PDF Shop Manual Komatsu 930E-4SE Dump Truck - 2 MB
Tackle any repair or maintenance task on your Komatsu 930E-4SE Dump Truck with this official shop manual.
This extensive guide is designed for professional service technicians and contains in-depth procedures for every system on the truck.
From the engine and powertrain to the complex hydraulic and electrical systems, this manual provides the detailed information needed for diagnostics and overhauls.
It's an essential resource for maintaining the performance and reliability of these massive haul trucks.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
CEBM020804
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS A30727 - A30756
®
--- Page 3 ---
SPECIFICATIONS
These specifications are for the standard Komatsu 930E-4SE Truck. Customer options may change this listing.
ENGINE
Komatsu SSDA18V170
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Stroke
Rated Brake Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 611 kW (3,500 HP) at 1900 RPM
Flywheel Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 558 kW (3,429 HP) at 1900 RPM
Weight (Wet)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 000 kg (22,266 lb)
* Weight does not include radiator, sub-frame or alternator.
AC ELECTRIC DRIVE SYSTEM
(AC/DC Current)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Electric GTA-39
Dual Impeller, In-Line Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453 m³/ min (16,000 cfm)
Motorized Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GDY106 AC Induction Traction Motors
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.62:1
Maximum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5 kph (40 mph)
* Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters.
Komatsu and GE must analyze each job condition to ensure proper application.
DYNAMIC RETARDING
Electric Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard
Maximum Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 026 kW (5,400 HP)
Continuous* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 909 kW (3,900 HP)
* Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.
BATTERY ELECTRIC SYSTEM
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four 8D, 12 volt wet batteries with disconnect switch
Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 CCA
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt, 140 Amp Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
SERVICE CAPACITIES
Crankcase (including oil filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 liters (90 gallons)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .799 liters (211 gallons)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 300 liters (1400 gallons)
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 325 liters (350 gallons)
Wheel Motor Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 liters (25 gallons) per wheel
A02080 3/12 Major Components & Specifications A2-3
--- Page 4 ---
WORKING NEAR BATTERIES • Batteries generate hydrogen gas. Hydrogen gas
is very explosive and can easily be ignited with a
Battery Hazard Prevention small spark or flame.
• Battery electrolyte contains sulfuric acid, which • Before working with batteries, stop the engine
can quickly burn the skin and eat holes in and turn the key switch to the OFF position.
clothing. If you spill acid on yourself, immediately • Avoid short-circuiting the battery terminals
flush the area with water. through accidental contact with metallic objects,
• Battery acid can cause blindness if splashed into such as tools, across the terminals.
your eyes. If acid gets into your eyes, flush them • When removing or installing batteries, check
immediately with large quantities of water and which is the positive (+) terminal and the negative
see a doctor at once. (-) terminal.
• If you accidentally drink acid, drink a large • Tighten the battery terminals securely. Loose
quantity of water, milk, beaten eggs or vegetable terminals can generate sparks and lead to an
oil. Call a doctor or poison prevention center explosion.
immediately.
• Tighten battery caps securely.
• Always wear safety glasses or goggles when
working with batteries.
A03038 1/13 General Safety & Operating Instructions A3-9
--- Page 5 ---
Manual DC Link Capacitor Discharge Procedure
Follow any and all local and site specific procedures
and requirements for working on off-highway mining
equipment.
1. Verify that the engine is off and the parking
brake is on.
FIGURE 3-4. INFORMATION DISPLAY PANEL
2. Verify that the generator field contactor (GF)
switch (2, Figure 3-4) in the low voltage area of 1. Control Power Switch 3. Capacitor Charge
the control cabinet is in the CUTOUT position. 2. GF Cutout Switch Light
3. Move the control power switch (1) to the ON
position for a minimum of 30 seconds. Then,
turn the control power switch to the OFF posi-
tion.
In most control cabinets, RP2 is the normal dis-
(With control power on, an RP contactor closes
charge path. In groups containing an RP3 contactor,
and discharges the DC link through the retard-
RP2 and RP3 are alternated as the normal discharge
ing grids in less than 10 seconds.)
path. Refer to Figure 3-5.
FIGURE 3-5. DISCHARGE PATHS
A03038 1/13 General Safety & Operating Instructions A3-21
--- Page 6 ---
OPERATION If the brake check light does not illuminate immedi-
ately after pressing the brake test switch, there is
The static brake test utilizes a momentary switch and
most likely a problem with the setup. Refer to the
a check light located in the overhead display panel.
setup conditions and take action to prepare the truck
for a brake test.
Brake Test Switch
The brake test switch is used to If there is a problem with the truck setup, the DID
initiate a brake test. Press on the panel will display the problem.
momentary switch to enter the For example if the engine is off:
brake test mode. If certain condi-
tions are met, the operator can ERROR Entering Brake Test
enter a brake test sequence. Engine not running
If the Truck is loaded:
ERROR Entering Brake Test
Truck is NOT Empty
Brake Check Light If all of the conditions are correct, except the brakes
The amber light is used to indi- are not set correctly, an error message will be dis-
cate when the truck is in the played. For example, if the service brake and parking
brake test mode. When illumi- brake are both applied together:
nated, a brake test is ready. ERROR Entering Brake Test
When flashing, the brake test is Set Brakes for Test
at the validation point, or the
retard system test is finished.
Brake Test Exit Criteria
Description Numerous conditions can occur which may interrupt
a brake test, including the following:
The operator can choose which brake test to per-
form, and will set the truck controls based on the set- • Any of the setup conditions becoming false
tings in Table 1. The drive system will detect the • Drive system fault which restricts the LINK or
position of the directional control lever, and will pre- Propel mode
pare for the appropriate test. The operator will then
• Truck Speed greater than 3.2 kph (2.0 mph)
press the brake test switch.
• Drive system at torque level for more than 30
If the brake check light is illuminated solid after seconds
pressing the brake test switch, the system is in brake
test mode and is ready for the chosen test to be initi- • Brake test requested, but not initiated by the
ated by the operator. After testing, the operator will operator within 60 seconds after pressing the
brake test switch
then determine if the truck passed the brake tests,
and if it is safe for operation.
Table 1: BRAKE TEST SETTINGS
Wheel Brake Service Brake Directional
Test Type Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF RELEASED PARK
Retard Test OFF RELEASED PARK
A03038 1/13 General Safety & Operating Instructions A3-33
--- Page 7 ---
SUDDEN LOSS OF ENGINE POWER FUEL DEPLETION
If the engine suddenly stops, there is enough The high pressure injection (HPI) fuel system uses
hydraulic pressure stored in the brake and steering fuel to adjust fuel delivery timing by creating a
accumulators to allow the operation of the steering hydraulic link between the upper plunger and the tim-
and brake functions. However, this oil supply is ing plunger. Metered fuel is also used for lubricating
limited, so it is important to stop the truck as quickly the injector plunger and barrel. The maximum
and safely as possible after the loss of engine power. demand for metered fuel is required during high
speed / low load conditions.
If the brake supply pressure drops to a pre-
determined level, the low brake oil pressure warning
light will illuminate and sonalarm will sound. If the
brake pressure continues to decrease, the auto-apply
feature will activate and the service brakes will apply
automatically to stop the truck.
Operating the truck to fuel depletion forces the
1. Bring the truck to a safe stop as quickly as injector train into a no-follow condition. No fuel
possible by using the foot pedal to apply the flow between the plungers may cause damage to
service brakes. If possible, safely steer the truck the injectors and the overhead due to adhesive
to the side of the road while braking. wear, resulting in costly repairs and unnecessary
downtime.
Dynamic retarding will not be available. Do not
use the service brakes for continuous retarding Allowing the Komatsu truck to operate until fuel
purposes. depletion can lead to unsafe operating
2. Move the directional control lever to PARK as conditions possibly resulting in an
soon as the truck has stopped moving. uncontrollable vehicle and/or personal injury.
3. Turn the key switch to the OFF position and
notify maintenance personnel immediately.
4. If traffic is heavy near the disabled machine,
mark the truck with warning flags during
daylight hours or use flares at night. Adhere to
local regulations.
A03038 1/13 General Safety & Operating Instructions A3-45
--- Page 8 ---
TORQUE TABLES AND CONVERSION CHARTS
This manual provides dual dimensioning for many
specifications. Metric units are specified first, with
References throughout the manual to standard
U.S. standard units in parentheses. When torque val-
torques or other standard values will be to one of
ues are not specified in the assembly instructions
the following tables. Do not use standard values
contained in this manual, use the standard torque
to replace specific torque values in assembly
value for the hardware being used. Standard value
instructions.
torque tables are contained in this chapter for metric
and SAE hardware.
NOTE: This truck is assembled with both metric and For values not shown in any of the charts or tables,
SAE (U.S.) hardware. Reference the correct table standard conversion factors for most commonly used
when determining the proper torque value. measurements are provided in the following tables.
INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
TABLE 1 Standard Tightening Torque For Metric Cap screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
TABLE 2 Standard Tightening Torque For SAE Grade 5 & 8 Cap Screws and Nuts . . . . . . . . . . . . . . . . 12-3
TABLE 3 Standard Tightening Torque 12-Pt, Grade 9, Cap Screws (SAE) . . . . . . . . . . . . . . . . . . . . . . . 12-4
TABLE 4 Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
TABLE 5 Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
TABLE 6 Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
TABLE 7 JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
TABLE 8 Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
TABLE 9 O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
TABLE 10 O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
TABLE 11 Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
TABLE 12 Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
TABLE 13 Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
A05001 1/13 Torque Tables and Conversion Charts A5-1
--- Page 9 ---
11. All lubrication points (grease fittings) should be REMOVAL FROM STORAGE
serviced with the recommended lubricants.
If the storage preparations were followed when
12. Relieve the tension from all drive belts. The placing the vehicle into storage, getting it back to
engine manufacturer recommends insertion of operational status is a matter of reversing those
heavy kraft paper between the belts and pulleys steps.
to prevent sticking.
NOTE: Before starting the job of restoring a vehicle
13. All vandalism covers and locks should be in to operation, obtain copies of the Operation and
place and secured. Maintenance Manual, Service Manual, Engine
14. All cab windows should be closed, locked and Manuals and Parts Book, if possible, and follow all
sealed, and the cab door should be locked to special instructions regarding servicing the vehicle
prevent vandalism and weather effects. and its components.
15. The fuel tank should be completely drained of In addition to removing the storage materials, the
fuel, fogged with preservative lubricant (NOX- following actions should be taken:
RUST MOTOR STOR., SAE10), and closed 1. Inspect the entire vehicle carefully for rust and
tightly. All fuel filters should be replaced. corrosion. Correct as necessary.
16. If possible, all available service publications 2. Service the engine according to the engine
(vehicle and engine) and a current parts catalog manufacturer's Operation and Maintenance
should be packaged in a moisture proof Manual.
package and placed in the cab to aid whomever
3. Clean the radiator. Refer to Section C, Cooling
will eventually place the unit back in operation.
System, for cleaning instructions.
17. Ensure that the water drain holes in the truck 4. The cooling system should be completely
body are open. drained, chemically flushed, and refilled with a
conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
Fluid Specifications in Section P, Lubrication
and Service, for the proper anti-freeze and
conditioner concentrations. After refilling the
system, always operate the engine until the
thermostats open to circulate the solution
through the cooling system.
5. Thoroughly inspect all drive belts and hydraulic
oil lines for damage, wear or deterioration.
Replace any suspected lines. Do not take
chances on possible ruptures or blow-outs.
6. New hydraulic filters should be installed and the
hydraulic tank checked and serviced with Type
C-4 oil as specified in Section P, Lubrication
and Service.
A07003 11/05 Storage Procedures and Idle Machine Preparation A7-3
--- Page 10 ---
7. Perform a megohmmeter test. Refer to the 10. Check the retarding grids and insulators for
truck's Vehicle Test Instructions for the correct loose connections and dirt accumulation. Clean
procedure. If Megger readings are less than 2.0 and tighten connections as necessary.
megohms, the problem could be an 11. Where applicable, check exciter drive belts for
accumulation of moisture in the motor or cracks and deterioration. If acceptable, set the
alternator. If this is the case, the faulty belt tension to specification.
component will have to be isolated and dried
out using procedures outlined in the G.E. 12. Before starting the engine, turn on the control
Service Manual. power. Check that the contactors and relays
pick up and drop out normally.
8. Perform a thorough inspection of the motorized
wheels, alternator, blowers and control 13. Perform a startup procedure on the complete
compartments. Look for: system to ensure maximum performance during
service. Refer to the truck's Vehicle Test
•Rust or dirt accumulation on machine
Instructions for the complete test procedure.
surfaces
•Damaged insulation
•Any accumulation of moisture or debris, After all storage protection has been removed, the
especially in the ductwork truck has been cleaned and inspected, all repairs
have been made, the motorized wheel gearcase has
•Loose wiring and cables been filled with new oil, the dirt seals have been
•Any rust on electrical connectors in the control completely purged with new grease, and the system
compartment has been completely checked, the truck can be
•Any loose cards in the card panels placed into service. However, it is recommended that
the truck be driven unloaded at a low speed of no
9. Clean and make repairs as necessary.
more than 16 km/h (10 mph) for the first hour of
operation.
A07003 11/05 Storage Procedures and Idle Machine Preparation A7-15
--- Page 11 ---
SECTION B3
DUMP BODY
INDEX
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Body Pad Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
BODY-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
BODY RETENTION SLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9
B03020 12/11 Dump Body B3-1
--- Page 12 ---
FUEL TANK
FUEL TANK Cleaning
Removal The fuel tank has a drain cock and a cleaning port in
the side that allow steam or solvent to be used for
1. Raise the truck body and install the body
cleaning tanks that have accumulated foreign
retention sling.
material.
2. Loosen filler cap (5, Figure 4-1) and open the
drain cock on the bottom of fuel tank (1) to drain It is not necessary to remove the tank from the truck
the fuel from the tank into clean containers. for cleaning of sediment. However, rust and scale on
Tighten the filler cap when the fuel is completely the walls and baffles may require complete tank
drained. removal. This allows cleaning solutions to be in
contact with all interior surfaces by rotating the tank
3. Disconnect the wire harness from hoist circuit
in various positions.
filter assemblies (11) and steering circuit filter
assembly (12). Remove ground wire (13). Before a cleaning procedure of this type, the fuel
4. If equipped, close the inline shutoff valves. gauge sender, vent assembly (8, Figure 4-1) and all
Remove fuel return hose (6), fuel supply hose hose connections must be removed and temporarily
(7) and quick fill hose (10). Cap the hoses and sealed. After cleaning is complete, the temporary
tank fittings to prevent contamination. plugs can be removed.
5. Remove hoist circuit filter assemblies (11) and If the tank is to remain out of service, a small amount
steering circuit filter assembly (12) from the fuel of light oil should be sprayed into the tank to prevent
tank. Support the filter assemblies by placing a rust. Seal all openings for rust prevention.
chain over the frame rail. It is not necessary to
remove the hydraulic hoses. Installation
1. Thoroughly clean the frame mounting brackets
and the mounting hardware holes. Re-tap the
threads if damaged.
The weight of the empty fuel tank is
approximately 2 045 kg (4,510 lb). Use lifting
devices with adequate capacity to remove the
fuel tank. The weight of the empty fuel tank is
6. Attach a lifting device to the lifting eyes on each approximately 2 045 kg (4,510 lb). Use lifting
side of the tank. devices with adequate capacity to install the fuel
7. Remove capscrews (14), lockwashers (15), flat tank.
washers (16), large washers (17) and rubber 2. Attach a lifting device to the lifting eyes on each
mounts (16). Remove capscrews (2), side of the tank. Lift the fuel tank into position
lockwashers (3) and mounting caps (4). over the frame trunnion mounts and lower it into
8. Lift the fuel tank from the brackets and move it position.
to a work area. 3. Install mounting caps (4, Figure 4-1),
lockwashers (3) and capscrews (2). Do not
Repair tighten the capscrews at this time.
If a tank has been damaged and requires structural 4. Install rubber mounts (18), large washers (17),
repair, perform such repairs before final cleaning. flat washers (16), lockwashers (15) and
capscrews (14). Tighten the lower mounting
capscrews to 800 ± 80 N·m (590 ± 59 ft lb).
5. Tighten the upper mounting capscrews to 712 ±
72 N·m (525 ± 53 ft lb).
If a tank is to be weld repaired, special 6. Install hoist circuit filter assemblies (11) and
precautions are necessary to prevent fire or steering circuit filter assembly (12) on the tank.
explosion. Consult local authorities for safety
regulations before proceeding.
B04023 3/12 Fuel Tank B4-3
--- Page 13 ---
19. Remove radiator upper support rod (1, Figure 2-
7) at each side of radiator.
20. Remove the diagonal ladder from truck. Refer to
Section B2, Structural Components, for the
removal procedure.
21. Refer to Section N4, Heater/Air Conditioner, for
the procedures required to properly remove the
refrigerant.
NOTE: The system contains HFC-134A refrigerant.
Federal regulations prohibit venting air
conditioning system refrigerants into the
FIGURE 2-7. RADIATOR UPPER SUPPORT ROD
atmosphere. An approved recovery/recycle
station must be used to remove the refrigerant 1. Radiator Upper Support Rod
from the air conditioning system.
22. After the air conditioning system has been
discharged, disconnect the refrigerant hoses
that are routed to the cab at the compressor
and the receiver/drier.
C02025 1/11 Power Module C2-7
--- Page 14 ---
Disassembly
To aid in removal of the tubes, clean the radiator
prior to disassembly. Heating the seals with hot
water helps to loosen the grip on the tubes.
Cleaning the radiator prior to disassembly also
reduces the risk of internal contamination. After
cleaning, spray lubricating oil at the top end of
the tubes.
FIGURE 3-7. INSTALLATION TOOL (VJ6567)
2. After the tube is loose, position the installation
tool (VJ6567) at the bottom of the tube to be
removed. Refer to Figure 3-7. The upper jaw of
the installation tool should be positioned just
below the rectangular section of the tube. The
bottom jaw should rest on the seal. Squeeze
the installation tool just enough to allow the