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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30141 – A30173) KOMATSU 830E 1AC – PDF DOWNLOAD
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- KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30141 – A30173
- PUBLICATION NUMBER:CEBM020102
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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30141 – A30173) KOMATSU 830E 1AC
KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30141 – A30173) KOMATSU 830E 1AC – PDF DOWNLOAD:
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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30141 – A30173) KOMATSU 830E 1AC
- 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 metric (SI) and U.S. standard 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 135 N·m (100 ft lbs) 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 designatesthe 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. 830E). The three numbers represent the basic truck model. 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.
TABLE OF CONTENTS:
KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30141 – A30173) KOMATSU 830E 1AC
COVER .............................................................................................. 1 FOREWORD .......................................................................................... 5 TABLE OF CONTENTS .................................................................................. 7 SECTION A: GENERAL INFORMATION .................................................................... 9 MAJOR COMPONENT DESCRIPTION..................................................................... 11 Truck And Engine............................................................................ 11 AC Induction Traction Motorized Wheels...................................................... 11 Suspension.................................................................................. 11 Operator's Cab.............................................................................. 11 Power Steering.............................................................................. 11 Dynamic Retarding........................................................................... 11 Brake System................................................................................ 11 SPECIFICATIONS.............................................................................. 13 GENERAL SAFETY AND OPERATING INSTRUCTIONS....................................................... 15 GENERAL SAFETY.............................................................................. 19 Safety Rules............................................................................ 19 Truck Safety Features................................................................... 19 Clothing And Personal Items............................................................. 19 Unauthorized Modification............................................................... 19 Leaving The Operator’s Seat............................................................. 19 Mounting And Dismounting................................................................ 20 Fire Extinguishers And First Aid Kits................................................... 20 Precautions For High Temperature Fluids................................................. 20 Asbestos Dust Hazard Prevention......................................................... 20 Fire Prevention For Fuel And Oil........................................................ 21 ROPS Precautions........................................................................ 21 Preventing Injury From Work Equipment................................................... 21 Precautions For Optional Attachments.................................................... 21 Precautions When Starting The Machine................................................... 21 PRECAUTIONS FOR TRUCK OPERATION............................................................. 22 Safety Is Thinking Ahead................................................................ 22 Safety At The Worksite.................................................................. 22 Fire Prevention......................................................................... 22 Preparing For Operation................................................................. 22 Ventilation For Enclosed Areas.......................................................... 22 Mirrors, Windows, And Lights............................................................ 23 In The Operator’s Cab - Before Starting The Engine...................................... 23 Seat Belts.............................................................................. 23 OPERATING THE TRUCK......................................................................... 23 Starting The Engine..................................................................... 23 Truck Operation - General............................................................... 23 Traveling In The Truck.................................................................. 24 Precautions When Traveling In Reverse................................................... 24 Traveling On Slopes..................................................................... 24 Ensuring Good Visibility................................................................ 25 Operating On Snow....................................................................... 25 Avoid Damage To The Dump Body........................................................... 25 Driving Near High Voltage Cables........................................................ 25 When Loading The Truck.................................................................. 25 When Dumping............................................................................ 25 Working On Loose Ground................................................................. 26 Parking The Machine..................................................................... 26 TOWING...................................................................................... 26 WORKING NEAR BATTERIES...................................................................... 27 Jump Starting With Booster Cables....................................................... 28 Jump Starting With Receptacles.......................................................... 28 PRECAUTIONS FOR MAINTENANCE................................................................. 29 BEFORE PERFORMING MAINTENANCE........................................................... 29 Stopping The Engine Before Service.................................................. 29 Warning Tag......................................................................... 29 Proper Tools........................................................................ 29 Securing The Dump Body.............................................................. 30 WHILE PERFORMING MAINTENANCE............................................................ 31 Personnel........................................................................... 31 Attachments......................................................................... 31 Working Under The Machine........................................................... 31 Keeping The Machine Clean........................................................... 31 Rules To Follow When Adding Fuel Or Oil............................................. 31 Radiator Coolant Level.............................................................. 31 Use Of Lighting..................................................................... 31 Precautions With The Battery........................................................ 32 Handling High Pressure Hoses........................................................ 32 Precautions With High Pressure Oil.................................................. 32 Maintenance Near High Temperatures And High Pressures............................... 32 Rotating Fan And Belts.............................................................. 32 Waste Materials..................................................................... 32 TIRES................................................................................... 33 Handling Tires...................................................................... 33 Tire Maintenance.................................................................... 34 Storing Tires After Removal......................................................... 34 ADDITIONAL JOB SITE RULES................................................................... 35 WHEN REPAIRS ARE NECESSARY.............................................................. 36 Use of Tie-Off Anchor During Maintenance............................................ 36 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK.................................... 37 Preliminary Procedures before Welding or Performing Maintenance..................... 37 Engine Shutdown Procedure before Welding or Performing Maintenance.................. 37 CAPACITOR DISCHARGE SYSTEM.................................................................. 39 Necessary Tools......................................................................... 39 Warnings And Cautions................................................................... 40 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE............................................ 41 Preparation......................................................................... 41 CAPACITOR CHARGE LIGHTS................................................................. 43 FAILURE OF DISCHARGE SYSTEM............................................................. 44 Measuring Dc Voltage On Capacitors.................................................. 44 MANUAL DISCHARGE OF CAPACITORS.......................................................... 45 SHORT ISOLATED CAPACITOR TERMINALS...................................................... 47 OPERATING INSTRUCTIONS...................................................................... 49 PREPARING FOR OPERATION................................................................. 49 Safety Is Thinking Ahead............................................................ 49 WALK AROUND INSPECTION.................................................................. 49 ENGINE START-UP SAFETY PRACTICES........................................................ 53 AFTER ENGINE HAS STARTED................................................................ 54 EMERGENCY STEERING SYSTEM............................................................... 55 Operation........................................................................... 55 Pre-Operation Testing............................................................... 55 Additional Guidelines............................................................... 56 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 56 MACHINE OPERATION ON THE HAUL ROAD...................................................... 57 STARTING ON A GRADE WITH A LOADED TRUCK................................................. 58 PASSING................................................................................. 58 LOADING................................................................................. 58 DUMPING................................................................................. 58 Raising The Dump Body............................................................... 58 Lowering The Dump Body.............................................................. 59 SUDDEN LOSS OF ENGINE POWER............................................................. 61 FUEL DEPLETION.......................................................................... 61 SAFE PARKING PROCEDURES................................................................. 62 NORMAL ENGINE SHUTDOWN PROCEDURE........................................................ 62 DISABLED TRUCK CONNECTORS............................................................... 63 GENERAL............................................................................. 63 STEERING AND BRAKE SYSTEM........................................................... 63 Hookup.......................................................................... 63 HOIST SYSTEM........................................................................ 64 Hookup.......................................................................... 65 Dumping Procedure............................................................... 65 TOWING.............................................................................. 66 Special Wiring Harness.......................................................... 66 Towing Procedure................................................................ 66 RESERVE ENGINE OIL SYSTEM (Optional)................................................ 69 Operation....................................................................... 69 WARNINGS AND CAUTIONS........................................................................... 71 TORQUE TABLES AND CONVERSION CHARTS ............................................................ 83 STORAGE PROCEDURES.............................................................................. 93 STORAGE AND IDLE MACHINE PREPARATION........................................................ 95 SHORT TERM IDLE PERIODS................................................................. 95 PREPARATION FOR STORAGE................................................................. 96 REMOVAL FROM STORAGE.................................................................... 97 RECONDITIONING AN IDLE VEHICLE.......................................................... 99 ENGINE OPERATION........................................................................ 101 AFTER ENGINE HAS STARTED................................................................ 102 ENGINE STORAGE.......................................................................... 103 Engine Storage-(Short Term)......................................................... 103 Engine Storage- (Long Term)......................................................... 104 TRANSMISSION PRESERVATION AND STORAGE................................................... 109 Restoring Transmission to Service................................................... 109 ELECTRIC DRIVE TRUCKS................................................................... 105 SECTION B: STRUCTURES .............................................................................. 111 STRUCTURAL COMPONENTS........................................................................... 113 STRUCTURAL COMPONENTS....................................................................... 115 Preparation............................................................................. 115 LADDERS................................................................................. 116 Removal............................................................................. 116 Installation........................................................................ 116 RIGHT DECK.............................................................................. 116 Removal............................................................................. 116 Installation........................................................................ 118 LEFT DECK............................................................................... 118 Removal............................................................................. 118 Installation........................................................................ 119 CENTER DECK............................................................................. 119 DUMP BODY....................................................................................... 121 DUMP BODY................................................................................... 123 Removal................................................................................. 123 Installation............................................................................ 124 BODY PADS............................................................................... 125 Removal............................................................................. 125 Installation........................................................................ 125 Adjustment.......................................................................... 126 BODY GUIDE.............................................................................. 127 BODY-UP RETENTION CABLE................................................................. 128 BODY POSITION INDICATOR................................................................. 128 HOIST LIMIT SWITCH...................................................................... 128 BODY UP SWITCH.......................................................................... 128 ROCK EJECTORS........................................................................... 129 Inspection.......................................................................... 129 FUEL TANK....................................................................................... 131 FUEL TANK................................................................................... 132 Removal................................................................................. 132 Installation............................................................................ 132 Repair.................................................................................. 134 Cleaning................................................................................ 134 FUEL GAUGE SENDER....................................................................... 134 Removal............................................................................. 134 Installation........................................................................ 134 FUEL TANK BREATHER VALVE................................................................ 135 Disassembly......................................................................... 135 Assembly............................................................................ 135 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 136 SECTION C: ENGINE .................................................................................. 137 POWER MODULE.................................................................................... 139 POWER MODULE................................................................................ 141 PREPARATION............................................................................. 141 Removal............................................................................. 141 Installation........................................................................ 146 COOLING SYSTEM.................................................................................. 151 COOLING SYSTEM DESCRIPTION.................................................................. 153 RADIATOR................................................................................ 154 Removal............................................................................. 154 Installation........................................................................ 157 Radiator Filling Procedure.......................................................... 158 REPAIRING THE RADIATOR.................................................................. 159 Internal Inspection................................................................. 159 External Cleaning................................................................... 159 Disassembly......................................................................... 159 Cleaning and Inspection............................................................. 160 Assembly............................................................................ 160 Pressure Testing.................................................................... 162 COOLANT SYSTEM TROUBLESHOOTING.......................................................... 162 POWER TRAIN..................................................................................... 163 ALTERNATOR REMOVAL PROCEDURE................................................................ 165 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)........................................ 165 ENGINE/ALTERNATOR MATING.................................................................... 167 General Instructions.................................................................... 167 Measuring Procedure..................................................................... 167 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine........................... 169 ENGINE...................................................................................... 170 Removal................................................................................. 170 Service................................................................................. 171 Installation............................................................................ 171 AIR CLEANERS.................................................................................... 173 AIR CLEANERS................................................................................ 175 OPERATION............................................................................... 175 SERVICING THE AIR CLEANERS.............................................................. 175 Replacing The Filter Element........................................................ 176 AIR CLEANER ASSEMBLY CLEANING........................................................... 177 Main Filter Cleaning................................................................ 177 Precleaner Section Cleaning......................................................... 179 AIR INTAKE TROUBLESHOOTING.............................................................. 180 FAN CLUTCH ..................................................................................... 181 FAN CLUTCH.................................................................................. 183 REMOVAL & INSTALLATION TOOLING.......................................................... 183 DISASSEMBLY............................................................................. 186 CLEANING AND INSPECTION................................................................. 196 ASSEMBLY................................................................................ 200 TEST PROCEDURE.......................................................................... 214 SECTION D: 24V DC ELECTRICAL SYSTEM ................................................................ 215 24VDC ELECTRIC SUPPLY SYSTEM.................................................................... 217 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 219 ELECTRICAL SYSTEM DESCRIPTION........................................................... 219 BATTERIES............................................................................... 219 Maintenance and Service............................................................. 219 Troubleshooting..................................................................... 219 BATTERY SUPPLY SYSTEM................................................................... 221 24VDC Battery Charging Alternator................................................... 221 Battery Box......................................................................... 221 Battery Control Box................................................................. 222 Battery Disconnect Switches......................................................... 222 24VDC Auxiliary Battery Receptacles................................................. 222 Isolator Diode...................................................................... 222 Engine Start Relay.................................................................. 222 24VDC to 12VDC Converter............................................................ 222 24 VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE).................................... 223 Operation........................................................................... 223 Pressure Switch..................................................................... 224 Check Valve......................................................................... 224 Timer Solenoid...................................................................... 224 MAINTENANCE............................................................................. 224 Prelube System Operation Checks..................................................... 224 Check Valve......................................................................... 224 Timer Solenoid...................................................................... 224 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.......................................... 225 24 VDC ELECTRIC START SYSTEM............................................................ 227 CRANKING MOTORS..................................................................... 227 Operation....................................................................... 227 Removal......................................................................... 227 Installation.................................................................... 227 CRANKING MOTOR TROUBLESHOOTING...................................................... 228 Preliminary Inspection.......................................................... 228 No-Load Test.................................................................... 228 Interpreting Results of Tests................................................... 229 Disassembly..................................................................... 229 Cleaning and Inspection......................................................... 230 Armature Servicing.............................................................. 232 Field Coil Checks............................................................... 232 Field Coil Removal.............................................................. 232 SOLENOID CHECKS..................................................................... 233 Test............................................................................ 233 Assembly........................................................................ 234 Bearing Replacement:............................................................ 234 Motor Assembly:................................................................. 234 Pinion Clearance................................................................ 235 MAGNETIC SWITCH..................................................................... 235 Removal......................................................................... 235 Installation.................................................................... 235 Coil Test....................................................................... 236 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................. 237 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................................... 239 TRUCK SHUTDOWN PROCEDURE................................................................ 239 BRAKE WARNING BUZZER.................................................................... 239 AUXILIARY CONTROL CABINET COMPONENTS.................................................... 239 Power Distribution Terminals........................................................ 239 Pulse Voltage Modulator (PMV)....................................................... 240 Control Power Relay................................................................. 240 Auto Lube Timer..................................................................... 240 Ground Level Power Relay............................................................ 240 Diode Board - DB1................................................................... 242 Fuse Blocks......................................................................... 243 Alarm Indicating Device (AID) System................................................ 243 Diode Matrix (With Sound)........................................................... 244 Diode Matrix (Without Sound)........................................................ 244 Hot Switch Inverter................................................................. 244 Hot Switch Inverter (Not Used)...................................................... 245 Temperature and Latch............................................................... 245 RELAY BOARDS............................................................................ 246 Relay Boards RB1, RB3, RB4, RB5..................................................... 246 Relay Boards RB6, RB7, RB8, RB9..................................................... 247 Service............................................................................. 247 Relay Board Functions............................................................... 249 BODY-UP SWITCH.......................................................................... 251 Operation........................................................................... 251 Adjustment.......................................................................... 251 Service............................................................................. 251 HOIST LIMIT SWITCH...................................................................... 252 Operation........................................................................... 252 Adjustment.......................................................................... 252 Service............................................................................. 252 FUSE BLOCK CHARTS....................................................................... 253 CIRCUIT BREAKER CHART................................................................... 255 CIRCUIT BREAKERS........................................................................ 255 CHARGING SYSTEM ............................................................................... 257 CHARGING SYSTEM DESCRIPTION................................................................. 259 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION............................................... 259 Excessive heat.......................................................................... 259 Dirt and dust........................................................................... 259 Vibration............................................................................... 259 PREVENTIVE MAINTENANCE PROCEDURES........................................................... 260 Alternator Cleanliness.................................................................. 260 Alternator Mounting..................................................................... 260 Belt Tension And Condition.............................................................. 260 TROUBLESHOOTING PROCEDURES.................................................................. 260 ALTERNATOR PERFORMANCE TEST................................................................. 260 ALTERNATOR PERFORMANCE TEST - LOAD APPLIED.................................................. 261 ALTERNATOR CABLE TEST....................................................................... 261 VOLTAGE REGULATOR ADJUSTMENT................................................................ 262 ALTERNATOR.................................................................................. 263 Removal................................................................................. 263 Installation............................................................................ 264 KOMTRAX Plus SYSTEM ............................................................................ 267 KOMTRAX Plus COMPONENTS..................................................................... 269 KOMTRAX Plus BASIC FEATURES............................................................. 269 Gather Data......................................................................... 269 Convert and Record Data............................................................. 269 Communicate Data to Off-Board Systems............................................... 270 USING THE KOMTRAX Plus SYSTEM........................................................... 271 Turning the KOMTRAX Plus System ON.................................................. 271 Normal KOMTRAX Plus Operation....................................................... 271 Turning the KOMTRAX Plus System OFF................................................. 272 Downloading from the KOMTRAX Plus Controller........................................ 272 KOMTRAX Plus DATA ITEMS................................................................. 273 Fault Codes......................................................................... 273 Machine History..................................................................... 273 KOMTRAX Plus History................................................................ 273 Snapshots........................................................................... 274 Manual Snapshots.................................................................... 274 Trends.............................................................................. 276 Histogram (Load Map) Data........................................................... 276 Haul Cycle Data..................................................................... 277 Alarm and Snapshot Triggers......................................................... 278 Satellite Features.................................................................. 278 KOMTRAX Plus DIAGNOSTIC FEATURES........................................................ 280 Fault History....................................................................... 280 KOMTRAX Plus LED Digits............................................................. 280 KOMTRAX Plus CONTROLLER................................................................. 280 Removal............................................................................. 281 Installation........................................................................ 281 KOMTRAX Plus SOFTWARE................................................................... 283 NECESSARY SOFTWARE.................................................................. 283 NECESSARY TOOLS..................................................................... 283 KOMTRAX Plus SYSTEM SET UP.......................................................... 284 KOMTRAX Plus Controller......................................................... 284 KOMTRAX Plus CONTROLLER............................................................. 284 KOMTRAX Plus TOOL BOX........................................................... 284 Installation................................................................ 284 KOMTRAX Plus SETTING TOOL....................................................... 284 Installation................................................................ 284 KOMTRAX Plus INITIALIZATION PROCEDURE............................................... 285 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE...................................... 285 KOMTRAX Plus Setting Tool software program.................................. 285 Select Operation............................................................ 285 KOMTRAX Plus Setting Function............................................... 286 Machine Information Setting(1).............................................. 286 Machine Information Setting(2).............................................. 286 Date & Time Setting......................................................... 286 GCC Setting................................................................. 287 Setting Summary............................................................. 287 2. KOMTRAX Plus SNAPSHOT PROCEDURE.............................................. 288 3. KOMTRAX Plus DOWNLOAD PROCEDURE.............................................. 289 4. LOCATION OF DOWNLOAD FILES................................................... 289 5. KOMTRAX Plus FTP UPLOAD PROCEDURE............................................ 290 6. KOMTRAX Plus INITIALIZATION FORMS............................................ 291 WHEN REPLACING A KOMTRAX Plus CONTROLLER............................................ 292 To Set: Date & Time; Satellite; Payload Meter................................... 294 Review Setting Information...................................................... 296 KOMTRAX Plus CONTROLLER CHECKOUT................................................ 297 KOMTRAX Plus Controller..................................................... 297 Necessary Equipment:........................................................ 297 Preliminary................................................................. 298 KOMTRAX Plus Controller Checkout Procedure.................................. 299 ORBCOMM CONTROLLER.............................................................. 301 Removal..................................................................... 301 Installation................................................................ 301 INTERFACE MODULE ............................................................................... 303 INTERFACE MODULE............................................................................ 305 Removal................................................................................. 305 Installation............................................................................ 305 SENSORS................................................................................. 306 Temperature Sensors................................................................. 306 Pressure Sensors.................................................................... 306 INTERFACE MODULE SOFTWARE................................................................... 307 NECESSARY SOFTWARE...................................................................... 307 NECESSARY TOOLS......................................................................... 307 FLASHBURN PROGRAM....................................................................... 308 Installation........................................................................ 308 INTERFACE MODULE APPLICATION CODE....................................................... 308 Installation........................................................................ 308 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM................................. 308 Installation........................................................................ 308 Using The Program................................................................... 308 INTERFACE MODULE CHECKOUT............................................................... 309 Interface Module.................................................................... 309 Necessary Equipment:................................................................ 309 Preliminary......................................................................... 310 Checking Inputs And Outputs From The Interface Module............................... 310 Check Analog Inputs To The Interface Module......................................... 314 Check CAN RPC & J1939 Interfaces To The IM.......................................... 314 Check Outputs From The Interface Module............................................. 314 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES ................................ 317 KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING........................... 319 TROUBLESHOOTING......................................................................... 319 GENERAL............................................................................. 319 Structure and Purpose........................................................... 319 TROUBLESHOOTING..................................................................... 320 Communications Networks......................................................... 320 Coaxial Cable................................................................... 320 FAULT CODES......................................................................... 321 Fault History................................................................... 321 KOMTRAX Plus LED Display Fault Codes............................................ 322 Chassis Fault Codes............................................................. 323 Engine Fault Codes.............................................................. 327 FAULT TREE ANALYSIS................................................................. 333 Unable to connect to KOMTRAX Plus from laptop PC................................ 333 Flashing Error Code N4-23 (PLM III Communications Fault)........................ 334 Flashing Error Code N4-22 (Engine Communications Fault)......................... 335 No Data Received By WebCARE..................................................... 336 Coaxial Cable Troubleshooting................................................... 337 KOMTRAX PLUS FORMS ............................................................................ 339 KOMTRAX PLUS FORMS.......................................................................... 341 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 341 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 342 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 343 KOMTRAX PLUS INITIALIZATION FORM........................................................ 345 SECTION E: ELECTRIC PROPULSION SYSTEM .............................................................. 347 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 349 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 351 GENERAL SYSTEM DESCRIPTION.............................................................. 351 SYSTEM COMPONENTS....................................................................... 353 Propulsion System Controller (PSC).................................................. 353 Truck Control Interface (TCI)....................................................... 354 Diagnostic Information Display (DID) Panel.......................................... 355 DID Panel Event Codes............................................................... 355 PSC SOFTWARE FUNCTIONS.................................................................. 374 Input Processing.................................................................... 374 State Machine....................................................................... 374 DC Link State....................................................................... 377 Engine Control...................................................................... 378 ALTERNATOR FIELD CONTROL................................................................ 378 Desired Three-Phase Voltage......................................................... 378 Desired DC Link Voltage............................................................. 378 Self-Load........................................................................... 379 Propel Torque Control............................................................... 379 Retard Torque Control............................................................... 379 Wheel Slide Control................................................................. 380 Resistor Grid Control............................................................... 380 Chopper Voltage Control............................................................. 380 EVENT DETECTION AND PROCESSING.......................................................... 380 Power-On Tests...................................................................... 380 Initiated Tests..................................................................... 381 Periodic Tests...................................................................... 381 EVENT RESTRICTIONS...................................................................... 381 EVENT LOGGING AND STORAGE............................................................... 381 Event History Buffer................................................................ 382 Data Packs.......................................................................... 382 To Record and Save a Data Pack to a Disk............................................ 382 Event Reset......................................................................... 383 SERIAL DATA COMMUNICATIONS.............................................................. 383 PSC - TCI Communications Processing................................................. 383 PSC - PTU Communications Processing................................................. 383 Inverter Communications Processing.................................................. 384 OUTPUT PROCESSING....................................................................... 384 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 384 Fast Start.......................................................................... 384 Engine Shutdown/Engine Not Running.................................................. 384 Limp Home Mode...................................................................... 385 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 386 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 394 Removal............................................................................. 394 Installation........................................................................ 394 Disassembly......................................................................... 394 Assembly............................................................................ 394 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 395 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 397 AC DRIVE SYSTEM MAINTENANCE............................................................. 397 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 398 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 398 SYSTEM CHECKOUT......................................................................... 399 Battery and Control Circuit Checks - Battery Power OFF.............................. 399 Battery and Control Circuit Checks - Battery Power ON............................... 402 Checks with Key Switch OFF.......................................................... 403 Checks with Key Switch ON........................................................... 403 CPU Battery Checks.................................................................. 403 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 404 TCI PROGRAMMING......................................................................... 404 PSC PROGRAMMING......................................................................... 405 INVERTER PROGRAMMING.................................................................... 405 CPU RESET............................................................................... 405 PSC CHECKOUT............................................................................ 406 PSC Digital Input Checks............................................................ 406 PSC Digital Output Checks........................................................... 410 TCI CHECKOUT............................................................................ 411 Modular Mining Communication Port Check............................................. 411 TCI Digital Input Checks............................................................ 411 TCI Digital Output Tests............................................................ 417 CALIBRATIONS............................................................................ 419 Speedometer......................................................................... 419 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 419 ERASING EVENTS.......................................................................... 419 PSC................................................................................. 419 TCI................................................................................. 420 GATE DRIVER POWER CONVERTER TEST........................................................ 420 LOAD TESTING............................................................................ 421 Preparation......................................................................... 421 Alternator Speed Sensor Checks...................................................... 421 Battery Boost Check................................................................. 421 Brake Circuit Switch Checks......................................................... 422 Hoist & Steering Circuit Switch Checks.............................................. 422 Link Energized Checks............................................................... 422 Loadbox Test........................................................................ 424 TROUBLESHOOTING......................................................................... 428 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 428 Phase Module and Chopper Module Troubleshooting..................................... 428 PHASE MODULE REPLACEMENT................................................................ 429 Phase Module Removal................................................................ 429 Phase Module Installation........................................................... 429 SECTION G: DRIVE AXLE, SPINDLE, AND WHEELS ......................................................... 431 TIRES AND RIMS.................................................................................. 433 TIRES AND RIMS.............................................................................. 435 FRONT TIRES AND RIMS.................................................................... 435 Removal............................................................................. 435 Installation........................................................................ 437 REAR TIRES AND RIMS..................................................................... 437 Removal............................................................................. 437 Installation........................................................................ 438 RIM AND TIRE............................................................................ 440 Tire Removal........................................................................ 440 Rim And Tire Preparation............................................................ 440 Lubricants.......................................................................... 441 Tire Installation................................................................... 441 FRONT WHEEL HUB AND SPINDLES.................................................................... 443 FRONT WHEEL HUB AND SPINDLE................................................................. 445 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 445 Removal............................................................................. 445 Spindle Removal Procedure (Optional) (off of the truck)............................. 448 Installation........................................................................ 450 Disassembly......................................................................... 453 Cleaning and Inspection............................................................. 453 Assembly............................................................................ 454 Wheel Bearing Adjustment (Tire Removed)............................................. 456 Wheel Bearing Adjustment (Tire mounted)............................................. 457 OIL SAMPLING PROCEDURE.................................................................. 458 Oil Sampling Guidelines............................................................. 459 Procedure........................................................................... 459 OIL DRAIN AND REFILL PROCEDURE.......................................................... 459 STEERING CYLINDERS...................................................................... 460 Spherical Bearing Wear Limits....................................................... 460 Removal............................................................................. 461 Installation........................................................................ 461 Bearing Replacement (Steering cylinder and tie rod)................................. 461 TIE ROD................................................................................. 463 Removal............................................................................. 463 Installation........................................................................ 463 Disassembly......................................................................... 463 Assembly............................................................................ 464 TOE-IN ADJUSTMENT....................................................................... 465 REAR AXLE HOUSING ATTACHMENT.................................................................... 467 REAR AXLE HOUSING ATTACHMENT................................................................ 469 PIVOT PIN............................................................................... 469 Removal............................................................................. 469 Installation........................................................................ 469 PIVOT EYE BEARING....................................................................... 470 Disassembly......................................................................... 470 Assembly............................................................................ 470 PIVOT EYE REPAIR........................................................................ 471 Removal............................................................................. 471 Installation........................................................................ 471 Disassembly......................................................................... 471 Assembly............................................................................ 471 ANTI-SWAY BAR........................................................................... 472 Removal............................................................................. 472 Installation........................................................................ 472 Disassembly......................................................................... 472 Cleaning and Inspection............................................................. 472 Assembly............................................................................ 472 REAR AXLE HOUSING............................................................................... 473 REAR AXLE HOUSING........................................................................... 475 REAR AXLE HOUSING....................................................................... 475 Removal............................................................................. 475 Installation........................................................................ 475 WHEEL MOTOR............................................................................. 476 Removal............................................................................. 476 Cleaning and Inspection............................................................. 476 Installation........................................................................ 477 WHEEL MOTOR GEAR OIL.................................................................... 480 Change/Filter The Gear case Oil..................................................... 480 Oil................................................................................. 480 Remove And Clean Magnetic Plugs..................................................... 480 Flushing The Gearbox................................................................ 480 Check Gear Case Oil Level........................................................... 480 SECTION H: SUSPENSIONS INDEX....................................................................... 481 FRONT SUSPENSION................................................................................ 483 FRONT SUSPENSION............................................................................ 485 Removal................................................................................. 485 Installation............................................................................ 486 TURN-OF-THE-NUT Tightening Procedure.................................................... 488 Upper Mounting Joint - 60° Advance.................................................. 488 Lower Mounting Joint - 90° Advance.................................................. 490 Inspection.......................................................................... 490 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 491 Bearing Structure Removal........................................................... 491 Bearing Structure Installation...................................................... 491 MAJOR SUSPENSION REBUILD................................................................ 492 Disassembly......................................................................... 492 Assembly............................................................................ 493 PRESSURE TEST........................................................................... 495 REAR SUSPENSIONS ............................................................................... 497 REAR SUSPENSIONS............................................................................ 499 Removal................................................................................. 499 Installation............................................................................ 502 ROD UP SUSPENSION....................................................................... 504 Disassembly......................................................................... 504 Cleaning and Inspection............................................................. 504 Assembly............................................................................ 504 ROD DOWN SUSPENSION..................................................................... 506 Disassembly......................................................................... 506 Cleaning and Inspection............................................................. 506 Assembly............................................................................ 508 PRESSURE TEST........................................................................... 510 Suspension pressure test............................................................ 510 OILING AND CHARGING PROCEDURE................................................................... 511 OILING AND CHARGING PROCEDURE............................................................... 513 GENERAL................................................................................. 513 EQUIPMENT LIST.......................................................................... 513 HYDRAIR® CHARGING KIT................................................................... 514 Installation of Charging Kit........................................................ 514 Removal of Charging Kit............................................................. 514 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 515 FRONT SUSPENSION........................................................................ 515 Front Suspension Oiling............................................................. 515 Front Suspension Nitrogen Charging.................................................. 517 REAR SUSPENSION - ROD UP................................................................ 519 Rear Suspension Oiling (Rod Up Only)................................................ 519 Rear Suspension Nitrogen Charging (Rod Up Only)..................................... 520 REAR SUSPENSION - ROD DOWN.............................................................. 522 Rear Suspension Oiling (Rod Down Only).............................................. 522 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 524 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 526 SECTION J: BRAKE SYSTEM ............................................................................ 527 BRAKE CIRCUIT................................................................................... 529 BRAKE CIRCUIT............................................................................... 531 OPERATION............................................................................... 531 SERVICE BRAKE CIRCUIT OPERATION......................................................... 531 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 533 PARKING BRAKE CIRCUIT................................................................... 533 Normal Operation (key switch on, engine running).................................... 533 BRAKE LOCK CIRCUIT...................................................................... 534 WARNING CIRCUIT......................................................................... 534 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 537 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 539 BRAKE VALVE............................................................................. 539 Rebuild Criteria.................................................................... 539 Removal............................................................................. 539 Installation........................................................................ 541 DISASSEMBLY............................................................................. 543 Cleaning and Inspection............................................................. 545 ASSEMBLY................................................................................ 545 Actuator Base Threaded Inserts...................................................... 545 Boot and Cap........................................................................ 545 Valve Body Seal Installation........................................................ 546 Regulator Sleeve O-Ring Installation................................................ 546 Actuator Plunger O-ring Installation................................................ 547 Assembly of Valve................................................................... 547 VALVE BENCH TEST AND ADJUSTMENT......................................................... 549 Test Set Up Procedure............................................................... 550 Brake Valve Output Pressure Adjustment.............................................. 550 Final Test and Adjustment........................................................... 551 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 552 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 554 Installation of Retard Pedal To Brake Pedal......................................... 554 HYDRAULIC BRAKE ACCUMULATORS............................................................ 555 Brake Accumulator Bleed Down Procedure.............................................. 555 Removal............................................................................. 555 Installation........................................................................ 555 Disassembly......................................................................... 555 Cleaning and Inspection............................................................. 557 Assembly............................................................................ 557 Charging Procedure.................................................................. 559 BRAKE MANIFOLD.......................................................................... 560 Removal............................................................................. 560 Removal............................................................................. 560 Installation........................................................................ 561 Disassembly......................................................................... 561 Cleaning and Inspection............................................................. 562 Assembly............................................................................ 562 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 563 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 565 EQUIPMENT REQUIRED...................................................................... 567 INITIAL SYSTEM SET-UP................................................................... 568 PARKING BRAKE........................................................................... 568 BRAKE SYSTEM CHECK-OUT.................................................................. 569 BRAKE LOCK.............................................................................. 569 FAILURE MODES CHECK-OUT................................................................. 570 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 571 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 574 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 575 FRONT BRAKES.................................................................................... 577 WHEEL SPEED FRONT DISC BRAKES............................................................... 579 BRAKE CALIPER........................................................................... 579 Caliper Removal..................................................................... 579 Installation........................................................................ 580 Disassembly......................................................................... 581 Assembly............................................................................ 581 Cleaning and Inspection............................................................. 582 BRAKE LINING............................................................................ 583 Replacement......................................................................... 583 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................. 585 GENERAL............................................................................. 585 Safety Precautions.............................................................. 585 Front Brake Conditioning........................................................ 585 BRAKE BLEEDING PROCEDURES........................................................... 586 ARMATURE SPEED REAR DISC BRAKES................................................................. 587 ARMATURE SPEED REAR DISC BRAKES............................................................. 589 REAR BRAKES............................................................................. 589 CALIPER AND DISC.................................................................... 589 Removal......................................................................... 589 Installation.................................................................... 591 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 593 BRAKE BLEEDING PROCEDURE............................................................ 594 Service Brake................................................................... 594 Park Brake...................................................................... 594 CALIPER............................................................................. 595 Disassembly..................................................................... 595 PISTON SUBASSEMBLY.................................................................. 598 Disassembly..................................................................... 598 PREPARATION FOR ASSEMBLY............................................................ 599 Clean Parts..................................................................... 599 For Rough Metal Parts........................................................... 600 Dry and Inspect Parts........................................................... 600 Corrosion Protection............................................................ 600 INSPECTION.......................................................................... 600 Caliper Parts................................................................... 600 Shoes, Linings and End Plates................................................... 601 Inspect linings................................................................. 601 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 601 Piston Assembly Adjuster Grip Force............................................. 602 Adjuster Force.................................................................. 604 Piston Return Spring............................................................ 606 ASSEMBLY............................................................................ 607 Adjuster and Pin Assembly....................................................... 607 Piston Subassembly.............................................................. 608 Brake Caliper................................................................... 609 PERIODIC INSPECTIONS................................................................ 615 Shoes, Linings and End Plates................................................... 615 Inspect the following areas for fluid leaks..................................... 615 Dust Boots...................................................................... 615 Brake Disc...................................................................... 615 BRAKE LINING........................................................................ 616 Replacement..................................................................... 616 BRAKE DISC.......................................................................... 616 Inspection...................................................................... 616 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE....................................... 617 GENERAL............................................................................. 617 SAFETY PRECAUTIONS.................................................................. 617 Rear Brake Conditioning......................................................... 618 SECTION L: HYDRAULIC SYSTEM........................................................................ 621 HYDRAULIC SYSTEM................................................................................ 623 HYDRAULIC SYSTEM............................................................................ 625 HYDRAULIC SYSTEM OPERATION.............................................................. 625 COMPONENT DESCRIPTION................................................................... 626 Hoist Pump.......................................................................... 626 Steering/Brake Pump................................................................. 626 Tank................................................................................ 626 High Pressure Hydraulic Filters..................................................... 626 Bleeddown Manifold.................................................................. 626 Steering System Accumulators........................................................ 626 DISABLED TRUCK CONNECTORS............................................................... 628 GENERAL............................................................................. 628 STEERING AND BRAKE SYSTEM........................................................... 628 Hookup.......................................................................... 628 HOIST SYSTEM........................................................................ 629 Hookup.......................................................................... 629 Dumping Procedure............................................................... 629 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 631 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 633 HOIST PUMP.............................................................................. 633 Removal............................................................................. 633 Installation........................................................................ 634 Disassembly......................................................................... 636 Inspection Of Parts................................................................. 639 Assembly............................................................................ 640 HYDRAULIC TANK.......................................................................... 646 Filling Instructions................................................................ 646 Removal............................................................................. 646 Installation........................................................................ 647 HYDRAULIC TANK STRAINERS................................................................ 648 Removal............................................................................. 648 Inspect and Clean................................................................... 648 Installation........................................................................ 649 HYDRAULIC TANK BREATHERS................................................................ 649 HOIST CIRCUIT FILTERS................................................................... 650 FILTER ELEMENT REPLACEMENT.............................................................. 651 Removal............................................................................. 651 Installation........................................................................ 651 INDICATOR SWITCH........................................................................ 651 STEERING CIRCUIT................................................................................ 653 STEERING CIRCUIT............................................................................ 655 STEERING CIRCUIT OPERATION.............................................................. 655 COMPONENT DESCRIPTION................................................................... 656 STEERING CONTROL UNIT............................................................... 656 FLOW AMPLIFIER...................................................................... 656 No Steer........................................................................ 658 Steering Left................................................................... 660 Steering Right.................................................................. 662 No Steer, External Shock Load................................................... 664 BLEED DOWN MANIFOLD................................................................. 666 ACCUMULATORS........................................................................ 667 Low Precharge Warning Switch.................................................... 667 HIGH PRESSURE FILTER................................................................ 667 STEERING/BRAKE PUMP................................................................. 667 Operation....................................................................... 668 PRINCIPLE OF OPERATION.............................................................. 670 Full Pump Volume:............................................................... 670 Half Pump Volume:............................................................... 670 Neutral Position:............................................................... 671 STEERING CIRCUIT COMPONENT REPAIR............................................................... 673 STEERING CIRCUIT COMPONENT REPAIR........................................................... 675 BLEED DOWN MANIFOLD..................................................................... 675 Removal............................................................................. 675 Installation........................................................................ 675 ACCUMULATOR............................................................................. 676 Removal............................................................................. 676 Installation........................................................................ 677 Disassembly......................................................................... 677 Cleaning and Inspection............................................................. 678 Assembly............................................................................ 678 LEAK TESTING............................................................................ 680 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 681 Temperature During Precharge........................................................ 684 ACCUMULATOR STORAGE PROCEDURES.......................................................... 684 Instructions For Storing Bladder Accumulators....................................... 684 Installation........................................................................ 685 Bladder Storage Procedures.......................................................... 685 FLOW AMPLIFIER.......................................................................... 686 Removal............................................................................. 686 Installation........................................................................ 686 Disassembly......................................................................... 688 Reassembly.......................................................................... 689 STEERING CONTROL UNIT................................................................... 690 Removal............................................................................. 690 Spline Inspection................................................................... 690 Installation........................................................................ 691 Disassembly......................................................................... 691 Cleaning and Inspection............................................................. 692 Assembly............................................................................ 693 STEERING CYLINDER....................................................................... 697 Disassembly......................................................................... 697 Inspection and Cleaning............................................................. 697 Assembly............................................................................ 697 STEERING CIRCUIT FILTER................................................................. 698 Filter Element Replacement.......................................................... 698 Removal............................................................................. 699 Installation........................................................................ 699 Indicator Switch.................................................................... 699 STEERING AND BRAKE PUMP................................................................. 700 Removal............................................................................. 700 Installation........................................................................ 701 Disassembly......................................................................... 702 Control Piston Group................................................................ 702 Valve Plate Group................................................................... 703 Rotating Group...................................................................... 703 Swashblock Group.................................................................... 704 Driveshaft Group.................................................................... 704 INSPECTION.............................................................................. 704 Control Piston Group................................................................ 704 Valve Plate Group................................................................... 704 Rotating Group...................................................................... 704 Swashblock Group.................................................................... 708 Driveshaft Group.................................................................... 708 Compensator Block and Unloader Module............................................... 708 Stroke Adjuster Assembly............................................................ 708 ASSEMBLY................................................................................ 708 Swashblock Group.................................................................... 708 Control Piston Group................................................................ 710 Valve Plate Group................................................................... 711 HOIST CIRCUIT................................................................................... 713 HOIST CIRCUIT............................................................................... 715 HOIST CIRCUIT OPERATION................................................................. 715 COMPONENT DESCRIPTION................................................................... 716 Hydraulic Tank...................................................................... 716 Hoist Pump.......................................................................... 716 High Pressure Filters............................................................... 716 Hoist Valve......................................................................... 717 Hoist Pilot Valve................................................................... 718 Hoist-up Limit Solenoid............................................................. 718 Pilot Operated Check Valve.......................................................... 718 Counterbalance Valve Manifold....................................................... 719 HOIST SYSTEM OPERATION MODES............................................................ 720 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 720 Power Up Operation (Figure 7-7)..................................................... 722 Hold Operation (Figure 7-8)......................................................... 724 Power Down Operation (Figure 7-9)................................................... 726 Float Operation (Figure 7-10)....................................................... 728 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 731 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 733 HOIST VALVE............................................................................. 733 Removal............................................................................. 733 Installation........................................................................ 733 O-Ring Replacement.................................................................. 734 INLET SECTION........................................................................... 735 Disassembly......................................................................... 735 Cleaning and Inspection............................................................. 736 Assembly............................................................................ 736 SPOOL SECTION........................................................................... 736 Disassembly......................................................................... 736 Cleaning and Inspection............................................................. 739 Assembly............................................................................ 739 HOIST PILOT VALVE....................................................................... 740 Removal............................................................................. 740 Installation........................................................................ 740 Disassembly......................................................................... 741 Cleaning and Inspection............................................................. 742 Assembly............................................................................ 743 BODY UP LIMIT SOLENOID.................................................................. 744 PILOT OPERATED CHECK VALVE.............................................................. 744 HOIST CYLINDERS......................................................................... 744 Removal............................................................................. 744 Installation........................................................................ 745 Disassembly......................................................................... 746 Cleaning and Inspection............................................................. 748 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 749 Quill Installation.................................................................. 749 Installation of Check Balls and Plugs in Quill...................................... 750 Assembly of Cylinder................................................................ 751 Assembly of Cylinder................................................................ 751 Pressure Testing.................................................................... 752 OVERCENTER MANIFOLD..................................................................... 753 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 755 HYDRAULIC CHECKOUT PROCEDURE................................................................ 757 STEERING AND BRAKE PUMP................................................................. 757 Pressure Check And Adjustment Procedure............................................. 757 BLEEDDOWN MANIFOLD...................................................................... 759 SHOCK & SUCTION VALVES.................................................................. 759 Shock & Suction Valve Settings...................................................... 759 LEAKAGE TESTS........................................................................... 761 Steering Control Unit & Flow Amplifier.............................................. 761 Bleeddown Manifold.................................................................. 761 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 763 LOW STEERING PRESSURE SWITCH............................................................ 763 CHECKING HOIST SYSTEM PRESSURES......................................................... 770 Hoist System Relief Pressure Adjustment............................................. 770 Power Down Relief Pressure Adjustment............................................... 771 HOIST COUNTERBALANCE VALVE.......................................................... 772 Preparation:.................................................................... 772 Counterbalance Valve Pressure Check Only:....................................... 772 Counterbalance Valve Adjustment................................................. 773 HYDRAULIC SYSTEM FLUSHING PROCEDURE..................................................... 776 Hydraulic System Flushing Procedure................................................. 776 OIL CLEANLINESS CHECK............................................................... 781 SECTION M: OPTIONS AND SPECIAL TOOLS ............................................................... 783 HEATER OPTIONS ................................................................................. 785 GENERAL INFORMATION......................................................................... 787 TROUBLESHOOTING............................................................................. 787 HEATER ELEMENT.............................................................................. 787 Removal................................................................................. 787 Installation............................................................................ 788 GENERAL..................................................................................... 789 Maintenance............................................................................. 789 HEATING ELEMENT............................................................................. 790 Removal................................................................................. 790 Installation............................................................................ 790 THERMOSTAT.................................................................................. 790 Removal................................................................................. 790 Installation............................................................................ 790 GENERAL INFORMATION......................................................................... 791 TROUBLESHOOTING............................................................................. 791 HEATER ELEMENT.............................................................................. 791 Removal................................................................................. 791 Installation............................................................................ 792 SPECIAL TOOLS................................................................................... 793 NITROGEN CHARGING VALVE..................................................................... 793 ROLL-OUT ASSEMBLY........................................................................... 793 EYE BOLT.................................................................................... 793 OFFSET WRENCH............................................................................... 794 TORQUE ADAPTER.............................................................................. 794 HANDLE...................................................................................... 794 SEAL INSTALLER.............................................................................. 794 SLEEVE ALIGNMENT TOOLS...................................................................... 795 QUICK DISCONNECT COUPLING................................................................... 795 HARNESS..................................................................................... 795 SEAL INSTALLATION RING...................................................................... 795 BELT TENSION TESTER......................................................................... 796 BELT ALIGNMENT TOOL......................................................................... 796 SOCKETS AND ADAPTERS........................................................................ 796 DUST CAPS................................................................................... 796 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 797 PAYLOAD DATA MANAGER........................................................................ 797 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 797 MISCELLANEOUS SERVICE TOOLS................................................................. 798 BRAKE PISTON TOOL........................................................................... 799 HIGH VOLTAGE TOOLS.......................................................................... 802 2000 VDC METER.............................................................................. 802 GROUNDING STICKS............................................................................ 802 BODY PAD SPACER TOOL........................................................................ 803 RADIATOR SHUTTERS ............................................................................. 805 RADIATOR SHUTTERS........................................................................... 807 OPERATION............................................................................... 807 Hydraulic Circuit................................................................... 807 Electrical Circuit:................................................................. 808 MAINTENANCE AND REPAIR.................................................................. 808 TROUBLESHOOTING......................................................................... 809 Hydraulic Troubleshooting........................................................... 812 Electrical Troubleshooting.......................................................... 814 PAYLOAD METER III ™ ........................................................................... 815 OPERATION SECTION........................................................................... 819 Introduction............................................................................ 819 Data Summary........................................................................ 819 Data Gathering...................................................................... 819 COMPONENT DESCRIPTION................................................................... 820 System Diagram...................................................................... 820 Suspension Pressure Sensors......................................................... 820 Inclinometer........................................................................ 820 Operator Display.................................................................... 820 Operator Switch..................................................................... 821 Speed Input......................................................................... 821 Body-Up Switch...................................................................... 821 Brake Lock Switch................................................................... 821 Payload Meter....................................................................... 821 Communications Ports................................................................ 821 Key Switch Input.................................................................... 822 Payload Meter Power................................................................. 822 Load Lights......................................................................... 822 Wiring and Termination.............................................................. 823 TCI Outputs......................................................................... 823 OPERATOR’S DISPLAY AND SWITCH........................................................... 824 Reading the Speedometer............................................................. 824 Reading the Load Display............................................................ 824 Using the Operator ID............................................................... 824 Using the Load and Ton Counter...................................................... 824 Total Ton Counter................................................................... 824 Total Load Counter.................................................................. 825 Clearing the Counters............................................................... 825 Viewing Live Sensor Data............................................................ 825 Other Display Messages.............................................................. 825 PAYLOAD OPERATION & CALCULATION......................................................... 826 Description of Haul Cycle States.................................................... 826 Haul Cycle Description.............................................................. 826 Load Calculation.................................................................... 827 Carry Back.......................................................................... 827 Measurement Accuracy................................................................ 827 SOURCES FOR PAYLOAD ERROR............................................................... 827 Payload Error....................................................................... 827 Loading Conditions.................................................................. 828 Pressure Sensors.................................................................... 828 Swingloads.......................................................................... 828 Speed and Distance.................................................................. 828 HAUL CYCLE DATA......................................................................... 828 Haul Cycle Warning Flags............................................................ 830 Frame Torque Data................................................................... 831 Sprung Weight Data.................................................................. 831 Maximum Speed Data.................................................................. 831 Alarm Records....................................................................... 831 Fault Code Data..................................................................... 832 PC SOFTWARE OVERVIEW.................................................................... 833 System Configuration................................................................ 833 Installing the PLMIII Software...................................................... 833 DOWNLOADING DATA........................................................................ 834 PLM III SYSTEM CONFIGURATION............................................................ 835 Starting Communications............................................................. 835 Displayed Payload Units............................................................. 835 Time Units.......................................................................... 835 Connection Menu..................................................................... 835 Connecting to the Payload Meter..................................................... 836 Configure the Payload Meter......................................................... 836 Setting the Date and Time........................................................... 836 Setting the Truck Type.............................................................. 837 Setting the Gauge Display Units..................................................... 837 Setting the Frame Serial Number..................................................... 837 Setting the Truck Number............................................................ 837 Setting the Komatsu Distributor..................................................... 837 Setting the Komatsu Customer........................................................ 837 Clean Truck Tare.................................................................... 838 Inclinometer Calibration............................................................ 838 DATA ANALYSIS........................................................................... 839 Creating a Query.................................................................... 839 Sorting on Truck Unit Number........................................................ 839 Sorting on Truck Type............................................................... 839 Sorting on Date Range............................................................... 840 Sorting on Time Range............................................................... 840 Payload Detail Screen............................................................... 841 Creating Reports.................................................................... 841 Summary - one page report........................................................... 842 Detailed - multi-page report........................................................ 842 Creating Graphs..................................................................... 843 Exporting Data...................................................................... 843 CSV Export.......................................................................... 843 Compressed.......................................................................... 844 Importing Data...................................................................... 845 Deleting Haul Cycle Records......................................................... 845 Viewing Alarms...................................................................... 846 Deleting Alarm Records.............................................................. 846 TROUBLESHOOTING SECTION..................................................................... 847 TROUBLESHOOTING......................................................................... 847 Viewing Active Alarms............................................................... 847 Real-Time Data Display.............................................................. 847 Testing the Payload Lights.......................................................... 847 Creating Log Files of Inputs........................................................ 848 Daily Inspections................................................................... 848 Periodic Maintenance................................................................ 848 Abnormal Displays at Power-Up....................................................... 849 No Payload Display When Key Switch is Turned ON..................................... 850 No Display on Speedometer........................................................... 851 No Display on Operator Display...................................................... 851 No Communications With PC........................................................... 852 Load Lights Don’t Light During Loading.............................................. 853 Load Lights Remain ON............................................................... 854 Load Lights Remain ON During Dumping................................................ 854 Display Doesn't Clear When The Load Is Dumped....................................... 854 Calibration Problems................................................................ 855 Alarm 1 - Left Front Pressure High.................................................. 856 Alarm 2 - Left Front Pressure Low................................................... 856 Troubleshoot Wiring to Left Front Suspension........................................ 856 Alarm 3 - Right Front Pressure High................................................. 857 Alarm 4 - Right Front Pressure Low.................................................. 857 Troubleshoot Wiring to Right Front Suspension....................................... 857 Alarm 5 -Left Rear Pressure High.................................................... 858 Alarm 6 - Left Rear Pressure Low.................................................... 858 Troubleshoot Wiring to Left Rear Suspension......................................... 858 Alarm 7 - Right Rear Pressure High.................................................. 859 Alarm 8 - Right Rear Pressure Low................................................... 859 Troubleshoot Wiring to Right Rear Suspension........................................ 859 Alarm 9 - Inclinometer High......................................................... 860 Alarm 10 - Inclinometer Low......................................................... 860 Troubleshoot Inclinometer Wiring.................................................... 860 Alarm 13 - Body Up Input Failure.................................................... 861 Alarm 16 - Memory Write Failure..................................................... 862 Alarm 17 - Memory Read Failure...................................................... 862 Alarm 18............................................................................ 863 Alarm 19............................................................................ 863 Alarm 22............................................................................ 863 Operator Switch Doesn't Work........................................................ 864 Alarm 26 - User Switch Fault - SELECT............................................... 864 Alarm 27 - User Switch Fault - SET.................................................. 864 Connector Map....................................................................... 865 Connectors.......................................................................... 866 PLMIII CHECK OUT PROCEDURE.................................................................. 867 General Description..................................................................... 867 Tools Required.......................................................................... 867 Checkout Procedure...................................................................... 867 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 871 Flashburn Programming............................................................... 871 Confirmation Checklist.............................................................. 873 SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX..................................................... 875 RESERVE ENGINE OIL SYSTEM................................................................... 877 Operation............................................................................... 878 LED Monitor Light....................................................................... 878 Tank Fill Control (Optional)............................................................ 879 Filling Procedure (Remote Fill Feature)................................................. 879 SERVICE................................................................................. 880 Every 10 Hours, or once each shift:................................................. 880 Every 500 Hours..................................................................... 880 Changing Oil........................................................................ 880 TROUBLESHOOTING......................................................................... 881 Circuit Fuse........................................................................ 881 SYSTEM ELECTRICAL SCHEMATICS............................................................ 882 SECTION N: OPERATOR CAB ............................................................................ 883 TRUCK CAB AND COMPONENTS........................................................................ 885 TRUCK CAB AND COMPONENTS.................................................................... 887 TRUCK CAB............................................................................... 887 Description......................................................................... 887 Removal............................................................................. 888 Installation........................................................................ 889 CAB DOOR................................................................................ 890 Removal............................................................................. 890 Installation........................................................................ 890 Door Adjustment..................................................................... 890 Door Jamb Bolt Adjustment........................................................... 891 Door Handle Plunger Adjustment...................................................... 892 Replace Door Glass.................................................................. 893 Replace Door Window Regulator....................................................... 897 Replacing the Door Handle or Latch Assembly......................................... 898 Replacing the Door and Door Hinge Seal.............................................. 898 Removing the Door Opening Seal...................................................... 899 Installation........................................................................ 899 GLASS REPLACEMENT....................................................................... 900 Adhesive-bonded Windows............................................................. 900 Replacement Procedure............................................................... 900 WINDSHIELD & REAR GLASS................................................................. 902 Removal............................................................................. 902 Installation........................................................................ 902 CAB COMPONENTS ................................................................................ 905 CAB COMPONENTS.............................................................................. 907 WINDSHIELD WIPERS....................................................................... 907 WIPER MOTOR......................................................................... 907 Removal......................................................................... 907 Installation.................................................................... 907 WIPER ARM........................................................................... 907 Removal......................................................................... 907 Installation.................................................................... 908 WIPER LINKAGE....................................................................... 908 Removal......................................................................... 908 Installation.................................................................... 908 WINDSHIELD WASHER....................................................................... 909 Operation........................................................................... 909 Service............................................................................. 909 OPERATOR SEAT........................................................................... 910 Seat Belts.......................................................................... 910 Adjustment.......................................................................... 910 Inspection.......................................................................... 911 Removal............................................................................. 911 Installation........................................................................ 911 PASSENGER SEAT.......................................................................... 912 Inspection.......................................................................... 912 Removal............................................................................. 912 Installation........................................................................ 912 OPERATOR COMFORT................................................................................ 913 OPERATOR COMFORT............................................................................ 915 HEATER / AIR CONDITIONER................................................................ 915 Operation........................................................................... 915 Fan Control Knob.................................................................... 915 Temperature Control Knob............................................................ 915 Directional Control Knob............................................................ 915 Heater Vents........................................................................ 915 COMPONENTS.............................................................................. 916 Circuit Breakers.................................................................... 916 Relays.............................................................................. 916 Heater Core......................................................................... 916 Fan Motor And Speed Control......................................................... 917 Actuators........................................................................... 917 Cab Air Filter...................................................................... 917 ENVIRONMENTAL IMPACT OF AIR CONDITIONING................................................ 920 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 920 PRINCIPLES OF REFRIGERATION............................................................. 920 Air Conditioning.................................................................... 920 Refrigeration - The Act Of Cooling.................................................. 921 The Refrigeration Cycle............................................................. 921 AIR CONDITIONER SYSTEM COMPONENTS....................................................... 922 Compressor (Refrigerant Pump)....................................................... 922 Service Valves...................................................................... 922 Condenser........................................................................... 922 Receiver-Drier...................................................................... 922 Expansion Block Valve............................................................... 923 Accumulator......................................................................... 923 Evaporator.......................................................................... 923 ELECTRICAL CIRCUIT...................................................................... 924 Thermostat.......................................................................... 924 Compressor Clutch................................................................... 924 Trinary™ Switch..................................................................... 925 SYSTEM SERVICING........................................................................ 926 SERVICE TOOLS AND EQUIPMENT............................................................. 927 Recovery/Recycle Station............................................................ 927 Leak Detector....................................................................... 927 Service Valves...................................................................... 928 Vacuum Pump......................................................................... 928 Manifold Gauge Set.................................................................. 929 Installing Manifold Gauge Set....................................................... 930 Purging Air From Service Hoses...................................................... 930 SYSTEM PERFORMANCE TEST................................................................. 931 SYSTEM OIL.............................................................................. 932 Handling and Reusing PAG Oil........................................................ 932 Oil Quantity........................................................................ 932 Checking System Oil................................................................. 932 REFRIGERANT............................................................................. 933 Recycled Refrigerant................................................................ 933 Reclaimed Refrigerant............................................................... 933 Refrigerant Quantity................................................................ 933 R-134a Refrigerant Containers....................................................... 934 SYSTEM LEAK TESTING..................................................................... 934 Electronic Leak Detector............................................................ 935 Tracer Dyes......................................................................... 935 Soap and Water...................................................................... 935 RECOVERING AND RECYCLING THE REFRIGERANT................................................ 935 Performing the Recovery Cycle....................................................... 935 Performing the Recycling Procedure.................................................. 936 Evacuating and Charging the A/C System.............................................. 936 SYSTEM REPAIR........................................................................... 936 System Flushing..................................................................... 937 A/C DRIVE BELT CHECKOUT PROCEDURE....................................................... 938 Pulley Alignment.................................................................... 938 Belt Tension Check.................................................................. 938 COMPONENT REPLACEMENT................................................................... 940 Hoses and Fittings.................................................................. 940 Lines............................................................................... 940 Expansion Valve..................................................................... 940 Receiver-Drier...................................................................... 940 Thermostat.......................................................................... 940 Compressor.......................................................................... 941 Accumulator......................................................................... 941 Clutch.............................................................................. 941 Servicing the Compressor Clutch..................................................... 942 Pulley Removal...................................................................... 944 Clutch Coil Check................................................................... 945 Pulley Installation................................................................. 945 Clutch Assembly Installation........................................................ 945 EVACUATING THE SYSTEM................................................................... 947 CHARGING THE A/C SYSTEM................................................................. 949 TROUBLESHOOTING......................................................................... 950 Preliminary Checks.................................................................. 950 Diagnosis Of Gauge Readings And System Performance.................................. 950 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.......................................... 951 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.......................................... 957 OPERATOR CAB CONTROLS........................................................................... 959 OPERATOR CAB AND CONTROLS................................................................... 961 STEERING WHEEL AND CONTROLS............................................................. 962 Horn Button......................................................................... 962 Tilt / Telescope Lever.............................................................. 962 Multi-Function Turn Signal Switch................................................... 962 STEERING COLUMN......................................................................... 963 Removal............................................................................. 963 Steering Column Inspection.......................................................... 963 Installation........................................................................ 963 STEERING WHEEL.......................................................................... 964 Removal............................................................................. 964 Installation........................................................................ 964 PEDALS.................................................................................. 966 Service Brake Pedal................................................................. 966 Dynamic Retarding................................................................... 966 Dynamic Retard Pedal................................................................ 966 Throttle/Accelerator Pedal.......................................................... 966 GRADE/SPEED RETARD CHART................................................................ 967 OVERHEAD PANEL AND DISPLAYS............................................................. 968 CENTER CONSOLE.......................................................................... 969 Directional Control Lever........................................................... 969 Override/Fault Reset Switch......................................................... 970 Engine Stop Switch.................................................................. 970 L.H. Window Control Switch.......................................................... 970 R.H. Window Control Switch.......................................................... 970 Hoist Control Lever................................................................. 970 Raising The Dump Body............................................................... 970 Lowering The Dump Body.............................................................. 970 Retard Speed Control (RSC) Adjust Dial.............................................. 971 Retard Speed Control (RSC) Switch................................................... 971 Data Store Button................................................................... 972 KOMTRAX Plus Snapshot In Progress Light............................................. 972 Link Energized Light................................................................ 972 Service Engine Light................................................................ 972 DIAGNOSTIC PORTS.................................................................... 972 KOMTRAX Plus Diagnostic Port........................................................ 972 Interface Module (IM) Diagnostic Port............................................... 972 Payload Meter Diagnostic Port....................................................... 972 Truck Control Interface (TCI) Diagnostic Port....................................... 972 Propulsion System Controller (PSC) Diagnostic Port.................................. 972 Engine Diagnostic Port (CENSE)...................................................... 972 Engine Diagnostic Port (QUANTUM).................................................... 972 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 973 Fan Control Knob.................................................................... 973 Temperature Control Knob............................................................ 973 Directional Control Knob............................................................ 973 Heater Vents........................................................................ 973 INSTRUMENT PANEL........................................................................ 974 Key Switch.......................................................................... 976 Starting............................................................................ 976 Air Conditioner Compressor Switch................................................... 976 Rotating Beacon Light Switch (Optional)............................................. 976 Heated Mirror Switch (Optional)..................................................... 976 Rest Switch......................................................................... 977 Wheel Brake Lock Control............................................................ 977 Hazard Warning Lights............................................................... 977 Cab/Air Conditioner Vents........................................................... 978 Engine Oil Pressure Gauge........................................................... 978 Right Turn Signal Indicator......................................................... 978 Tachometer.......................................................................... 978 High Beam Indicator................................................................. 978 Speedometer/Payload Meter Display................................................... 978 Left Turn Signal Indicator.......................................................... 978 Water Temperature Gauge............................................................. 978 Lamp Test Switch.................................................................... 979 Light Switch........................................................................ 979 Ladder Light Switch................................................................. 979 Manual Backup Switch................................................................ 979 Fog Lights (Optional)............................................................... 979 Payload Meter Switch................................................................ 979 Panel Light Dimmer.................................................................. 980 Hydraulic Oil Temperature Gauge..................................................... 980 Hourmeter........................................................................... 980 Fuel Level Gauge.................................................................... 980 OVERHEAD STATUS / WARNING INDICATORS.................................................... 981 Status / Warning Indicator Light Symbols............................................ 982 KOMTRAX Plus............................................................................ 988 Operation........................................................................... 988 Interface Module.................................................................... 989 Basic Precautions................................................................... 989 SECTION P: LUBRICATION AND SERVICE ................................................................. 991 LUBRICATION AND SERVICE......................................................................... 993 LUBRICATION AND SERVICE..................................................................... 995 GENERAL................................................................................. 995 830E SERVICE CAPACITIES................................................................. 995 HYDRAULIC TANK SERVICE.................................................................. 995 Adding Oil.......................................................................... 995 COOLING SYSTEM SERVICE.................................................................. 996 Radiator Filling Procedure.......................................................... 996 Coolant Specifications.............................................................. 996 Unacceptable Practices.............................................................. 996 WHEEL MOTOR SERVICE..................................................................... 996 RESERVE ENGINE OIL SYSTEM (Optional).................................................... 997 Reserve Oil Tank Filling Procedure (Remote fill).................................... 997 Inline Screen....................................................................... 997 QUICK FILL SERVICE CENTER............................................................... 998 LUBRICATION CHART....................................................................... 999 10 HOUR (DAILY) INSPECTION..............................................................1000 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................1003 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................1004 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1005 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1009 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................1011 2500 HOUR MAINTENANCE CHECKS............................................................1012 5000 HOUR MAINTENANCE CHECKS............................................................1012 AUTOMATIC LUBRICATION SYSTEM....................................................................1013 AUTOMATIC LUBRICATION SYSTEM................................................................1015 GENERAL DESCRIPTION.....................................................................1015 SYSTEM COMPONENTS.......................................................................1017 Filter..............................................................................1017 Hydraulic Motor and Pump............................................................1017 Grease Reservoir....................................................................1017 Pressure Reducing Valve.............................................................1017 Flow Control Valve..................................................................1017 Solenoid Valve......................................................................1017 Vent Valve..........................................................................1017 Lubrication Cycle Timer.............................................................1017 Over Pressure Cut Off Switch........................................................1017 Grease Pressure Failure Switch......................................................1017 Injectors...........................................................................1017 Relief Valve........................................................................1017 SYSTEM OPERATION........................................................................1018 Normal Operation....................................................................1018 Required Lubricant..................................................................1019 System Priming......................................................................1019 Filter Assembly.....................................................................1019 LUBRICANT PUMP..........................................................................1020 Pump Housing Oil Level..............................................................1020 Pump Pressure Control...............................................................1020 INJECTORS (SL-1 Series “H”).............................................................1021 Injector Specifications.............................................................1021 Injector Adjustment.................................................................1021 INJECTOR OPERATION......................................................................1022 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1023 Daily Lubrication System Inspection.................................................1023 250 Hour Inspection.................................................................1023 1000 Hour Inspection................................................................1023 SYSTEM CHECKOUT.........................................................................1024 Lubrication Controller Check........................................................1024 Lubrication Controller Operation....................................................1024 Lubrication Controller Components...................................................1024 Lubrication Controller Adjustment...................................................1024 SYSTEM TROUBLESHOOTING CHART............................................................1026 SECTION Q: A;PHABETICAL INDEX ......................................................................1029 SECTION R: SYSTEM SCHEMATICS .......................................................................1033 HH360 Hydraulic Schematic - Brake System .......................................................1035 HH366 Hydraulic Schematic - Steering & Hoist ...................................................1036 HE484 Electrical Schematic - Heater A/C Controls ...............................................1038 XS5100 Electrical System Schematic .............................................................1039
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1 review for KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30141 – A30173) KOMATSU 830E 1AC – PDF DOWNLOAD
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G Kayden –
The file I downloaded will not download completely. The transfer rate is extremely slow.