COMPONENT CODE

PARTS & SERVICE

NEWS

60

REF NO. AA01044A

DATE August 16, 2006

(C)

Page 1 of 3

This Parts & Service News supersedes the previous issuance, AA01044, dated February 26, 2001.
AA01044 is to be discarded.
SUBJECT:
HYDRAULIC ACCUMULATOR WELDS
PURPOSE:

To inform the field to inspect and/or replace the piston accumulator.

APPLICATION:

Komatsu Electric Drive Dump Trucks Equipped with TY3541 or EF0143

Accumulator:
830E: 31320-32390

FAILURE CODE:

6030HB

DESCRIPTION:

The potential exists for cracks to develop in the welds used to join the end cap to the tube portion of the
TY3541 piston accumulators. A crack(s) will reduce the structural integrity of that weld and could lead
to external leaks or a catastrophic failure of the weld itself.
If the end cap weld develops a crack, the end cap could separate from the tube portion of the accumulator. This separation can occur without warning and will cause severe damage to the components that
are located directly above the accumulator.
It is highly recommended that all trucks using the (TY3541 or EF0143) piston accumulators be reworked
to use a dual accumulator arrangement by installing accumulator kit (AK4735-002).
All trucks still using piston accumulator (TY3541 or EF0143) must have the welds on the accumulator
housings ultrasonically inspected for cracks. This inspection is to be done as soon as possible. The ultrasonic inspection procedure to be used is described in this Parts and Service News.
Once the initial inspection has been completed, the welds of the (TY3541 or EF0143) accumulators must
be ultrasonically inspected for cracks every 12 months or 5,000 hours, which ever comes first. Use the
form on page 3 to record the results of each inspection and keep this record in a permanent location.

If a crack is identified, the entire accumulator must be scrapped. No weld repairs are allowed.
The only serviceable parts on the (TY3541 or EF0143) accumulator are the seals and the piston. If any
flaws are detected on the accumulator, it must be discarded and accumulator kit (AK4735-002) must be
installed.
If, at any time during truck start up, the low accumulator precharge pressure light illuminates, do not start
the truck. Notify maintenance personnel immediately to correct the problem. If the accumulator is low on
nitrogen gas, determine the source of the leak. If the leak can not be located, perform an ultrasonic
inspection on the accumulator welds and record the results on the form.
AA01044A

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INSPECTION PROCEDURE
1. Remove the piston accumulator from the truck. Follow the instructions in the shop manual for
removal, disassembly, inspection, reassembly, and charging of the accumulators. To avoid unsafe or
improper operation and maintenance, Caution, Warning, Danger, and Alert symbols are included in
this section.
2. Equipment Needed
a. Panamertrics Epoch III Model 2300 Flaw Detector or equivalent.
b. 2.25 MHz, 0.375 inch diameter contact transducer.
c. ASTM E-164 II W Type I calibration block.
d. SonoTech Grade 40 ultrasonic couplant or equivalent.
3. Settings
a. Velocity = 0.2330 inch
b. Angle = 0
c. Thickness = 0
d. Range = 2.0 inch/division
e. 2.5 Pulser = low
4. Calibration
a. Couple the transducer to the 4 inch section of the calibration block.
b. Adjust the gain so that the calibration echoes are clearly visible (100% screen height).
c. Bring the first calibration echo to the four inch division using the zero offset.
d. Couple the transducer to the 1 inch section of the calibration block.
e. Bring the first calibration echo to the 1 inch division using the zero offset.
f. Repeat items 3c and 3e until the unit reads 4 inches and 1 inch without adjustment.
5. Scanning End Plate (TY3536) On The Housing.
a. Set the gain at 60% screen height. This is for reference only.
b. Set the left edge of the gate at 0.50 inch (first division). Set the right edge of the gate at 2.0 inches
(fourth division).
c. Scan from the outer edge of the end plate inward toward the center. Refer to Figure 1. Note that
for the first 0.875 inches, there will be no reflector. The reflector should be beyond the 2.0 inch
range of the display. If a reflector appears within this range, a weld defect has been detected.
Depending on its length, this should be investigated by shear wave per the requirements of the
American Welding Society (AWS D1.1). The next reflector will appear at 1.0 inch for a short distance and then the reflector will jump to 1.50 inches. If an indication appears between these
reflectors, a fatigue crack has been detected, and the accumulator must be discarded. If no indication appears, move the transducer back to the outer edge. Repeat this step for the entire circumference of the end plate.
d. If a crack is detected anywhere on the accumulator, discard the accumulator and install accumulator kit AK4735-002.

AA01044A

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ACCUMULATOR (TY3541 or EF0143) INSPECTION FORM

Date of inspection
Serial number of accumulator
Hours of usage at time of inspection
Truck serial number
Results of inspection
Person performing inspection

Probe

Weld

Depth of
Penetration
22.23 mm
0.875 in.

No Back Reflector
Move the probe
inward to the specified
distance and move it
back out to the edge.
Repeat for the entire
circumference of the cap.

1. End Plate

1 inch Back Reflector

1.5 inch Back Reflector

2. Housing

FIGURE 1. SCANNING LOCATIONS ON THE ACCUMULATOR

AA01044A