2. If all red drive system warning lights are “OFF”, follow the “Normal Engine Shutdown Procedure”. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage may be induced into the electrical harness and cause damage to components. 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, alterna- tor, and power cables connecting these devices are safe to work on.
Before welding on the truck, open the battery discon- nect switches and disconnect the battery charging alternator lead wire. Never allow welding current to pass through ball bear- ings, roller bearings, suspensions, or hydraulic cylin- ders. 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” posi- tion. This will prevent the alternator from re-ener- gizing and creating system voltage, until the switch is returned to its former position. 11.
If the red lights on the exterior of the control cabi- net and/or the back wall of the operator's cab con- tinue to be illuminated after following the above procedure, a fault has occurred. 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. 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 a KMS factory representative, immediately.
Only qualified personnel, specifically trained for servicing the AC Drive System, should perform this service. If these lights are “OFF”, the blower system, blower power cables, and remainder of the control cabinet is safe to work on. 12. If the red lights on the blower control panel are illu- minated after following the above procedure, a fault has occurred. Reinstall the control cabinet panel. Do not perform maintenance on the blower control panel, or blower motor power cables. If these lights are ON, refer to steps 11 & 12. 6. 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. 7.
DO NOT weld on the retard grid exhaust louvers; they are made of stainless steel. Any welding done here must be done by qualified welders, using the appropriate equipment and materials. 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. Notify a KMS factory 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.
Re-connect all harnesses prior to restarting the truck. Leave the drive system in the REST position until the truck is to be moved. 8. 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 insula- tion prior to servicing the cables and prior to returning the truck to service. Discard cables with broken insulation. 10. Power cables and wiring harnesses must be pro- tected 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.
Page 4-8 930E FIELD ASSEMBLY MANUAL FAM0403 Field Welding Procedures