been engineered for operator

AC Induction Traction Motorized Wheels

Major Component Description

930E MAJOR COMPONENTS

Major Component Description

. . . . . . . . . . . . . . . . . . . . . . U.S. Gallons . . . . (Liters)

AC ELECTRIC DRIVE SYSTEM

BATTERY ELECTRIC SYSTEM

* Includes Lube Oil Filters

Cooling System . . . . . . . . . . . . . 157. . . . . . . . . . . .594

Major Component Description

STANDARD DUMP BODY CAPACITIES

Empty Vehicle . . . . . . . . . Pounds . . . (Kilograms)

Radial Tires (standard) . . . . . . . . . . . . . . . 53/80 R63

Loaded Vehicle . . . . . . . . Pounds . . . (Kilograms)

Major Component Description

General Safety and Operating Instructions

Stopping The Engine Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13

General Safety and Operating Instructions

Clothing And Personal Items

General Safety and Operating Instructions

Leaving The Operators Seat

Mounting And Dismounting

Never hold any control levers when getting on or off a machine.

Fire Prevention For Fuel And Oil

Keep flames away from flammable fluids.

Stop the engine and never smoke when refueling.

Tighten all fuel and oil tank caps securely.

Refueling and oiling should be done in well ventilated areas.

General Safety and Operating Instructions

Precautions When Handling At High Temperatures

To prevent hot coolant from spraying:

To prevent hot engine oil spray:

Asbestos Dust Hazard Prevention

Never use compressed air for cleaning.

Use water for cleaning to control dust.

Use an approved respirator when necessary.

Prevention Of Injury By Work Equipment

Fire Extinguisher And First Aid Kit

Provide a first aid kit at the storage point.

Know what to do in the event of a fire.

General Safety and Operating Instructions

Precautions When Using ROPS

Precautions For Attachments

General Safety and Operating Instructions

PRECAUTIONS DURING OPERATION

Ensure a fire extinguisher is present and in proper working condition.

Do not operate the machine near open flames.