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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30174 – A30209) KOMATSU 830E 1AC – PDF DOWNLOAD
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- KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30174 – A30209
- PUBLICATION NUMBER:CEBM020403
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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30174 – A30209) KOMATSU 830E 1AC
KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30174 – A30209) KOMATSU 830E 1AC – PDF DOWNLOAD:
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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30174 – A30209) KOMATSU 830E 1AC
- This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing 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 component has a section in the shop manual. Disassembly of any component should only be done 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 in metric units and in U.S. English units. 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 for common fasteners are shown in torque charts in the general information section. Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive 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 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). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30174 – A30209) 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 KOMTRAX Plus SYSTEM ............................................................................ 257 KOMTRAX Plus COMPONENTS..................................................................... 259 KOMTRAX Plus BASIC FEATURES............................................................. 259 Gather Data......................................................................... 259 Convert and Record Data............................................................. 259 Communicate Data to Off-Board Systems............................................... 260 USING THE KOMTRAX Plus SYSTEM........................................................... 261 Turning the KOMTRAX Plus System ON.................................................. 261 Normal KOMTRAX Plus Operation....................................................... 261 Turning the KOMTRAX Plus System OFF................................................. 262 Downloading from the KOMTRAX Plus Controller........................................ 262 KOMTRAX Plus DATA ITEMS................................................................. 263 Fault Codes......................................................................... 263 Machine History..................................................................... 263 KOMTRAX Plus History................................................................ 263 Snapshots........................................................................... 264 Manual Snapshots.................................................................... 264 Trends.............................................................................. 266 Histogram (Load Map) Data........................................................... 266 Haul Cycle Data..................................................................... 267 Alarm and Snapshot Triggers......................................................... 268 Satellite Features.................................................................. 268 KOMTRAX Plus DIAGNOSTIC FEATURES........................................................ 270 Fault History....................................................................... 270 KOMTRAX Plus LED Digits............................................................. 270 KOMTRAX Plus CONTROLLER................................................................. 270 Removal............................................................................. 271 Installation........................................................................ 271 KOMTRAX Plus SOFTWARE................................................................... 273 NECESSARY SOFTWARE.................................................................. 273 NECESSARY TOOLS..................................................................... 273 KOMTRAX Plus SYSTEM SET UP.......................................................... 274 KOMTRAX Plus Controller......................................................... 274 KOMTRAX Plus CONTROLLER............................................................. 274 KOMTRAX Plus TOOL BOX........................................................... 274 Installation................................................................ 274 KOMTRAX Plus SETTING TOOL....................................................... 274 Installation................................................................ 274 KOMTRAX Plus INITIALIZATION PROCEDURE............................................... 275 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE...................................... 275 KOMTRAX Plus Setting Tool software program.................................. 275 Select Operation............................................................ 275 KOMTRAX Plus Setting Function............................................... 276 Machine Information Setting(1).............................................. 276 Machine Information Setting(2).............................................. 276 Date & Time Setting......................................................... 276 GCC Setting................................................................. 277 Setting Summary............................................................. 277 2. KOMTRAX Plus SNAPSHOT PROCEDURE.............................................. 278 3. KOMTRAX Plus DOWNLOAD PROCEDURE.............................................. 279 4. LOCATION OF DOWNLOAD FILES................................................... 279 5. KOMTRAX Plus FTP UPLOAD PROCEDURE............................................ 280 6. KOMTRAX Plus INITIALIZATION FORMS............................................ 281 WHEN REPLACING A KOMTRAX Plus CONTROLLER............................................ 282 To Set: Date & Time; Satellite; Payload Meter................................... 284 Review Setting Information...................................................... 286 KOMTRAX Plus CONTROLLER CHECKOUT................................................ 287 KOMTRAX Plus Controller..................................................... 287 Necessary Equipment:........................................................ 287 Preliminary................................................................. 288 KOMTRAX Plus Controller Checkout Procedure.................................. 289 ORBCOMM CONTROLLER.............................................................. 291 Removal..................................................................... 291 Installation................................................................ 291 INTERFACE MODULE ............................................................................... 293 INTERFACE MODULE............................................................................ 295 Removal................................................................................. 295 Installation............................................................................ 295 SENSORS................................................................................. 296 Temperature Sensors................................................................. 296 Pressure Sensors.................................................................... 296 INTERFACE MODULE SOFTWARE................................................................... 297 NECESSARY SOFTWARE...................................................................... 297 NECESSARY TOOLS......................................................................... 297 FLASHBURN PROGRAM....................................................................... 298 Installation........................................................................ 298 INTERFACE MODULE APPLICATION CODE....................................................... 298 Installation........................................................................ 298 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM................................. 298 Installation........................................................................ 298 Using The Program................................................................... 298 INTERFACE MODULE CHECKOUT............................................................... 299 Interface Module.................................................................... 299 Necessary Equipment:................................................................ 299 Preliminary......................................................................... 300 Checking Inputs And Outputs From The Interface Module............................... 300 Check Analog Inputs To The Interface Module......................................... 304 Check CAN RPC & J1939 Interfaces To The IM.......................................... 304 Check Outputs From The Interface Module............................................. 304 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES ................................ 307 KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING........................... 309 TROUBLESHOOTING......................................................................... 309 GENERAL............................................................................. 309 Structure and Purpose........................................................... 309 TROUBLESHOOTING..................................................................... 310 Communications Networks......................................................... 310 Coaxial Cable................................................................... 310 FAULT CODES......................................................................... 311 Fault History................................................................... 311 KOMTRAX Plus LED Display Fault Codes............................................ 312 Chassis Fault Codes............................................................. 313 Engine Fault Codes.............................................................. 317 FAULT TREE ANALYSIS................................................................. 323 Unable to connect to KOMTRAX Plus from laptop PC................................ 323 Flashing Error Code N4-23 (PLM III Communications Fault)........................ 324 Flashing Error Code N4-22 (Engine Communications Fault)......................... 325 No Data Received By WebCARE..................................................... 326 Coaxial Cable Troubleshooting................................................... 327 KOMTRAX PLUS FORMS ............................................................................ 329 KOMTRAX PLUS FORMS.......................................................................... 331 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 331 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 332 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 333 KOMTRAX PLUS INITIALIZATION FORM........................................................ 335 SECTION E: ELECTRIC PROPULSION SYSTEM .............................................................. 337 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 339 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 341 GENERAL SYSTEM DESCRIPTION.............................................................. 341 SYSTEM COMPONENTS....................................................................... 343 Propulsion System Controller (PSC).................................................. 343 Truck Control Interface (TCI)....................................................... 344 Diagnostic Information Display (DID) Panel.......................................... 345 DID Panel Event Codes............................................................... 345 PSC SOFTWARE FUNCTIONS.................................................................. 364 Input Processing.................................................................... 364 State Machine....................................................................... 364 DC Link State....................................................................... 367 Engine Control...................................................................... 368 ALTERNATOR FIELD CONTROL................................................................ 368 Desired Three-Phase Voltage......................................................... 368 Desired DC Link Voltage............................................................. 368 Self-Load........................................................................... 369 Propel Torque Control............................................................... 369 Retard Torque Control............................................................... 369 Wheel Slide Control................................................................. 370 Resistor Grid Control............................................................... 370 Chopper Voltage Control............................................................. 370 EVENT DETECTION AND PROCESSING.......................................................... 370 Power-On Tests...................................................................... 370 Initiated Tests..................................................................... 371 Periodic Tests...................................................................... 371 EVENT RESTRICTIONS...................................................................... 371 EVENT LOGGING AND STORAGE............................................................... 371 Event History Buffer................................................................ 372 Data Packs.......................................................................... 372 To Record and Save a Data Pack to a Disk............................................ 372 Event Reset......................................................................... 373 SERIAL DATA COMMUNICATIONS.............................................................. 373 PSC - TCI Communications Processing................................................. 373 PSC - PTU Communications Processing................................................. 373 Inverter Communications Processing.................................................. 374 OUTPUT PROCESSING....................................................................... 374 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 374 Fast Start.......................................................................... 374 Engine Shutdown/Engine Not Running.................................................. 374 Limp Home Mode...................................................................... 375 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 376 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 384 Removal............................................................................. 384 Installation........................................................................ 384 Disassembly......................................................................... 384 Assembly............................................................................ 384 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 385 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 387 AC DRIVE SYSTEM MAINTENANCE............................................................. 387 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 388 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 388 SYSTEM CHECKOUT......................................................................... 389 Battery and Control Circuit Checks - Battery Power OFF.............................. 389 Battery and Control Circuit Checks - Battery Power ON............................... 392 Checks with Key Switch OFF.......................................................... 393 Checks with Key Switch ON........................................................... 393 CPU Battery Checks.................................................................. 393 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 394 TCI PROGRAMMING......................................................................... 394 PSC PROGRAMMING......................................................................... 395 INVERTER PROGRAMMING.................................................................... 395 CPU RESET............................................................................... 395 PSC CHECKOUT............................................................................ 396 PSC Digital Input Checks............................................................ 396 PSC Digital Output Checks........................................................... 400 TCI CHECKOUT............................................................................ 401 Modular Mining Communication Port Check............................................. 401 TCI Digital Input Checks............................................................ 401 TCI Digital Output Tests............................................................ 407 CALIBRATIONS............................................................................ 409 Speedometer......................................................................... 409 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 409 ERASING EVENTS.......................................................................... 409 PSC................................................................................. 409 TCI................................................................................. 410 GATE DRIVER POWER CONVERTER TEST........................................................ 410 LOAD TESTING............................................................................ 411 Preparation......................................................................... 411 Alternator Speed Sensor Checks...................................................... 411 Battery Boost Check................................................................. 411 Brake Circuit Switch Checks......................................................... 412 Hoist & Steering Circuit Switch Checks.............................................. 412 Link Energized Checks............................................................... 412 Loadbox Test........................................................................ 414 TROUBLESHOOTING......................................................................... 418 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 418 Phase Module and Chopper Module Troubleshooting..................................... 418 PHASE MODULE REPLACEMENT................................................................ 419 Phase Module Removal................................................................ 419 Phase Module Installation........................................................... 419 SECTION G: DRIVE AXLE, SPINDLE, AND WHEELS ......................................................... 421 TIRES AND RIMS.................................................................................. 423 TIRES AND RIMS.............................................................................. 425 FRONT TIRES AND RIMS.................................................................... 425 Removal............................................................................. 425 Installation........................................................................ 427 REAR TIRES AND RIMS..................................................................... 427 Removal............................................................................. 427 Installation........................................................................ 428 RIM AND TIRE............................................................................ 430 Tire Removal........................................................................ 430 Rim And Tire Preparation............................................................ 430 Lubricants.......................................................................... 431 Tire Installation................................................................... 431 FRONT WHEEL HUB AND SPINDLES.................................................................... 433 FRONT WHEEL HUB AND SPINDLE................................................................. 435 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 435 Removal............................................................................. 435 Spindle Removal Procedure (Optional) (off of the truck)............................. 438 Installation........................................................................ 440 Disassembly......................................................................... 443 Cleaning and Inspection............................................................. 443 Assembly............................................................................ 444 Wheel Bearing Adjustment (Tire Removed)............................................. 446 Wheel Bearing Adjustment (Tire mounted)............................................. 447 OIL SAMPLING PROCEDURE.................................................................. 448 Oil Sampling Guidelines............................................................. 449 Procedure........................................................................... 449 OIL DRAIN AND REFILL PROCEDURE.......................................................... 449 STEERING CYLINDERS...................................................................... 450 Spherical Bearing Wear Limits....................................................... 450 Removal............................................................................. 451 Installation........................................................................ 451 Bearing Replacement (Steering cylinder and tie rod)................................. 451 TIE ROD................................................................................. 453 Removal............................................................................. 453 Installation........................................................................ 453 Disassembly......................................................................... 453 Assembly............................................................................ 454 TOE-IN ADJUSTMENT....................................................................... 455 REAR AXLE HOUSING ATTACHMENT.................................................................... 457 REAR AXLE HOUSING ATTACHMENT................................................................ 459 PIVOT PIN............................................................................... 459 Removal............................................................................. 459 Installation........................................................................ 459 PIVOT EYE BEARING....................................................................... 460 Disassembly......................................................................... 460 Assembly............................................................................ 460 PIVOT EYE REPAIR........................................................................ 461 Removal............................................................................. 461 Installation........................................................................ 461 Disassembly......................................................................... 461 Assembly............................................................................ 461 ANTI-SWAY BAR........................................................................... 462 Removal............................................................................. 462 Installation........................................................................ 462 Disassembly......................................................................... 462 Cleaning and Inspection............................................................. 462 Assembly............................................................................ 462 REAR AXLE HOUSING............................................................................... 463 REAR AXLE HOUSING........................................................................... 465 REAR AXLE HOUSING....................................................................... 465 Removal............................................................................. 465 Installation........................................................................ 465 WHEEL MOTOR............................................................................. 466 Removal............................................................................. 466 Cleaning and Inspection............................................................. 466 Installation........................................................................ 467 WHEEL MOTOR GEAR OIL.................................................................... 470 Change/Filter The Gear case Oil..................................................... 470 Oil................................................................................. 470 Remove And Clean Magnetic Plugs..................................................... 470 Flushing The Gearbox................................................................ 470 Check Gear Case Oil Level........................................................... 470 SECTION H: SUSPENSIONS INDEX....................................................................... 471 FRONT SUSPENSION................................................................................ 473 FRONT SUSPENSION............................................................................ 475 Removal................................................................................. 475 Installation............................................................................ 476 TURN-OF-THE-NUT Tightening Procedure.................................................... 478 Upper Mounting Joint - 60° Advance.................................................. 478 Lower Mounting Joint - 90° Advance.................................................. 480 Inspection.......................................................................... 480 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 481 Bearing Structure Removal........................................................... 481 Bearing Structure Installation...................................................... 481 MAJOR SUSPENSION REBUILD................................................................ 482 Disassembly......................................................................... 482 Assembly............................................................................ 483 PRESSURE TEST........................................................................... 485 REAR SUSPENSIONS ............................................................................... 487 REAR SUSPENSIONS............................................................................ 489 Removal................................................................................. 489 Installation............................................................................ 492 ROD UP SUSPENSION....................................................................... 494 Disassembly......................................................................... 494 Cleaning and Inspection............................................................. 494 Assembly............................................................................ 494 ROD DOWN SUSPENSION..................................................................... 496 Disassembly......................................................................... 496 Cleaning and Inspection............................................................. 496 Assembly............................................................................ 498 PRESSURE TEST........................................................................... 500 Suspension pressure test............................................................ 500 OILING AND CHARGING PROCEDURE................................................................... 501 OILING AND CHARGING PROCEDURE............................................................... 503 GENERAL................................................................................. 503 EQUIPMENT LIST.......................................................................... 503 HYDRAIR® CHARGING KIT................................................................... 504 Installation of Charging Kit........................................................ 504 Removal of Charging Kit............................................................. 504 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 505 FRONT SUSPENSION........................................................................ 505 Front Suspension Oiling............................................................. 505 Front Suspension Nitrogen Charging.................................................. 507 REAR SUSPENSION - ROD UP................................................................ 509 Rear Suspension Oiling (Rod Up Only)................................................ 509 Rear Suspension Nitrogen Charging (Rod Up Only)..................................... 510 REAR SUSPENSION - ROD DOWN.............................................................. 512 Rear Suspension Oiling (Rod Down Only).............................................. 512 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 514 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 516 SECTION J: BRAKE SYSTEM ............................................................................ 517 BRAKE CIRCUIT................................................................................... 519 BRAKE CIRCUIT............................................................................... 521 OPERATION............................................................................... 521 SERVICE BRAKE CIRCUIT OPERATION......................................................... 521 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 523 PARKING BRAKE CIRCUIT................................................................... 523 Normal Operation (key switch on, engine running).................................... 523 BRAKE LOCK CIRCUIT...................................................................... 524 WARNING CIRCUIT......................................................................... 524 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 527 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 529 BRAKE VALVE............................................................................. 529 Rebuild Criteria.................................................................... 529 Removal............................................................................. 529 Installation........................................................................ 531 DISASSEMBLY............................................................................. 533 Cleaning and Inspection............................................................. 535 ASSEMBLY................................................................................ 535 Actuator Base Threaded Inserts...................................................... 535 Boot and Cap........................................................................ 535 Valve Body Seal Installation........................................................ 536 Regulator Sleeve O-Ring Installation................................................ 536 Actuator Plunger O-ring Installation................................................ 537 Assembly of Valve................................................................... 537 VALVE BENCH TEST AND ADJUSTMENT......................................................... 539 Test Set Up Procedure............................................................... 540 Brake Valve Output Pressure Adjustment.............................................. 540 Final Test and Adjustment........................................................... 541 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 542 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 544 Installation of Retard Pedal To Brake Pedal......................................... 544 HYDRAULIC BRAKE ACCUMULATORS............................................................ 545 Brake Accumulator Bleed Down Procedure.............................................. 545 Removal............................................................................. 545 Installation........................................................................ 545 Disassembly......................................................................... 545 Cleaning and Inspection............................................................. 547 Assembly............................................................................ 547 Charging Procedure.................................................................. 549 BRAKE MANIFOLD.......................................................................... 550 Removal............................................................................. 550 Removal............................................................................. 550 Installation........................................................................ 551 Disassembly......................................................................... 551 Cleaning and Inspection............................................................. 552 Assembly............................................................................ 552 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 553 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 555 EQUIPMENT REQUIRED...................................................................... 557 INITIAL SYSTEM SET-UP................................................................... 558 PARKING BRAKE........................................................................... 558 BRAKE SYSTEM CHECK-OUT.................................................................. 559 BRAKE LOCK.............................................................................. 559 FAILURE MODES CHECK-OUT................................................................. 560 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 561 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 564 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 565 FRONT BRAKES.................................................................................... 567 WHEEL SPEED FRONT DISC BRAKES............................................................... 569 BRAKE CALIPER........................................................................... 569 Caliper Removal..................................................................... 569 Installation........................................................................ 570 Disassembly......................................................................... 571 Assembly............................................................................ 571 Cleaning and Inspection............................................................. 572 BRAKE LINING............................................................................ 573 Replacement......................................................................... 573 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................. 575 GENERAL............................................................................. 575 Safety Precautions.............................................................. 575 Front Brake Conditioning........................................................ 575 BRAKE BLEEDING PROCEDURES........................................................... 576 ARMATURE SPEED REAR DISC BRAKES................................................................. 577 ARMATURE SPEED REAR DISC BRAKES............................................................. 579 REAR BRAKES............................................................................. 579 CALIPER AND DISC.................................................................... 579 Removal......................................................................... 579 Installation.................................................................... 581 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 583 BRAKE BLEEDING PROCEDURE............................................................ 584 Service Brake................................................................... 584 Park Brake...................................................................... 584 CALIPER............................................................................. 585 Disassembly..................................................................... 585 PISTON SUBASSEMBLY.................................................................. 588 Disassembly..................................................................... 588 PREPARATION FOR ASSEMBLY............................................................ 589 Clean Parts..................................................................... 589 For Rough Metal Parts........................................................... 590 Dry and Inspect Parts........................................................... 590 Corrosion Protection............................................................ 590 INSPECTION.......................................................................... 590 Caliper Parts................................................................... 590 Shoes, Linings and End Plates................................................... 591 Inspect linings................................................................. 591 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 591 Piston Assembly Adjuster Grip Force............................................. 592 Adjuster Force.................................................................. 594 Piston Return Spring............................................................ 596 ASSEMBLY............................................................................ 597 Adjuster and Pin Assembly....................................................... 597 Piston Subassembly.............................................................. 598 Brake Caliper................................................................... 599 PERIODIC INSPECTIONS................................................................ 605 Shoes, Linings and End Plates................................................... 605 Inspect the following areas for fluid leaks..................................... 605 Dust Boots...................................................................... 605 Brake Disc...................................................................... 605 BRAKE LINING........................................................................ 606 Replacement..................................................................... 606 BRAKE DISC.......................................................................... 606 Inspection...................................................................... 606 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE....................................... 607 GENERAL............................................................................. 607 SAFETY PRECAUTIONS.................................................................. 607 Rear Brake Conditioning......................................................... 608 SECTION L: HYDRAULIC SYSTEM........................................................................ 611 HYDRAULIC SYSTEM................................................................................ 613 HYDRAULIC SYSTEM............................................................................ 615 HYDRAULIC SYSTEM OPERATION.............................................................. 615 COMPONENT DESCRIPTION................................................................... 616 Hoist Pump.......................................................................... 616 Steering/Brake Pump................................................................. 616 Tank................................................................................ 616 High Pressure Hydraulic Filters..................................................... 616 Bleeddown Manifold.................................................................. 616 Steering System Accumulators........................................................ 616 DISABLED TRUCK CONNECTORS............................................................... 618 GENERAL............................................................................. 618 STEERING AND BRAKE SYSTEM........................................................... 618 Hookup.......................................................................... 618 HOIST SYSTEM........................................................................ 619 Hookup.......................................................................... 619 Dumping Procedure............................................................... 619 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 621 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 623 HOIST PUMP.............................................................................. 623 Removal............................................................................. 623 Installation........................................................................ 624 Disassembly......................................................................... 626 Inspection Of Parts................................................................. 629 Assembly............................................................................ 630 HYDRAULIC TANK.......................................................................... 636 Filling Instructions................................................................ 636 Removal............................................................................. 636 Installation........................................................................ 637 HYDRAULIC TANK STRAINERS................................................................ 638 Removal............................................................................. 638 Inspect and Clean................................................................... 638 Installation........................................................................ 639 HYDRAULIC TANK BREATHERS................................................................ 639 HOIST CIRCUIT FILTERS................................................................... 640 FILTER ELEMENT REPLACEMENT.............................................................. 641 Removal............................................................................. 641 Installation........................................................................ 641 INDICATOR SWITCH........................................................................ 641 STEERING CIRCUIT................................................................................ 643 STEERING CIRCUIT............................................................................ 645 STEERING CIRCUIT OPERATION.............................................................. 645 COMPONENT DESCRIPTION................................................................... 646 STEERING CONTROL UNIT............................................................... 646 FLOW AMPLIFIER...................................................................... 646 No Steer........................................................................ 648 Steering Left................................................................... 650 Steering Right.................................................................. 652 No Steer, External Shock Load................................................... 654 BLEED DOWN MANIFOLD................................................................. 656 ACCUMULATORS........................................................................ 657 Low Precharge Warning Switch.................................................... 657 HIGH PRESSURE FILTER................................................................ 657 STEERING/BRAKE PUMP................................................................. 657 Operation....................................................................... 658 PRINCIPLE OF OPERATION.............................................................. 660 Full Pump Volume:............................................................... 660 Half Pump Volume:............................................................... 660 Neutral Position:............................................................... 661 STEERING CIRCUIT COMPONENT REPAIR............................................................... 663 STEERING CIRCUIT COMPONENT REPAIR........................................................... 665 BLEED DOWN MANIFOLD..................................................................... 665 Removal............................................................................. 665 Installation........................................................................ 665 ACCUMULATOR............................................................................. 666 Removal............................................................................. 666 Installation........................................................................ 667 Disassembly......................................................................... 667 Cleaning and Inspection............................................................. 668 Assembly............................................................................ 668 LEAK TESTING............................................................................ 670 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 671 Temperature During Precharge........................................................ 674 ACCUMULATOR STORAGE PROCEDURES.......................................................... 674 Instructions For Storing Bladder Accumulators....................................... 674 Installation........................................................................ 675 Bladder Storage Procedures.......................................................... 675 FLOW AMPLIFIER.......................................................................... 676 Removal............................................................................. 676 Installation........................................................................ 676 Disassembly......................................................................... 678 Reassembly.......................................................................... 679 STEERING CONTROL UNIT................................................................... 680 Removal............................................................................. 680 Spline Inspection................................................................... 680 Installation........................................................................ 681 Disassembly......................................................................... 681 Cleaning and Inspection............................................................. 682 Assembly............................................................................ 683 STEERING CYLINDER....................................................................... 687 Disassembly......................................................................... 687 Inspection and Cleaning............................................................. 687 Assembly............................................................................ 687 STEERING CIRCUIT FILTER................................................................. 688 Filter Element Replacement.......................................................... 688 Removal............................................................................. 689 Installation........................................................................ 689 Indicator Switch.................................................................... 689 STEERING AND BRAKE PUMP................................................................. 690 Removal............................................................................. 690 Installation........................................................................ 691 Disassembly......................................................................... 692 Control Piston Group................................................................ 692 Valve Plate Group................................................................... 693 Rotating Group...................................................................... 693 Swashblock Group.................................................................... 694 Driveshaft Group.................................................................... 694 INSPECTION.............................................................................. 694 Control Piston Group................................................................ 694 Valve Plate Group................................................................... 694 Rotating Group...................................................................... 694 Swashblock Group.................................................................... 698 Driveshaft Group.................................................................... 698 Compensator Block and Unloader Module............................................... 698 Stroke Adjuster Assembly............................................................ 698 ASSEMBLY................................................................................ 698 Swashblock Group.................................................................... 698 Control Piston Group................................................................ 700 Valve Plate Group................................................................... 701 HOIST CIRCUIT................................................................................... 703 HOIST CIRCUIT............................................................................... 705 HOIST CIRCUIT OPERATION................................................................. 705 COMPONENT DESCRIPTION................................................................... 706 Hydraulic Tank...................................................................... 706 Hoist Pump.......................................................................... 706 High Pressure Filters............................................................... 706 Hoist Valve......................................................................... 707 Hoist Pilot Valve................................................................... 708 Hoist-up Limit Solenoid............................................................. 708 Pilot Operated Check Valve.......................................................... 708 Counterbalance Valve Manifold....................................................... 709 HOIST SYSTEM OPERATION MODES............................................................ 710 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 710 Power Up Operation (Figure 7-7)..................................................... 712 Hold Operation (Figure 7-8)......................................................... 714 Power Down Operation (Figure 7-9)................................................... 716 Float Operation (Figure 7-10)....................................................... 718 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 721 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 723 HOIST VALVE............................................................................. 723 Removal............................................................................. 723 Installation........................................................................ 723 O-Ring Replacement.................................................................. 724 INLET SECTION........................................................................... 725 Disassembly......................................................................... 725 Cleaning and Inspection............................................................. 726 Assembly............................................................................ 726 SPOOL SECTION........................................................................... 726 Disassembly......................................................................... 726 Cleaning and Inspection............................................................. 729 Assembly............................................................................ 729 HOIST PILOT VALVE....................................................................... 730 Removal............................................................................. 730 Installation........................................................................ 730 Disassembly......................................................................... 731 Cleaning and Inspection............................................................. 732 Assembly............................................................................ 733 BODY UP LIMIT SOLENOID.................................................................. 734 PILOT OPERATED CHECK VALVE.............................................................. 734 HOIST CYLINDERS......................................................................... 734 Removal............................................................................. 734 Installation........................................................................ 735 Disassembly......................................................................... 736 Cleaning and Inspection............................................................. 738 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 739 Quill Installation.................................................................. 739 Installation of Check Balls and Plugs in Quill...................................... 740 Assembly of Cylinder................................................................ 741 Assembly of Cylinder................................................................ 741 Pressure Testing.................................................................... 742 OVERCENTER MANIFOLD..................................................................... 743 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 745 HYDRAULIC CHECKOUT PROCEDURE................................................................ 747 STEERING AND BRAKE PUMP................................................................. 747 Pressure Check And Adjustment Procedure............................................. 747 BLEEDDOWN MANIFOLD...................................................................... 749 SHOCK & SUCTION VALVES.................................................................. 749 Shock & Suction Valve Settings...................................................... 749 LEAKAGE TESTS........................................................................... 751 Steering Control Unit & Flow Amplifier.............................................. 751 Bleeddown Manifold.................................................................. 751 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 753 LOW STEERING PRESSURE SWITCH............................................................ 753 CHECKING HOIST SYSTEM PRESSURES......................................................... 760 Hoist System Relief Pressure Adjustment............................................. 760 Power Down Relief Pressure Adjustment............................................... 761 HOIST COUNTERBALANCE VALVE.......................................................... 762 Preparation:.................................................................... 762 Counterbalance Valve Pressure Check Only:....................................... 762 Counterbalance Valve Adjustment................................................. 763 HYDRAULIC SYSTEM FLUSHING PROCEDURE..................................................... 766 Hydraulic System Flushing Procedure................................................. 766 OIL CLEANLINESS CHECK............................................................... 771 SECTION M: OPTIONS AND SPECIAL TOOLS ............................................................... 773 HEATER OPTIONS ................................................................................. 775 GENERAL INFORMATION......................................................................... 777 TROUBLESHOOTING............................................................................. 777 HEATER ELEMENT.............................................................................. 777 Removal................................................................................. 777 Installation............................................................................ 778 GENERAL..................................................................................... 779 Maintenance............................................................................. 779 HEATING ELEMENT............................................................................. 780 Removal................................................................................. 780 Installation............................................................................ 780 THERMOSTAT.................................................................................. 780 Removal................................................................................. 780 Installation............................................................................ 780 GENERAL INFORMATION......................................................................... 781 TROUBLESHOOTING............................................................................. 781 HEATER ELEMENT.............................................................................. 781 Removal................................................................................. 781 Installation............................................................................ 782 SPECIAL TOOLS................................................................................... 783 NITROGEN CHARGING VALVE..................................................................... 783 ROLL-OUT ASSEMBLY........................................................................... 783 EYE BOLT.................................................................................... 783 OFFSET WRENCH............................................................................... 784 TORQUE ADAPTER.............................................................................. 784 HANDLE...................................................................................... 784 SEAL INSTALLER.............................................................................. 784 SLEEVE ALIGNMENT TOOLS...................................................................... 785 QUICK DISCONNECT COUPLING................................................................... 785 HARNESS..................................................................................... 785 SEAL INSTALLATION RING...................................................................... 785 BELT TENSION TESTER......................................................................... 786 BELT ALIGNMENT TOOL......................................................................... 786 SOCKETS AND ADAPTERS........................................................................ 786 DUST CAPS................................................................................... 786 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 787 PAYLOAD DATA MANAGER........................................................................ 787 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 787 MISCELLANEOUS SERVICE TOOLS................................................................. 788 BRAKE PISTON TOOL........................................................................... 789 HIGH VOLTAGE TOOLS.......................................................................... 792 2000 VDC METER.............................................................................. 792 GROUNDING STICKS............................................................................ 792 BODY PAD SPACER TOOL........................................................................ 793 RADIATOR SHUTTERS ............................................................................. 795 RADIATOR SHUTTERS........................................................................... 797 OPERATION............................................................................... 797 Hydraulic Circuit................................................................... 797 Electrical Circuit:................................................................. 798 MAINTENANCE AND REPAIR.................................................................. 798 TROUBLESHOOTING......................................................................... 799 Hydraulic Troubleshooting........................................................... 802 Electrical Troubleshooting.......................................................... 804 PAYLOAD METER III ™ ........................................................................... 805 OPERATION SECTION........................................................................... 809 Introduction............................................................................ 809 Data Summary........................................................................ 809 Data Gathering...................................................................... 809 COMPONENT DESCRIPTION................................................................... 810 System Diagram...................................................................... 810 Suspension Pressure Sensors......................................................... 810 Inclinometer........................................................................ 810 Operator Display.................................................................... 810 Operator Switch..................................................................... 811 Speed Input......................................................................... 811 Body-Up Switch...................................................................... 811 Brake Lock Switch................................................................... 811 Payload Meter....................................................................... 811 Communications Ports................................................................ 811 Key Switch Input.................................................................... 812 Payload Meter Power................................................................. 812 Load Lights......................................................................... 812 Wiring and Termination.............................................................. 813 TCI Outputs......................................................................... 813 OPERATOR’S DISPLAY AND SWITCH........................................................... 814 Reading the Speedometer............................................................. 814 Reading the Load Display............................................................ 814 Using the Operator ID............................................................... 814 Using the Load and Ton Counter...................................................... 814 Total Ton Counter................................................................... 814 Total Load Counter.................................................................. 815 Clearing the Counters............................................................... 815 Viewing Live Sensor Data............................................................ 815 Other Display Messages.............................................................. 815 PAYLOAD OPERATION & CALCULATION......................................................... 816 Description of Haul Cycle States.................................................... 816 Haul Cycle Description.............................................................. 816 Load Calculation.................................................................... 817 Carry Back.......................................................................... 817 Measurement Accuracy................................................................ 817 SOURCES FOR PAYLOAD ERROR............................................................... 817 Payload Error....................................................................... 817 Loading Conditions.................................................................. 818 Pressure Sensors.................................................................... 818 Swingloads.......................................................................... 818 Speed and Distance.................................................................. 818 HAUL CYCLE DATA......................................................................... 818 Haul Cycle Warning Flags............................................................ 820 Frame Torque Data................................................................... 821 Sprung Weight Data.................................................................. 821 Maximum Speed Data.................................................................. 821 Alarm Records....................................................................... 821 Fault Code Data..................................................................... 822 PC SOFTWARE OVERVIEW.................................................................... 823 System Configuration................................................................ 823 Installing the PLMIII Software...................................................... 823 DOWNLOADING DATA........................................................................ 824 PLM III SYSTEM CONFIGURATION............................................................ 825 Starting Communications............................................................. 825 Displayed Payload Units............................................................. 825 Time Units.......................................................................... 825 Connection Menu..................................................................... 825 Connecting to the Payload Meter..................................................... 826 Configure the Payload Meter......................................................... 826 Setting the Date and Time........................................................... 826 Setting the Truck Type.............................................................. 827 Setting the Gauge Display Units..................................................... 827 Setting the Frame Serial Number..................................................... 827 Setting the Truck Number............................................................ 827 Setting the Komatsu Distributor..................................................... 827 Setting the Komatsu Customer........................................................ 827 Clean Truck Tare.................................................................... 828 Inclinometer Calibration............................................................ 828 DATA ANALYSIS........................................................................... 829 Creating a Query.................................................................... 829 Sorting on Truck Unit Number........................................................ 829 Sorting on Truck Type............................................................... 829 Sorting on Date Range............................................................... 830 Sorting on Time Range............................................................... 830 Payload Detail Screen............................................................... 831 Creating Reports.................................................................... 831 Summary - one page report........................................................... 832 Detailed - multi-page report........................................................ 832 Creating Graphs..................................................................... 833 Exporting Data...................................................................... 833 CSV Export.......................................................................... 833 Compressed.......................................................................... 834 Importing Data...................................................................... 835 Deleting Haul Cycle Records......................................................... 835 Viewing Alarms...................................................................... 836 Deleting Alarm Records.............................................................. 836 TROUBLESHOOTING SECTION..................................................................... 837 TROUBLESHOOTING......................................................................... 837 Viewing Active Alarms............................................................... 837 Real-Time Data Display.............................................................. 837 Testing the Payload Lights.......................................................... 837 Creating Log Files of Inputs........................................................ 838 Daily Inspections................................................................... 838 Periodic Maintenance................................................................ 838 Abnormal Displays at Power-Up....................................................... 839 No Payload Display When Key Switch is Turned ON..................................... 840 No Display on Speedometer........................................................... 841 No Display on Operator Display...................................................... 841 No Communications With PC........................................................... 842 Load Lights Don’t Light During Loading.............................................. 843 Load Lights Remain ON............................................................... 844 Load Lights Remain ON During Dumping................................................ 844 Display Doesn't Clear When The Load Is Dumped....................................... 844 Calibration Problems................................................................ 845 Alarm 1 - Left Front Pressure High.................................................. 846 Alarm 2 - Left Front Pressure Low................................................... 846 Troubleshoot Wiring to Left Front Suspension........................................ 846 Alarm 3 - Right Front Pressure High................................................. 847 Alarm 4 - Right Front Pressure Low.................................................. 847 Troubleshoot Wiring to Right Front Suspension....................................... 847 Alarm 5 -Left Rear Pressure High.................................................... 848 Alarm 6 - Left Rear Pressure Low.................................................... 848 Troubleshoot Wiring to Left Rear Suspension......................................... 848 Alarm 7 - Right Rear Pressure High.................................................. 849 Alarm 8 - Right Rear Pressure Low................................................... 849 Troubleshoot Wiring to Right Rear Suspension........................................ 849 Alarm 9 - Inclinometer High......................................................... 850 Alarm 10 - Inclinometer Low......................................................... 850 Troubleshoot Inclinometer Wiring.................................................... 850 Alarm 13 - Body Up Input Failure.................................................... 851 Alarm 16 - Memory Write Failure..................................................... 852 Alarm 17 - Memory Read Failure...................................................... 852 Alarm 18............................................................................ 853 Alarm 19............................................................................ 853 Alarm 22............................................................................ 853 Operator Switch Doesn't Work........................................................ 854 Alarm 26 - User Switch Fault - SELECT............................................... 854 Alarm 27 - User Switch Fault - SET.................................................. 854 Connector Map....................................................................... 855 Connectors.......................................................................... 856 PLMIII CHECK OUT PROCEDURE.................................................................. 857 General Description..................................................................... 857 Tools Required.......................................................................... 857 Checkout Procedure...................................................................... 857 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 861 Flashburn Programming............................................................... 861 Confirmation Checklist.............................................................. 863 SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX..................................................... 865 RESERVE ENGINE OIL SYSTEM................................................................... 867 Operation............................................................................... 868 LED Monitor Light....................................................................... 868 Tank Fill Control (Optional)............................................................ 869 Filling Procedure (Remote Fill Feature)................................................. 869 SERVICE................................................................................. 870 Every 10 Hours, or once each shift:................................................. 870 Every 500 Hours..................................................................... 870 Changing Oil........................................................................ 870 TROUBLESHOOTING......................................................................... 871 Circuit Fuse........................................................................ 871 SYSTEM ELECTRICAL SCHEMATICS............................................................ 872 SECTION N: OPERATOR CAB ............................................................................ 873 TRUCK CAB AND COMPONENTS........................................................................ 875 TRUCK CAB AND COMPONENTS.................................................................... 877 TRUCK CAB............................................................................... 877 Description......................................................................... 877 Removal............................................................................. 878 Installation........................................................................ 879 CAB DOOR................................................................................ 880 Removal............................................................................. 880 Installation........................................................................ 880 Door Adjustment..................................................................... 880 Door Jamb Bolt Adjustment........................................................... 881 Door Handle Plunger Adjustment...................................................... 882 Replace Door Glass.................................................................. 883 Replace Door Window Regulator....................................................... 887 Replacing the Door Handle or Latch Assembly......................................... 888 Replacing the Door and Door Hinge Seal.............................................. 888 Removing the Door Opening Seal...................................................... 889 Installation........................................................................ 889 GLASS REPLACEMENT....................................................................... 890 Adhesive-bonded Windows............................................................. 890 Replacement Procedure............................................................... 890 WINDSHIELD & REAR GLASS................................................................. 892 Removal............................................................................. 892 Installation........................................................................ 892 CAB COMPONENTS ................................................................................ 895 CAB COMPONENTS.............................................................................. 897 WINDSHIELD WIPERS....................................................................... 897 WIPER MOTOR......................................................................... 897 Removal......................................................................... 897 Installation.................................................................... 897 WIPER ARM........................................................................... 897 Removal......................................................................... 897 Installation.................................................................... 898 WIPER LINKAGE....................................................................... 898 Removal......................................................................... 898 Installation.................................................................... 898 WINDSHIELD WASHER....................................................................... 899 Operation........................................................................... 899 Service............................................................................. 899 OPERATOR SEAT........................................................................... 900 Seat Belts.......................................................................... 900 Adjustment.......................................................................... 900 Inspection.......................................................................... 901 Removal............................................................................. 901 Installation........................................................................ 901 PASSENGER SEAT.......................................................................... 902 Inspection.......................................................................... 902 Removal............................................................................. 902 Installation........................................................................ 902 OPERATOR COMFORT ............................................................................... 903 HEATER / AIR CONDITIONER.................................................................... 905 Fan Speed Control Knob.................................................................. 905 Temperature Control Knob................................................................ 905 Air Flow Directional Knob............................................................... 905 Heater/Air Conditioner Vents............................................................ 906 COMPONENTS.................................................................................. 906 Fuse and Circuit Breaker................................................................ 906 Relays.................................................................................. 906 Heater Core............................................................................. 906 Fan Motor And Speed Control............................................................. 907 Actuators............................................................................... 907 Cab Air Filter.......................................................................... 907 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.................................................... 910 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES................................................... 910 PRINCIPLES OF REFRIGERATION................................................................. 910 Air Conditioning........................................................................ 910 Refrigeration - The Act Of Cooling...................................................... 911 The Refrigeration Cycle................................................................. 911 AIR CONDITIONER SYSTEM COMPONENTS........................................................... 912 Compressor (Refrigerant Pump)........................................................... 912 Service Valves.......................................................................... 912 Condenser............................................................................... 912 Receiver-Drier.......................................................................... 912 Expansion Block Valve................................................................... 913 Accumulator............................................................................. 913 Evaporator.............................................................................. 913 ELECTRICAL CIRCUIT.......................................................................... 914 Thermostat.............................................................................. 914 Compressor Clutch....................................................................... 914 Trinary™ Switch......................................................................... 915 SYSTEM SERVICING............................................................................ 916 SERVICE TOOLS AND EQUIPMENT................................................................. 917 Recovery/Recycle Station................................................................ 917 Leak Detector........................................................................... 917 Service Valves.......................................................................... 918 Vacuum Pump............................................................................. 918 Manifold Gauge Set...................................................................... 919 Installing Manifold Gauge Set........................................................... 920 Purging Air From Service Hoses.......................................................... 920 SYSTEM PERFORMANCE TEST..................................................................... 921 SYSTEM OIL.................................................................................. 922 Handling and Reusing PAG Oil............................................................ 922 Oil Quantity............................................................................ 922 Checking System Oil..................................................................... 922 REFRIGERANT................................................................................. 923 Recycled Refrigerant.................................................................... 923 Reclaimed Refrigerant................................................................... 923 Refrigerant Quantity.................................................................... 923 R-134a Refrigerant Containers........................................................... 924 SYSTEM LEAK TESTING......................................................................... 924 Electronic Leak Detector................................................................ 925 Tracer Dyes............................................................................. 925 Soap and Water.......................................................................... 925 RECOVERING AND RECYCLING THE REFRIGERANT.................................................... 925 Draining Oil from the Previous Recovery Cycle........................................... 925 Performing the Recovery Cycle........................................................... 925 Performing the Recycling Procedure...................................................... 926 Evacuating and Charging the A/C System.................................................. 926 SYSTEM REPAIR............................................................................... 926 System Flushing......................................................................... 926 A/C DRIVE BELT CHECKOUT PROCEDURE........................................................... 927 Pulley Alignment........................................................................ 927 Belt Tension Check...................................................................... 927 COMPONENT REPLACEMENT....................................................................... 929 Hoses and Fittings...................................................................... 929 Lines................................................................................... 929 Expansion Valve......................................................................... 929 Receiver-Drier.......................................................................... 929 Thermostat.............................................................................. 929 Compressor.............................................................................. 930 Accumulator............................................................................. 930 Clutch.................................................................................. 930 Servicing the Compressor Clutch......................................................... 931 Pulley Removal.......................................................................... 933 Clutch Coil Check....................................................................... 934 Pulley Installation..................................................................... 934 Clutch Assembly Installation............................................................ 934 EVACUATING THE SYSTEM....................................................................... 936 CHARGING THE A/C SYSTEM..................................................................... 938 Preliminary Checks...................................................................... 939 Diagnosis Of Gauge Readings And System Performance...................................... 939 OPERATOR CAB CONTROLS........................................................................... 947 OPERATOR CAB AND CONTROLS................................................................... 949 STEERING WHEEL AND CONTROLS............................................................. 950 Horn Button......................................................................... 950 Tilt / Telescope Lever.............................................................. 950 Multi-Function Turn Signal Switch................................................... 950 STEERING COLUMN......................................................................... 951 Removal............................................................................. 951 Steering Column Inspection.......................................................... 951 Installation........................................................................ 951 STEERING WHEEL.......................................................................... 952 Removal............................................................................. 952 Installation........................................................................ 952 PEDALS.................................................................................. 954 Service Brake Pedal................................................................. 954 Dynamic Retarding................................................................... 954 Dynamic Retard Pedal................................................................ 954 Throttle/Accelerator Pedal.......................................................... 954 GRADE/SPEED RETARD CHART................................................................ 955 OVERHEAD PANEL AND DISPLAYS............................................................. 956 CENTER CONSOLE.......................................................................... 957 Directional Control Lever........................................................... 957 Override/Fault Reset Switch......................................................... 958 Engine Stop Switch.................................................................. 958 L.H. Window Control Switch.......................................................... 958 R.H. Window Control Switch.......................................................... 958 Hoist Control Lever................................................................. 958 Raising The Dump Body............................................................... 958 Lowering The Dump Body.............................................................. 958 Retard Speed Control (RSC) Adjust Dial.............................................. 959 Retard Speed Control (RSC) Switch................................................... 959 Data Store Button................................................................... 960 KOMTRAX Plus Snapshot In Progress Light............................................. 960 Link Energized Light................................................................ 960 Service Engine Light................................................................ 960 DIAGNOSTIC PORTS.................................................................... 960 KOMTRAX Plus Diagnostic Port........................................................ 960 Interface Module (IM) Diagnostic Port............................................... 960 Payload Meter Diagnostic Port....................................................... 960 Truck Control Interface (TCI) Diagnostic Port....................................... 960 Propulsion System Controller (PSC) Diagnostic Port.................................. 960 Engine Diagnostic Port (CENSE)...................................................... 960 Engine Diagnostic Port (QUANTUM).................................................... 960 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 961 Fan Control Knob.................................................................... 961 Temperature Control Knob............................................................ 961 Directional Control Knob............................................................ 961 Heater Vents........................................................................ 961 INSTRUMENT PANEL........................................................................ 962 Key Switch.......................................................................... 964 Starting............................................................................ 964 Air Conditioner Compressor Switch................................................... 964 Rotating Beacon Light Switch (Optional)............................................. 964 Heated Mirror Switch (Optional)..................................................... 964 Rest Switch......................................................................... 965 Wheel Brake Lock Control............................................................ 965 Hazard Warning Lights............................................................... 965 Cab/Air Conditioner Vents........................................................... 966 Engine Oil Pressure Gauge........................................................... 966 Right Turn Signal Indicator......................................................... 966 Tachometer.......................................................................... 966 High Beam Indicator................................................................. 966 Speedometer/Payload Meter Display................................................... 966 Left Turn Signal Indicator.......................................................... 966 Water Temperature Gauge............................................................. 966 Lamp Test Switch.................................................................... 967 Light Switch........................................................................ 967 Ladder Light Switch................................................................. 967 Manual Backup Switch................................................................ 967 Fog Lights (Optional)............................................................... 967 Payload Meter Switch................................................................ 967 Panel Light Dimmer.................................................................. 968 Hydraulic Oil Temperature Gauge..................................................... 968 Hourmeter........................................................................... 968 Fuel Level Gauge.................................................................... 968 OVERHEAD STATUS / WARNING INDICATORS.................................................... 969 Status / Warning Indicator Light Symbols............................................ 970 KOMTRAX Plus............................................................................ 976 Operation........................................................................... 976 Interface Module.................................................................... 977 Basic Precautions................................................................... 977 SECTION P: LUBRICATION AND SERVICE ................................................................. 979 LUBRICATION AND SERVICE......................................................................... 981 LUBRICATION AND SERVICE..................................................................... 983 GENERAL................................................................................. 983 830E SERVICE CAPACITIES................................................................. 983 HYDRAULIC TANK SERVICE.................................................................. 983 Adding Oil.......................................................................... 983 COOLING SYSTEM SERVICE.................................................................. 984 Radiator Filling Procedure.......................................................... 984 Coolant Specifications.............................................................. 984 Unacceptable Practices.............................................................. 984 WHEEL MOTOR SERVICE..................................................................... 984 RESERVE ENGINE OIL SYSTEM (Optional).................................................... 985 Reserve Oil Tank Filling Procedure (Remote fill).................................... 985 Inline Screen....................................................................... 985 QUICK FILL SERVICE CENTER............................................................... 986 LUBRICATION CHART....................................................................... 987 10 HOUR (DAILY) INSPECTION.............................................................. 988 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................... 991 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................... 992 250 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 993 500 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 997 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS........................................... 999 2500 HOUR MAINTENANCE CHECKS............................................................1000 5000 HOUR MAINTENANCE CHECKS............................................................1000 AUTOMATIC LUBRICATION SYSTEM....................................................................1001 AUTOMATIC LUBRICATION SYSTEM................................................................1003 GENERAL DESCRIPTION.....................................................................1003 SYSTEM COMPONENTS.......................................................................1005 Filter..............................................................................1005 Hydraulic Motor and Pump............................................................1005 Grease Reservoir....................................................................1005 Pressure Reducing Valve.............................................................1005 Flow Control Valve..................................................................1005 Solenoid Valve......................................................................1005 Vent Valve..........................................................................1005 Lubrication Cycle Timer.............................................................1005 Over Pressure Cut Off Switch........................................................1005 Grease Pressure Failure Switch......................................................1005 Injectors...........................................................................1005 Relief Valve........................................................................1005 SYSTEM OPERATION........................................................................1006 Normal Operation....................................................................1006 Required Lubricant..................................................................1007 System Priming......................................................................1007 Filter Assembly.....................................................................1007 LUBRICANT PUMP..........................................................................1008 Pump Housing Oil Level..............................................................1008 Pump Pressure Control...............................................................1008 INJECTORS (SL-1 Series “H”).............................................................1009 Injector Specifications.............................................................1009 Injector Adjustment.................................................................1009 INJECTOR OPERATION......................................................................1010 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1011 Daily Lubrication System Inspection.................................................1011 250 Hour Inspection.................................................................1011 1000 Hour Inspection................................................................1011 SYSTEM CHECKOUT.........................................................................1012 Lubrication Controller Check........................................................1012 Lubrication Controller Operation....................................................1012 Lubrication Controller Components...................................................1012 Lubrication Controller Adjustment...................................................1012 SYSTEM TROUBLESHOOTING CHART............................................................1014 SECTION Q: A;PHABETICAL INDEX ......................................................................1017 SECTION R: SYSTEM SCHEMATICS .......................................................................1021 HH360 Hydraulic Schematic - Brake System .......................................................1023 HH366 Hydraulic Schematic - Steering & Hoist ...................................................1024 HE484 Electrical Schematic - Heater A/C Controls ...............................................1026 XS5100 Electrical System Schematic .............................................................1027
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