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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30240 – A30560) KOMATSU 830E 1AC – PDF DOWNLOAD
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- KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30240 – A30560
- PUBLICATION NUMBER:CEBM021903
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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30240 – A30560) KOMATSU 830E 1AC
KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30240 – A30560) KOMATSU 830E 1AC – PDF DOWNLOAD:
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KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30240 – A30560) KOMATSU 830E 1AC
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of metric (SI) and U.S. standard units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs) torque. All torque specifications have ±10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 830E-1AC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30240 – A30560) 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 MACHINE....................................................................... 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 Electrical Systems Isolation........................................................ 29 Warning Tag......................................................................... 31 Proper Tools........................................................................ 31 Securing The Dump Body.............................................................. 31 DURING MAINTENANCE...................................................................... 32 Personnel........................................................................... 32 Attachments......................................................................... 32 Working Under The Machine........................................................... 32 Keeping The Machine Clean........................................................... 32 Rules To Follow When Adding Fuel Or Oil............................................. 32 Radiator Coolant Level.............................................................. 32 Use Of Lighting..................................................................... 33 Precautions With The Battery........................................................ 33 Handling High Pressure Hoses........................................................ 33 Precautions With High Pressure Oil.................................................. 33 Maintenance Near High Temperatures And High Pressures............................... 33 Rotating Fan And Belts.............................................................. 33 Waste Materials..................................................................... 33 TIRES................................................................................... 34 Handling Tires...................................................................... 34 Tire Maintenance.................................................................... 35 Storing Tires After Removal......................................................... 35 ADDITIONAL JOB SITE RULES................................................................... 36 WHEN REPAIRS ARE NECESSARY.................................................................. 37 Use of Tie-Off Anchor During Maintenance................................................ 37 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK........................................ 38 Preliminary Procedures before Welding or Performing Maintenance......................... 38 Engine Shutdown Procedure before Welding or Performing Maintenance...................... 38 CAPACITOR DISCHARGE SYSTEM.................................................................. 40 Necessary Tools......................................................................... 40 Warnings And Cautions................................................................... 41 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE............................................ 42 Preparation......................................................................... 42 CAPACITOR CHARGE LIGHTS................................................................. 44 FAILURE OF DISCHARGE SYSTEM............................................................. 45 Measuring Dc Voltage On Capacitors.................................................. 45 MANUAL DISCHARGE OF CAPACITORS.......................................................... 46 SHORT ISOLATED CAPACITOR TERMINALS...................................................... 48 TRUCK OPERATION............................................................................. 50 PREPARING FOR OPERATION................................................................. 50 Safety Is Thinking Ahead............................................................ 50 WALK AROUND INSPECTION.................................................................. 50 RETRACTABLE LADDER SYSTEM (If equipped)..................................................... 54 LADDER SYSTEM DESCRIPTION............................................................... 54 LADDER SYSTEM OPERATION................................................................. 55 Normal Operation.................................................................... 55 GENERAL SAFETY.......................................................................... 55 IN-CAB CONTROL PANEL.................................................................... 55 IN-CAB CONTROL PANEL FEATURES........................................................... 56 Digital Display Screen.............................................................. 56 Command Buttons..................................................................... 56 USING THE IN-CAB CONTROL PANEL.......................................................... 57 Raising the Ladder.................................................................. 57 Lowering the Ladder................................................................. 58 USING THE GROUND LEVEL CONTROL BOX...................................................... 59 Raising the Ladder.................................................................. 59 Lowering the Ladder................................................................. 59 Emergency Operation................................................................. 60 ENGINE START-UP SAFETY PRACTICES........................................................ 61 AFTER ENGINE HAS STARTED................................................................ 62 PRE-SHIFT BRAKE CHECK (if equipped)......................................................... 63 Events.................................................................................. 63 OPERATION............................................................................... 63 Description......................................................................... 63 Brake Test Exit Criteria............................................................ 64 PERFORMING THE BRAKE TESTS.............................................................. 64 Setup............................................................................... 64 Service Brake Test.................................................................. 65 Parking Brake Test.................................................................. 66 Retard System Test:................................................................. 66 EMERGENCY STEERING SYSTEM............................................................... 67 Operation........................................................................... 67 Pre-Operation Testing............................................................... 67 Additional Guidelines............................................................... 68 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 68 MACHINE OPERATION ON THE HAUL ROAD...................................................... 69 STARTING ON A GRADE WITH A LOADED TRUCK................................................. 70 PASSING................................................................................. 70 LOADING................................................................................. 70 DUMPING................................................................................. 70 Raising The Dump Body............................................................... 70 Lowering The Dump Body.............................................................. 71 SUDDEN LOSS OF ENGINE POWER............................................................. 72 FUEL DEPLETION.......................................................................... 73 SAFE PARKING PROCEDURES................................................................. 73 NORMAL ENGINE SHUTDOWN PROCEDURE........................................................ 74 DISABLED TRUCK CONNECTORS................................................................... 75 GENERAL................................................................................. 75 STEERING AND BRAKE SYSTEM............................................................... 75 Hookup.............................................................................. 75 HOIST SYSTEM............................................................................ 76 Hookup.............................................................................. 76 Dumping Procedure................................................................... 76 TOWING...................................................................................... 78 Special Wiring Harness.................................................................. 78 Towing Procedure........................................................................ 78 RESERVE ENGINE OIL SYSTEM (Optional)........................................................ 81 WARNINGS AND CAUTIONS........................................................................... 83 TORQUE TABLES AND CONVERSION CHARTS ............................................................ 97 STORAGE PROCEDURES.............................................................................. 107 STORAGE AND IDLE MACHINE PREPARATION........................................................ 109 SHORT TERM IDLE PERIODS................................................................. 109 PREPARATION FOR STORAGE................................................................. 110 REMOVAL FROM STORAGE.................................................................... 111 RECONDITIONING AN IDLE VEHICLE.......................................................... 113 ENGINE OPERATION........................................................................ 115 AFTER ENGINE HAS STARTED................................................................ 116 ENGINE STORAGE.......................................................................... 117 Engine Storage-(Short Term)......................................................... 117 Engine Storage- (Long Term)......................................................... 118 TRANSMISSION PRESERVATION AND STORAGE................................................... 123 Restoring Transmission to Service................................................... 123 ELECTRIC DRIVE TRUCKS................................................................... 119 SECTION B: STRUCTURES .............................................................................. 125 STRUCTURAL COMPONENTS........................................................................... 127 STRUCTURAL COMPONENTS....................................................................... 129 Preparation............................................................................. 129 LADDERS................................................................................. 130 Removal............................................................................. 130 Installation........................................................................ 130 RIGHT DECK.............................................................................. 130 Removal............................................................................. 130 Installation........................................................................ 132 LEFT DECK............................................................................... 132 Removal............................................................................. 132 Installation........................................................................ 133 CENTER DECK............................................................................. 133 DUMP BODY ...................................................................................... 135 DUMP BODY................................................................................... 137 Removal................................................................................. 137 Installation............................................................................ 138 BODY PADS............................................................................... 139 Removal............................................................................. 139 Installation........................................................................ 139 Adjustment.......................................................................... 140 BODY GUIDE.............................................................................. 141 BODY-UP RETENTION CABLE................................................................. 142 BODY POSITION INDICATOR................................................................. 142 HOIST LIMIT SWITCH...................................................................... 142 BODY UP SWITCH.......................................................................... 142 ROCK EJECTORS........................................................................... 143 Inspection.......................................................................... 143 FUEL TANK....................................................................................... 145 FUEL TANK................................................................................... 146 Removal................................................................................. 146 Installation............................................................................ 146 Repair.................................................................................. 148 Cleaning................................................................................ 148 FUEL GAUGE SENDER....................................................................... 148 Removal............................................................................. 148 Installation........................................................................ 148 FUEL TANK BREATHER VALVE................................................................ 149 Disassembly......................................................................... 149 Assembly............................................................................ 149 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 150 SECTION C: ENGINE .................................................................................. 151 POWER MODULE.................................................................................... 153 POWER MODULE................................................................................ 155 PREPARATION............................................................................. 155 Removal............................................................................. 155 Installation........................................................................ 160 COOLING SYSTEM.................................................................................. 165 COOLING SYSTEM DESCRIPTION.................................................................. 167 RADIATOR................................................................................ 168 Removal............................................................................. 168 Installation........................................................................ 171 Radiator Filling Procedure.......................................................... 172 REPAIRING THE RADIATOR.................................................................. 173 Internal Inspection................................................................. 173 External Cleaning................................................................... 173 Disassembly......................................................................... 173 Cleaning and Inspection............................................................. 174 Assembly............................................................................ 174 Pressure Testing.................................................................... 176 COOLANT SYSTEM TROUBLESHOOTING.......................................................... 176 POWER TRAIN..................................................................................... 177 ALTERNATOR REMOVAL PROCEDURE................................................................ 179 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)........................................ 179 ENGINE/ALTERNATOR MATING.................................................................... 181 General Instructions.................................................................... 181 Measuring Procedure..................................................................... 181 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine........................... 183 ENGINE...................................................................................... 184 Removal................................................................................. 184 Service................................................................................. 185 Installation............................................................................ 185 AIR CLEANERS ................................................................................... 187 AIR CLEANERS................................................................................ 189 OPERATION............................................................................... 189 SERVICING THE AIR CLEANERS.............................................................. 189 Replacing The Elements.............................................................. 190 AIR CLEANER ASSEMBLY CLEANING........................................................... 191 Primary Element Cleaning............................................................ 191 Precleaner Section Cleaning......................................................... 193 AIR INTAKE TROUBLESHOOTING.............................................................. 194 FAN CLUTCH ..................................................................................... 195 FAN CLUTCH.................................................................................. 197 REMOVAL & INSTALLATION TOOLING.......................................................... 197 DISASSEMBLY............................................................................. 200 CLEANING AND INSPECTION................................................................. 210 ASSEMBLY................................................................................ 214 TEST PROCEDURE.......................................................................... 228 SECTION D: 24V DC ELECTRICAL SYSTEM ................................................................ 229 24VDC ELECTRIC SUPPLY SYSTEM.................................................................... 231 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 233 ELECTRICAL SYSTEM DESCRIPTION........................................................... 233 BATTERIES............................................................................... 233 Maintenance and Service............................................................. 233 Troubleshooting..................................................................... 233 BATTERY SUPPLY SYSTEM................................................................... 235 24VDC Battery Charging Alternator................................................... 235 Battery Box......................................................................... 235 Removal............................................................................. 236 Installation........................................................................ 236 Battery Control Box................................................................. 237 24VDC Auxiliary Battery Receptacles................................................. 237 Isolator Diode...................................................................... 237 Engine Start Relay.................................................................. 237 Isolation Box Assembly.............................................................. 237 Engine Shutdown Switch.............................................................. 238 Access Ladder Light Switch.......................................................... 238 Battery Disconnect Switches......................................................... 238 Propel Lockout Lever................................................................ 238 LED Lights.......................................................................... 238 24VDC to 12VDC Converter............................................................ 238 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)..................................... 239 Operation........................................................................... 239 Pressure Switch..................................................................... 240 Check Valve......................................................................... 240 Timer Solenoid...................................................................... 240 MAINTENANCE............................................................................. 240 Prelube System Operation Checks..................................................... 240 Check Valve......................................................................... 240 Timer Solenoid...................................................................... 240 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.............................................. 241 24VDC ELECTRIC START SYSTEM................................................................. 243 CRANKING MOTORS......................................................................... 243 Operation........................................................................... 243 Removal............................................................................. 243 Installation........................................................................ 243 CRANKING MOTOR TROUBLESHOOTING.......................................................... 244 Preliminary Inspection.............................................................. 244 No-Load Test........................................................................ 244 Interpreting Results of Tests....................................................... 245 Disassembly......................................................................... 245 Cleaning and Inspection............................................................. 246 Armature Servicing.................................................................. 248 Field Coil Checks................................................................... 248 Field Coil Removal.................................................................. 248 SOLENOID CHECKS......................................................................... 249 Test................................................................................ 249 Assembly............................................................................ 250 Bearing Replacement:................................................................ 250 Motor Assembly:..................................................................... 250 Pinion Clearance.................................................................... 251 MAGNETIC SWITCH......................................................................... 251 Removal............................................................................. 251 Installation........................................................................ 251 Coil Test........................................................................... 252 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................. 253 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................................... 255 TRUCK SHUTDOWN PROCEDURE................................................................ 255 BRAKE WARNING BUZZER.................................................................... 255 AUXILIARY CONTROL CABINET COMPONENTS.................................................... 255 Power Distribution Terminals........................................................ 255 Pulse Voltage Modulator (PMV)....................................................... 256 Control Power Relay................................................................. 256 Auto Lube Timer..................................................................... 256 Ground Level Power Relay............................................................ 256 Diode Board - DB1................................................................... 258 Fuse Blocks......................................................................... 259 Alarm Indicating Device (AID) System................................................ 259 Diode Matrix (With Sound)........................................................... 260 Diode Matrix (Without Sound)........................................................ 260 Hot Switch Inverter................................................................. 260 Hot Switch Inverter (Not Used)...................................................... 261 Temperature and Latch............................................................... 261 RELAY BOARDS............................................................................ 262 Relay Boards RB1, RB3, RB4, RB5..................................................... 262 Relay Boards RB6, RB7, RB8, RB9..................................................... 263 Service............................................................................. 263 Relay Board Functions............................................................... 265 MAGNETIC SWITCHES....................................................................... 267 Body position switches (With proximity switches).................................... 267 BODY-UP SWITCH...................................................................... 267 Operation....................................................................... 267 Adjustment...................................................................... 267 Service......................................................................... 267 HOIST LIMIT SWITCH.................................................................. 268 Operation....................................................................... 268 Adjustment...................................................................... 268 Service......................................................................... 268 MAGNETIC SWITCHES....................................................................... 269 Body position switches (With proximity switch and magnet)........................... 269 Proximity switch operation.......................................................... 269 Service............................................................................. 269 BODY-UP SWITCH...................................................................... 270 Adjust the body up switch....................................................... 270 HOIST LIMIT SWITCH.................................................................. 271 Operation....................................................................... 271 Adjust the hoist limit switch................................................... 272 FUSE BLOCK CHARTS................................................................... 274 CIRCUIT BREAKER CHART............................................................... 276 CIRCUIT BREAKERS.................................................................... 276 KOMTRAX Plus SYSTEM ............................................................................ 277 KOMTRAX Plus COMPONENTS..................................................................... 279 KOMTRAX Plus BASIC FEATURES............................................................. 279 Gather Data......................................................................... 279 Convert and Record Data............................................................. 279 Communicate Data to Off-Board Systems............................................... 280 USING THE KOMTRAX Plus SYSTEM........................................................... 281 Turning the KOMTRAX Plus System ON.................................................. 281 Normal KOMTRAX Plus Operation....................................................... 281 Turning the KOMTRAX Plus System OFF................................................. 282 Downloading from the KOMTRAX Plus Controller........................................ 282 KOMTRAX Plus DATA ITEMS................................................................. 283 Fault Codes......................................................................... 283 Machine History..................................................................... 283 KOMTRAX Plus History................................................................ 283 Snapshots........................................................................... 284 Manual Snapshots.................................................................... 284 Trends.............................................................................. 286 Histogram (Load Map) Data........................................................... 286 Haul Cycle Data..................................................................... 287 Alarm and Snapshot Triggers......................................................... 288 Satellite Features.................................................................. 288 KOMTRAX Plus DIAGNOSTIC FEATURES........................................................ 290 Fault History....................................................................... 290 KOMTRAX Plus LED Digits............................................................. 290 KOMTRAX Plus CONTROLLER................................................................. 290 Removal............................................................................. 291 Installation........................................................................ 291 KOMTRAX Plus SOFTWARE................................................................... 293 NECESSARY SOFTWARE.................................................................. 293 NECESSARY TOOLS..................................................................... 293 KOMTRAX Plus SYSTEM SET UP.......................................................... 294 KOMTRAX Plus Controller......................................................... 294 KOMTRAX Plus CONTROLLER............................................................. 294 KOMTRAX Plus TOOL BOX........................................................... 294 Installation................................................................ 294 KOMTRAX Plus SETTING TOOL....................................................... 294 Installation................................................................ 294 KOMTRAX Plus INITIALIZATION PROCEDURE............................................... 295 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE...................................... 295 KOMTRAX Plus Setting Tool software program.................................. 295 Select Operation............................................................ 295 KOMTRAX Plus Setting Function............................................... 296 Machine Information Setting(1).............................................. 296 Machine Information Setting(2).............................................. 296 Date & Time Setting......................................................... 296 GCC Setting................................................................. 297 Setting Summary............................................................. 297 2. KOMTRAX Plus SNAPSHOT PROCEDURE.............................................. 298 3. KOMTRAX Plus DOWNLOAD PROCEDURE.............................................. 299 4. LOCATION OF DOWNLOAD FILES................................................... 299 5. KOMTRAX Plus FTP UPLOAD PROCEDURE............................................ 300 6. KOMTRAX Plus INITIALIZATION FORMS............................................ 301 WHEN REPLACING A KOMTRAX Plus CONTROLLER............................................ 302 To Set: Date & Time; Satellite; Payload Meter................................... 304 Review Setting Information...................................................... 306 KOMTRAX Plus CONTROLLER CHECKOUT................................................ 307 KOMTRAX Plus Controller..................................................... 307 Necessary Equipment:........................................................ 307 Preliminary................................................................. 308 KOMTRAX Plus Controller Checkout Procedure.................................. 309 ORBCOMM CONTROLLER.............................................................. 311 Removal..................................................................... 311 Installation................................................................ 311 INTERFACE MODULE ............................................................................... 313 INTERFACE MODULE............................................................................ 315 Removal................................................................................. 315 Installation............................................................................ 315 SENSORS................................................................................. 316 Temperature Sensors................................................................. 316 Pressure Sensors.................................................................... 316 INTERFACE MODULE SOFTWARE................................................................... 317 NECESSARY SOFTWARE...................................................................... 317 NECESSARY TOOLS......................................................................... 317 FLASHBURN PROGRAM....................................................................... 318 Installation........................................................................ 318 INTERFACE MODULE APPLICATION CODE....................................................... 318 Installation........................................................................ 318 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM................................. 318 Installation........................................................................ 318 Using The Program................................................................... 318 INTERFACE MODULE CHECKOUT............................................................... 319 Interface Module.................................................................... 319 Necessary Equipment:................................................................ 319 Preliminary......................................................................... 320 Checking Inputs And Outputs From The Interface Module............................... 320 Check Analog Inputs To The Interface Module......................................... 324 Check CAN RPC & J1939 Interfaces To The IM.......................................... 324 Check Outputs From The Interface Module............................................. 324 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES ................................ 327 KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING........................... 329 TROUBLESHOOTING......................................................................... 329 GENERAL............................................................................. 329 Structure and Purpose........................................................... 329 TROUBLESHOOTING..................................................................... 330 Communications Networks......................................................... 330 Coaxial Cable................................................................... 330 FAULT CODES......................................................................... 331 Fault History................................................................... 331 KOMTRAX Plus LED Display Fault Codes............................................ 332 Chassis Fault Codes............................................................. 333 Engine Fault Codes.............................................................. 337 FAULT TREE ANALYSIS................................................................. 343 Unable to connect to KOMTRAX Plus from laptop PC................................ 343 Flashing Error Code N4-23 (PLM III Communications Fault)........................ 344 Flashing Error Code N4-22 (Engine Communications Fault)......................... 345 No Data Received By WebCARE..................................................... 346 Coaxial Cable Troubleshooting................................................... 347 KOMTRAX PLUS FORMS ............................................................................ 349 KOMTRAX PLUS FORMS.......................................................................... 351 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 351 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 352 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 353 KOMTRAX PLUS INITIALIZATION FORM........................................................ 355 SECTION E: ELECTRIC PROPULSION SYSTEM .............................................................. 357 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 359 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 361 GENERAL SYSTEM DESCRIPTION.............................................................. 361 SYSTEM COMPONENTS....................................................................... 363 Propulsion System Controller (PSC).................................................. 363 Truck Control Interface (TCI)....................................................... 364 Diagnostic Information Display (DID) Panel.......................................... 365 DID Panel Event Codes............................................................... 365 PSC SOFTWARE FUNCTIONS.................................................................. 384 Input Processing.................................................................... 384 State Machine....................................................................... 384 DC Link State....................................................................... 387 Engine Control...................................................................... 388 ALTERNATOR FIELD CONTROL................................................................ 388 Desired Three-Phase Voltage......................................................... 388 Desired DC Link Voltage............................................................. 388 Self-Load........................................................................... 389 Propel Torque Control............................................................... 389 Retard Torque Control............................................................... 389 Wheel Slide Control................................................................. 390 Resistor Grid Control............................................................... 390 Chopper Voltage Control............................................................. 390 EVENT DETECTION AND PROCESSING.......................................................... 390 Power-On Tests...................................................................... 390 Initiated Tests..................................................................... 391 Periodic Tests...................................................................... 391 EVENT RESTRICTIONS...................................................................... 391 EVENT LOGGING AND STORAGE............................................................... 391 Event History Buffer................................................................ 392 Data Packs.......................................................................... 392 To Record and Save a Data Pack to a Disk............................................ 392 Event Reset......................................................................... 393 SERIAL DATA COMMUNICATIONS.............................................................. 393 PSC - TCI Communications Processing................................................. 393 PSC - PTU Communications Processing................................................. 393 Inverter Communications Processing.................................................. 394 OUTPUT PROCESSING....................................................................... 394 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 394 Fast Start.......................................................................... 394 Engine Shutdown/Engine Not Running.................................................. 394 Limp Home Mode...................................................................... 395 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 396 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 404 Removal............................................................................. 404 Installation........................................................................ 404 Disassembly......................................................................... 404 Assembly............................................................................ 404 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 405 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 407 AC DRIVE SYSTEM MAINTENANCE............................................................. 407 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 408 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 408 SYSTEM CHECKOUT......................................................................... 409 Battery and Control Circuit Checks - Battery Power OFF.............................. 409 Battery and Control Circuit Checks - Battery Power ON............................... 412 Checks with Key Switch OFF.......................................................... 413 Checks with Key Switch ON........................................................... 413 CPU Battery Checks.................................................................. 413 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 414 TCI PROGRAMMING......................................................................... 414 PSC PROGRAMMING......................................................................... 415 INVERTER PROGRAMMING.................................................................... 415 CPU RESET............................................................................... 415 PSC CHECKOUT............................................................................ 416 PSC Digital Input Checks............................................................ 416 PSC Digital Output Checks........................................................... 420 TCI CHECKOUT............................................................................ 421 Modular Mining Communication Port Check............................................. 421 TCI Digital Input Checks............................................................ 421 TCI Digital Output Tests............................................................ 427 CALIBRATIONS............................................................................ 430 Speedometer......................................................................... 430 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 430 ERASING EVENTS.......................................................................... 430 PSC................................................................................. 430 TCI................................................................................. 431 GATE DRIVER POWER CONVERTER TEST........................................................ 431 LOAD TESTING............................................................................ 432 Preparation......................................................................... 432 Alternator Speed Sensor Checks...................................................... 432 Battery Boost Check................................................................. 432 Brake Circuit Switch Checks......................................................... 433 Hoist & Steering Circuit Switch Checks.............................................. 433 Link Energized Checks............................................................... 433 Loadbox Test........................................................................ 435 TROUBLESHOOTING......................................................................... 439 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 439 Phase Module and Chopper Module Troubleshooting..................................... 439 PHASE MODULE REPLACEMENT................................................................ 440 Phase Module Removal................................................................ 440 Phase Module Installation........................................................... 440 SECTION G: DRIVE AXLE, SPINDLE, AND WHEELS ......................................................... 441 TIRES AND RIMS.................................................................................. 443 TIRES AND RIMS.............................................................................. 445 FRONT TIRES AND RIMS.................................................................... 445 Removal............................................................................. 445 Installation........................................................................ 447 REAR TIRES AND RIMS..................................................................... 447 Removal............................................................................. 447 Installation........................................................................ 448 RIM AND TIRE............................................................................ 450 Tire Removal........................................................................ 450 Rim And Tire Preparation............................................................ 450 Lubricants.......................................................................... 451 Tire Installation................................................................... 451 FRONT WHEEL HUB AND SPINDLES.................................................................... 453 FRONT WHEEL HUB AND SPINDLE................................................................. 455 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 455 Removal............................................................................. 455 Spindle Removal Procedure (Optional) (off of the truck)............................. 458 Installation........................................................................ 460 Disassembly......................................................................... 463 Cleaning and Inspection............................................................. 463 Assembly............................................................................ 464 Wheel Bearing Adjustment (Tire Removed)............................................. 466 Wheel Bearing Adjustment (Tire mounted)............................................. 467 OIL SAMPLING PROCEDURE.................................................................. 468 Oil Sampling Guidelines............................................................. 469 Procedure........................................................................... 469 OIL DRAIN AND REFILL PROCEDURE.......................................................... 469 STEERING CYLINDERS...................................................................... 470 Spherical Bearing Wear Limits....................................................... 470 Removal............................................................................. 471 Installation........................................................................ 471 Bearing Replacement (Steering cylinder and tie rod)................................. 471 TIE ROD................................................................................. 473 Removal............................................................................. 473 Installation........................................................................ 473 Disassembly......................................................................... 473 Assembly............................................................................ 474 TOE-IN ADJUSTMENT....................................................................... 475 REAR AXLE HOUSING ATTACHMENT.................................................................... 477 REAR AXLE HOUSING ATTACHMENT................................................................ 479 PIVOT PIN............................................................................... 479 Removal............................................................................. 479 Installation........................................................................ 479 PIVOT EYE BEARING....................................................................... 480 Disassembly......................................................................... 480 Assembly............................................................................ 480 PIVOT EYE REPAIR........................................................................ 481 Removal............................................................................. 481 Installation........................................................................ 481 Disassembly......................................................................... 481 Assembly............................................................................ 481 ANTI-SWAY BAR........................................................................... 482 Removal............................................................................. 482 Installation........................................................................ 482 Disassembly......................................................................... 482 Cleaning and Inspection............................................................. 482 Assembly............................................................................ 482 REAR AXLE HOUSING............................................................................... 483 REAR AXLE HOUSING........................................................................... 485 REAR AXLE HOUSING....................................................................... 485 Removal............................................................................. 485 Installation........................................................................ 485 WHEEL MOTOR............................................................................. 486 Removal............................................................................. 486 Cleaning and Inspection............................................................. 486 Installation........................................................................ 487 WHEEL MOTOR GEAR OIL.................................................................... 490 Change/Filter The Gear case Oil..................................................... 490 Oil................................................................................. 490 Remove And Clean Magnetic Plugs..................................................... 490 Flushing The Gearbox................................................................ 490 Check Gear Case Oil Level........................................................... 490 SECTION H: SUSPENSIONS INDEX....................................................................... 491 FRONT SUSPENSION................................................................................ 493 FRONT SUSPENSION............................................................................ 495 Removal................................................................................. 495 Installation............................................................................ 496 TURN-OF-THE-NUT Tightening Procedure.................................................... 498 Upper Mounting Joint - 60° Advance.................................................. 498 Lower Mounting Joint - 90° Advance.................................................. 500 Inspection.......................................................................... 500 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 501 Bearing Structure Removal........................................................... 501 Bearing Structure Installation...................................................... 501 MAJOR SUSPENSION REBUILD................................................................ 502 Disassembly......................................................................... 502 Assembly............................................................................ 503 PRESSURE TEST........................................................................... 505 REAR SUSPENSIONS ............................................................................... 507 REAR SUSPENSIONS............................................................................ 509 Removal................................................................................. 509 Installation............................................................................ 512 ROD UP SUSPENSION....................................................................... 514 Disassembly......................................................................... 514 Cleaning and Inspection............................................................. 514 Assembly............................................................................ 514 ROD DOWN SUSPENSION..................................................................... 516 Disassembly......................................................................... 516 Cleaning and Inspection............................................................. 516 Assembly............................................................................ 518 PRESSURE TEST........................................................................... 520 Suspension pressure test............................................................ 520 OILING AND CHARGING PROCEDURE................................................................... 521 OILING AND CHARGING PROCEDURE............................................................... 523 GENERAL................................................................................. 523 EQUIPMENT LIST.......................................................................... 523 HYDRAIR® CHARGING KIT................................................................... 524 Installation of Charging Kit........................................................ 524 Removal of Charging Kit............................................................. 524 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 525 FRONT SUSPENSION........................................................................ 525 Front Suspension Oiling............................................................. 525 Front Suspension Nitrogen Charging.................................................. 527 REAR SUSPENSION - ROD UP................................................................ 529 Rear Suspension Oiling (Rod Up Only)................................................ 529 Rear Suspension Nitrogen Charging (Rod Up Only)..................................... 530 REAR SUSPENSION - ROD DOWN.............................................................. 532 Rear Suspension Oiling (Rod Down Only).............................................. 532 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 534 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 536 SECTION J: BRAKE SYSTEM ............................................................................ 537 BRAKE CIRCUIT................................................................................... 539 BRAKE CIRCUIT............................................................................... 541 OPERATION............................................................................... 541 SERVICE BRAKE CIRCUIT OPERATION......................................................... 541 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 543 PARKING BRAKE CIRCUIT................................................................... 543 Normal Operation (key switch on, engine running).................................... 543 BRAKE LOCK CIRCUIT...................................................................... 544 WARNING CIRCUIT......................................................................... 544 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 547 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 549 BRAKE VALVE............................................................................. 549 Rebuild Criteria.................................................................... 549 Removal............................................................................. 549 Installation........................................................................ 551 DISASSEMBLY............................................................................. 553 Cleaning and Inspection............................................................. 555 ASSEMBLY................................................................................ 555 Actuator Base Threaded Inserts...................................................... 555 Boot and Cap........................................................................ 555 Valve Body Seal Installation........................................................ 556 Regulator Sleeve O-Ring Installation................................................ 556 Actuator Plunger O-ring Installation................................................ 557 Assembly of Valve................................................................... 557 VALVE BENCH TEST AND ADJUSTMENT......................................................... 559 Test Set Up Procedure............................................................... 560 Brake Valve Output Pressure Adjustment.............................................. 560 Final Test and Adjustment........................................................... 561 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 562 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 564 Installation of Retard Pedal To Brake Pedal......................................... 564 HYDRAULIC BRAKE ACCUMULATORS............................................................ 565 Brake Accumulator Bleed Down Procedure.............................................. 565 Removal............................................................................. 565 Installation........................................................................ 565 Disassembly......................................................................... 565 Cleaning and Inspection............................................................. 567 Assembly............................................................................ 567 Charging Procedure.................................................................. 569 BRAKE MANIFOLD.......................................................................... 570 Removal............................................................................. 570 Removal............................................................................. 570 Installation........................................................................ 571 Disassembly......................................................................... 571 Cleaning and Inspection............................................................. 572 Assembly............................................................................ 572 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 573 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 575 EQUIPMENT REQUIRED...................................................................... 577 INITIAL SYSTEM SET-UP................................................................... 578 PARKING BRAKE........................................................................... 578 BRAKE SYSTEM CHECK-OUT.................................................................. 579 BRAKE LOCK.............................................................................. 579 FAILURE MODES CHECK-OUT................................................................. 580 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 581 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 584 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 585 FRONT BRAKES.................................................................................... 587 WHEEL SPEED FRONT DISC BRAKES............................................................... 589 BRAKE CALIPER........................................................................... 589 Caliper Removal..................................................................... 589 Installation........................................................................ 590 Disassembly......................................................................... 591 Assembly............................................................................ 591 Cleaning and Inspection............................................................. 592 BRAKE LINING............................................................................ 593 Replacement......................................................................... 593 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................. 595 GENERAL............................................................................. 595 Safety Precautions.............................................................. 595 Front Brake Conditioning........................................................ 595 BRAKE BLEEDING PROCEDURES........................................................... 596 ARMATURE SPEED REAR DISC BRAKES................................................................. 597 ARMATURE SPEED REAR DISC BRAKES............................................................. 599 REAR BRAKES............................................................................. 599 CALIPER AND DISC.................................................................... 599 Removal......................................................................... 599 Installation.................................................................... 601 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 603 BRAKE BLEEDING PROCEDURE............................................................ 604 Service Brake................................................................... 604 Park Brake...................................................................... 604 CALIPER............................................................................. 605 Disassembly..................................................................... 605 PISTON SUBASSEMBLY.................................................................. 608 Disassembly..................................................................... 608 PREPARATION FOR ASSEMBLY............................................................ 609 Clean Parts..................................................................... 609 For Rough Metal Parts........................................................... 610 Dry and Inspect Parts........................................................... 610 Corrosion Protection............................................................ 610 INSPECTION.......................................................................... 610 Caliper Parts................................................................... 610 Shoes, Linings and End Plates................................................... 611 Inspect linings................................................................. 611 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 611 Piston Assembly Adjuster Grip Force............................................. 612 Adjuster Force.................................................................. 614 Piston Return Spring............................................................ 616 ASSEMBLY............................................................................ 617 Adjuster and Pin Assembly....................................................... 617 Piston Subassembly.............................................................. 618 Brake Caliper................................................................... 619 PERIODIC INSPECTIONS................................................................ 625 Shoes, Linings and End Plates................................................... 625 Inspect the following areas for fluid leaks..................................... 625 Dust Boots...................................................................... 625 Brake Disc...................................................................... 625 BRAKE LINING........................................................................ 626 Replacement..................................................................... 626 BRAKE DISC.......................................................................... 626 Inspection...................................................................... 626 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE....................................... 627 GENERAL............................................................................. 627 SAFETY PRECAUTIONS.................................................................. 627 Rear Brake Conditioning......................................................... 628 SECTION L: HYDRAULIC SYSTEM........................................................................ 631 HYDRAULIC SYSTEM................................................................................ 633 HYDRAULIC SYSTEM............................................................................ 635 HYDRAULIC SYSTEM OPERATION.............................................................. 635 COMPONENT DESCRIPTION................................................................... 636 Hoist Pump.......................................................................... 636 Steering/Brake Pump................................................................. 636 Tank................................................................................ 636 High Pressure Hydraulic Filters..................................................... 636 Bleeddown Manifold.................................................................. 636 Steering System Accumulators........................................................ 636 DISABLED TRUCK CONNECTORS............................................................... 638 GENERAL............................................................................. 638 STEERING AND BRAKE SYSTEM........................................................... 638 Hookup.......................................................................... 638 HOIST SYSTEM........................................................................ 639 Hookup.......................................................................... 639 Dumping Procedure............................................................... 639 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 641 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 643 HOIST PUMP.............................................................................. 643 Removal............................................................................. 643 Installation........................................................................ 644 Disassembly......................................................................... 646 Inspection Of Parts................................................................. 649 Assembly............................................................................ 650 HYDRAULIC TANK.......................................................................... 656 Filling Instructions................................................................ 656 Removal............................................................................. 656 Installation........................................................................ 657 HYDRAULIC TANK STRAINERS................................................................ 658 Removal............................................................................. 658 Inspect and Clean................................................................... 658 Installation........................................................................ 659 HYDRAULIC TANK BREATHERS................................................................ 659 HOIST CIRCUIT FILTERS................................................................... 660 FILTER ELEMENT REPLACEMENT.............................................................. 661 Removal............................................................................. 661 Installation........................................................................ 661 INDICATOR SWITCH........................................................................ 661 STEERING CIRCUIT................................................................................ 663 STEERING CIRCUIT............................................................................ 665 STEERING CIRCUIT OPERATION.............................................................. 665 COMPONENT DESCRIPTION................................................................... 666 STEERING CONTROL UNIT............................................................... 666 FLOW AMPLIFIER...................................................................... 666 No Steer........................................................................ 668 Steering Left................................................................... 670 Steering Right.................................................................. 672 No Steer, External Shock Load................................................... 674 BLEED DOWN MANIFOLD................................................................. 676 ACCUMULATORS........................................................................ 677 Low Precharge Warning Switch.................................................... 677 HIGH PRESSURE FILTER................................................................ 677 STEERING/BRAKE PUMP................................................................. 677 Operation....................................................................... 678 PRINCIPLE OF OPERATION.............................................................. 680 Full Pump Volume:............................................................... 680 Half Pump Volume:............................................................... 680 Neutral Position:............................................................... 681 STEERING CIRCUIT COMPONENT REPAIR............................................................... 683 STEERING CIRCUIT COMPONENT REPAIR........................................................... 685 BLEED DOWN MANIFOLD..................................................................... 685 Removal............................................................................. 685 Installation........................................................................ 685 ACCUMULATOR............................................................................. 686 Removal............................................................................. 686 Installation........................................................................ 687 Disassembly......................................................................... 687 Cleaning and Inspection............................................................. 688 Assembly............................................................................ 688 LEAK TESTING............................................................................ 690 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 691 Temperature During Precharge........................................................ 694 ACCUMULATOR STORAGE PROCEDURES.......................................................... 694 Instructions For Storing Bladder Accumulators....................................... 694 Installation........................................................................ 695 Bladder Storage Procedures.......................................................... 695 FLOW AMPLIFIER.......................................................................... 696 Removal............................................................................. 696 Installation........................................................................ 696 Disassembly......................................................................... 698 Reassembly.......................................................................... 699 STEERING CONTROL UNIT................................................................... 700 Removal............................................................................. 700 Spline Inspection................................................................... 700 Installation........................................................................ 701 Disassembly......................................................................... 701 Cleaning and Inspection............................................................. 702 Assembly............................................................................ 703 STEERING CYLINDER....................................................................... 707 Disassembly......................................................................... 707 Inspection and Cleaning............................................................. 707 Assembly............................................................................ 707 STEERING CIRCUIT FILTER................................................................. 708 Filter Element Replacement.......................................................... 708 Removal............................................................................. 709 Installation........................................................................ 709 Indicator Switch.................................................................... 709 STEERING AND BRAKE PUMP................................................................. 710 Removal............................................................................. 710 Installation........................................................................ 711 Disassembly......................................................................... 712 Control Piston Group................................................................ 712 Valve Plate Group................................................................... 713 Rotating Group...................................................................... 713 Swashblock Group.................................................................... 714 Driveshaft Group.................................................................... 714 INSPECTION.............................................................................. 714 Control Piston Group................................................................ 714 Valve Plate Group................................................................... 714 Rotating Group...................................................................... 714 Swashblock Group.................................................................... 718 Driveshaft Group.................................................................... 718 Compensator Block and Unloader Module............................................... 718 Stroke Adjuster Assembly............................................................ 718 ASSEMBLY................................................................................ 718 Swashblock Group.................................................................... 718 Control Piston Group................................................................ 720 Valve Plate Group................................................................... 721 HOIST CIRCUIT................................................................................... 723 HOIST CIRCUIT............................................................................... 725 HOIST CIRCUIT OPERATION................................................................. 725 COMPONENT DESCRIPTION................................................................... 726 Hydraulic Tank...................................................................... 726 Hoist Pump.......................................................................... 726 High Pressure Filters............................................................... 726 Hoist Valve......................................................................... 727 Hoist Pilot Valve................................................................... 728 Hoist-up Limit Solenoid............................................................. 728 Pilot Operated Check Valve.......................................................... 728 Counterbalance Valve Manifold....................................................... 729 HOIST SYSTEM OPERATION MODES............................................................ 730 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 730 Power Up Operation (Figure 7-7)..................................................... 732 Hold Operation (Figure 7-8)......................................................... 734 Power Down Operation (Figure 7-9)................................................... 736 Float Operation (Figure 7-10)....................................................... 738 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 741 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 743 HOIST VALVE............................................................................. 743 Removal............................................................................. 743 Installation........................................................................ 743 O-Ring Replacement.................................................................. 744 INLET SECTION........................................................................... 745 Disassembly......................................................................... 745 Cleaning and Inspection............................................................. 746 Assembly............................................................................ 746 SPOOL SECTION........................................................................... 746 Disassembly......................................................................... 746 Cleaning and Inspection............................................................. 749 Assembly............................................................................ 749 HOIST PILOT VALVE....................................................................... 750 Removal............................................................................. 750 Installation........................................................................ 750 Disassembly......................................................................... 751 Cleaning and Inspection............................................................. 752 Assembly............................................................................ 753 BODY UP LIMIT SOLENOID.................................................................. 754 PILOT OPERATED CHECK VALVE.............................................................. 754 HOIST CYLINDERS......................................................................... 754 Removal............................................................................. 754 Installation........................................................................ 755 Disassembly......................................................................... 756 Cleaning and Inspection............................................................. 758 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 759 Quill Installation.................................................................. 759 Installation of Check Balls and Plugs in Quill...................................... 760 Assembly of Cylinder................................................................ 761 Pressure Testing.................................................................... 762 OVERCENTER MANIFOLD..................................................................... 763 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 765 HYDRAULIC CHECKOUT PROCEDURE................................................................ 767 STEERING AND BRAKE PUMP................................................................. 767 Pressure Check And Adjustment Procedure............................................. 767 BLEEDDOWN MANIFOLD...................................................................... 769 SHOCK & SUCTION VALVES.................................................................. 769 Shock & Suction Valve Settings...................................................... 769 LEAKAGE TESTS........................................................................... 771 Steering Control Unit & Flow Amplifier.............................................. 771 Bleeddown Manifold.................................................................. 771 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 773 LOW STEERING PRESSURE SWITCH............................................................ 773 CHECKING HOIST SYSTEM PRESSURES......................................................... 780 Hoist System Relief Pressure Adjustment............................................. 780 Power Down Relief Pressure Adjustment............................................... 781 HOIST COUNTERBALANCE VALVE.......................................................... 782 Preparation:.................................................................... 782 Counterbalance Valve Pressure Check Only:....................................... 782 Counterbalance Valve Adjustment................................................. 783 HYDRAULIC SYSTEM FLUSHING PROCEDURE..................................................... 786 Hydraulic System Flushing Procedure................................................. 786 OIL CLEANLINESS CHECK............................................................... 791 SECTION M: OPTIONS AND SPECIAL TOOLS ............................................................... 793 HEATER OPTIONS ................................................................................. 795 GENERAL INFORMATION......................................................................... 797 TROUBLESHOOTING............................................................................. 797 HEATER ELEMENT.............................................................................. 797 Removal................................................................................. 797 Installation............................................................................ 798 GENERAL..................................................................................... 799 Maintenance............................................................................. 799 HEATING ELEMENT............................................................................. 800 Removal................................................................................. 800 Installation............................................................................ 800 THERMOSTAT.................................................................................. 800 Removal................................................................................. 800 Installation............................................................................ 800 GENERAL INFORMATION......................................................................... 801 TROUBLESHOOTING............................................................................. 801 HEATER ELEMENT.............................................................................. 801 Removal................................................................................. 801 Installation............................................................................ 802 SPECIAL TOOLS................................................................................... 803 NITROGEN CHARGING VALVE..................................................................... 803 ROLL-OUT ASSEMBLY........................................................................... 803 EYE BOLT.................................................................................... 803 OFFSET WRENCH............................................................................... 804 TORQUE ADAPTER.............................................................................. 804 HANDLE...................................................................................... 804 SEAL INSTALLER.............................................................................. 804 SLEEVE ALIGNMENT TOOLS...................................................................... 805 QUICK DISCONNECT COUPLING................................................................... 805 HARNESS..................................................................................... 805 SEAL INSTALLATION RING...................................................................... 805 BELT TENSION TESTER......................................................................... 806 BELT ALIGNMENT TOOL......................................................................... 806 SOCKETS AND ADAPTERS........................................................................ 806 DUST CAPS................................................................................... 806 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 807 PAYLOAD DATA MANAGER........................................................................ 807 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 807 MISCELLANEOUS SERVICE TOOLS................................................................. 808 BRAKE PISTON TOOL........................................................................... 809 HIGH VOLTAGE TOOLS.......................................................................... 812 2000 VDC METER.............................................................................. 812 GROUNDING STICKS............................................................................ 812 BODY PAD SPACER TOOL........................................................................ 813 RADIATOR SHUTTERS ............................................................................. 815 RADIATOR SHUTTERS........................................................................... 817 OPERATION............................................................................... 817 Hydraulic Circuit................................................................... 817 Electrical Circuit:................................................................. 818 MAINTENANCE AND REPAIR.................................................................. 818 TROUBLESHOOTING......................................................................... 819 Hydraulic Troubleshooting........................................................... 822 Electrical Troubleshooting.......................................................... 824 PAYLOAD METER III ™ ........................................................................... 825 OPERATION SECTION........................................................................... 829 Introduction............................................................................ 829 Data Summary........................................................................ 829 Data Gathering...................................................................... 829 COMPONENT DESCRIPTION................................................................... 830 System Diagram...................................................................... 830 Suspension Pressure Sensors......................................................... 830 Inclinometer........................................................................ 830 Operator Display.................................................................... 830 Operator Switch..................................................................... 831 Speed Input......................................................................... 831 Body-Up Switch...................................................................... 831 Brake Lock Switch................................................................... 831 Payload Meter....................................................................... 831 Communications Ports................................................................ 831 Key Switch Input.................................................................... 832 Payload Meter Power................................................................. 832 Load Lights......................................................................... 832 Wiring and Termination.............................................................. 833 TCI Outputs......................................................................... 833 OPERATOR’S DISPLAY AND SWITCH........................................................... 834 Reading the Speedometer............................................................. 834 Reading the Load Display............................................................ 834 Using the Operator ID............................................................... 834 Using the Load and Ton Counter...................................................... 834 Total Ton Counter................................................................... 834 Total Load Counter.................................................................. 835 Clearing the Counters............................................................... 835 Viewing Live Sensor Data............................................................ 835 Other Display Messages.............................................................. 835 PAYLOAD OPERATION & CALCULATION......................................................... 836 Description of Haul Cycle States.................................................... 836 Haul Cycle Description.............................................................. 836 Load Calculation.................................................................... 837 Carry Back.......................................................................... 837 Measurement Accuracy................................................................ 837 SOURCES FOR PAYLOAD ERROR............................................................... 837 Payload Error....................................................................... 837 Loading Conditions.................................................................. 838 Pressure Sensors.................................................................... 838 Swingloads.......................................................................... 838 Speed and Distance.................................................................. 838 HAUL CYCLE DATA......................................................................... 838 Haul Cycle Warning Flags............................................................ 840 Frame Torque Data................................................................... 841 Sprung Weight Data.................................................................. 841 Maximum Speed Data.................................................................. 841 Alarm Records....................................................................... 841 Fault Code Data..................................................................... 842 PC SOFTWARE OVERVIEW.................................................................... 843 System Configuration................................................................ 843 Installing the PLMIII Software...................................................... 843 DOWNLOADING DATA........................................................................ 844 PLM III SYSTEM CONFIGURATION............................................................ 845 Starting Communications............................................................. 845 Displayed Payload Units............................................................. 845 Time Units.......................................................................... 845 Connection Menu..................................................................... 845 Connecting to the Payload Meter..................................................... 846 Configure the Payload Meter......................................................... 846 Setting the Date and Time........................................................... 846 Setting the Truck Type.............................................................. 847 Setting the Gauge Display Units..................................................... 847 Setting the Frame Serial Number..................................................... 847 Setting the Truck Number............................................................ 847 Setting the Komatsu Distributor..................................................... 847 Setting the Komatsu Customer........................................................ 847 Clean Truck Tare.................................................................... 848 Inclinometer Calibration............................................................ 848 DATA ANALYSIS........................................................................... 849 Creating a Query.................................................................... 849 Sorting on Truck Unit Number........................................................ 849 Sorting on Truck Type............................................................... 849 Sorting on Date Range............................................................... 850 Sorting on Time Range............................................................... 850 Payload Detail Screen............................................................... 851 Creating Reports.................................................................... 851 Summary - one page report........................................................... 852 Detailed - multi-page report........................................................ 852 Creating Graphs..................................................................... 853 Exporting Data...................................................................... 853 CSV Export.......................................................................... 853 Compressed.......................................................................... 854 Importing Data...................................................................... 855 Deleting Haul Cycle Records......................................................... 855 Viewing Alarms...................................................................... 856 Deleting Alarm Records.............................................................. 856 TROUBLESHOOTING SECTION..................................................................... 857 TROUBLESHOOTING......................................................................... 857 Viewing Active Alarms............................................................... 857 Real-Time Data Display.............................................................. 857 Testing the Payload Lights.......................................................... 857 Creating Log Files of Inputs........................................................ 858 Daily Inspections................................................................... 858 Periodic Maintenance................................................................ 858 Abnormal Displays at Power-Up....................................................... 859 No Payload Display When Key Switch is Turned ON..................................... 860 No Display on Speedometer........................................................... 861 No Display on Operator Display...................................................... 861 No Communications With PC........................................................... 862 Load Lights Don’t Light During Loading.............................................. 863 Load Lights Remain ON............................................................... 864 Load Lights Remain ON During Dumping................................................ 864 Display Doesn't Clear When The Load Is Dumped....................................... 864 Calibration Problems................................................................ 865 Alarm 1 - Left Front Pressure High.................................................. 866 Alarm 2 - Left Front Pressure Low................................................... 866 Troubleshoot Wiring to Left Front Suspension........................................ 866 Alarm 3 - Right Front Pressure High................................................. 867 Alarm 4 - Right Front Pressure Low.................................................. 867 Troubleshoot Wiring to Right Front Suspension....................................... 867 Alarm 5 -Left Rear Pressure High.................................................... 868 Alarm 6 - Left Rear Pressure Low.................................................... 868 Troubleshoot Wiring to Left Rear Suspension......................................... 868 Alarm 7 - Right Rear Pressure High.................................................. 869 Alarm 8 - Right Rear Pressure Low................................................... 869 Troubleshoot Wiring to Right Rear Suspension........................................ 869 Alarm 9 - Inclinometer High......................................................... 870 Alarm 10 - Inclinometer Low......................................................... 870 Troubleshoot Inclinometer Wiring.................................................... 870 Alarm 13 - Body Up Input Failure.................................................... 871 Alarm 16 - Memory Write Failure..................................................... 872 Alarm 17 - Memory Read Failure...................................................... 872 Alarm 18............................................................................ 873 Alarm 19............................................................................ 873 Alarm 22............................................................................ 873 Operator Switch Doesn't Work........................................................ 874 Alarm 26 - User Switch Fault - SELECT............................................... 874 Alarm 27 - User Switch Fault - SET.................................................. 874 Connector Map....................................................................... 875 Connectors.......................................................................... 876 PLMIII CHECK OUT PROCEDURE.................................................................. 877 General Description..................................................................... 877 Tools Required.......................................................................... 877 Checkout Procedure...................................................................... 877 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 881 Flashburn Programming............................................................... 881 Confirmation Checklist.............................................................. 883 RESERVE ENGINE OIL SYSTEM ..................................................................... 885 RESERVE ENGINE OIL SYSTEM................................................................... 887 Operation............................................................................... 888 LED Monitor Light....................................................................... 888 Tank Fill Control (Optional)............................................................ 889 Filling Procedure (Remote Fill Feature)................................................. 889 SERVICE................................................................................. 890 Every 10 Hours, or once each shift:................................................. 890 Every 500 Hours..................................................................... 890 Changing Oil........................................................................ 890 TROUBLESHOOTING......................................................................... 891 Circuit Fuse........................................................................ 891 SYSTEM ELECTRICAL SCHEMATICS............................................................ 892 RETRACTABLE LADDER SYSTEM....................................................................... 893 RETRACTABLE LADDER SYSTEM................................................................... 898 GENERAL SAFETY.......................................................................... 898 LADDER SYSTEM DESCRIPTION............................................................... 898 LADDER SYSTEM OPERATION................................................................. 898 Normal Operation.................................................................... 898 Emergency Operation................................................................. 900 Limit Switch Operation.............................................................. 900 IN-CAB CONTROL PANEL.................................................................... 900 IN-CAB CONTROL PANEL FEATURES........................................................... 902 Digital Display Screen.............................................................. 902 Command Buttons..................................................................... 902 IN-CAB CONTROL PANEL FUNCTIONS.......................................................... 904 Timing Control...................................................................... 904 Ladder System Status................................................................ 904 Fault Code Identification........................................................... 904 Ladder System Configuration......................................................... 905 In-Cab Control Panel Lockout........................................................ 905 Automatic Raising................................................................... 905 Diagnostics......................................................................... 905 Maintenance......................................................................... 905 USING THE IN-CAB CONTROL PANEL.......................................................... 906 Raising the Ladder.................................................................. 906 Lowering the Ladder................................................................. 907 USING THE GROUND LEVEL CONTROL BOX...................................................... 908 Raising the Ladder.................................................................. 908 Lowering the Ladder................................................................. 908 POWER PACK OPERATION.................................................................... 909 MAINTENANCE............................................................................. 913 Safety During Maintenance........................................................... 913 Unplanned Ladder Movements.......................................................... 913 Automatic Ladder Raising............................................................ 913 Automatic Accumulator Recharging (Ladder in UP position)............................ 914 PREVENTIVE MAINTENANCE PROCEDURES....................................................... 915 Daily Inspection.................................................................... 915 250 Hour Inspection................................................................. 915 5000 Hour Inspection................................................................ 915 SERVICING............................................................................... 916 Check Reservoir Oil Level........................................................... 916 Changing RLS Fluid.................................................................. 916 Cleaning the RLS.................................................................... 917 RLS DIAGNOSTICS......................................................................... 917 Description of Diagnostics Features................................................. 917 Continuous System Monitoring........................................................ 918 Historic System Data Review......................................................... 919 Comms Integrity Monitoring.......................................................... 919 Log and Service Information......................................................... 919 System Event Logs................................................................... 920 SECURITY ACCESS LEVELS.................................................................. 921 Access Level 1 – NONE............................................................... 921 Access Level 2 – RESTRICTED......................................................... 921 Access Level 3 – COMPLETE........................................................... 921 User Access Privileges.............................................................. 922 USER ID – PASSWORD...................................................................... 923 Sequential Field Value Selection Options............................................ 923 Password Character Table............................................................ 923 USER ID – NEW USER SETUP................................................................ 924 SYSTEM FAULTS........................................................................... 924 Fault Type 1: Communications error.................................................. 925 Fault Type 2: 10A/15A fuse blown.................................................... 925 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected........... 926 Fault Type 8: Power pack recharge too long.......................................... 926 Fault Type 9: Inhibit relay fail.................................................... 927 Fault Types 10, 11: Light/Siren relay failure....................................... 927 Fault Type 12: Ladder came off upper limit.......................................... 928 Fault Type 13: Ladder did not reach limit........................................... 928 Fault Type 14: Ladder stayed on limit............................................... 929 Fault Type 15: Low oil level........................................................ 929 Fault Type 16: System voltage over 18V during movement.............................. 930 Fault Type 17: System voltage under 18V............................................. 930 Fault Type 18: System voltage over 31V.............................................. 931 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)...... 931 Fault Type 21: Accumulator recharge > than once/hour................................ 932 Fault Type 22: System raised by park brake.......................................... 932 Fault Types 23, 24: Levels 1 and 2 service overdue.................................. 933 Fault Type 25: Levels 1 and 2 service complete...................................... 933 DATA MANAGEMENT......................................................................... 934 Log Files........................................................................... 934 Generating Reports.................................................................. 935 MENU DIAGRAMS........................................................................... 941 Controller Config................................................................... 941 Contact Information................................................................. 941 Show Recent Logs.................................................................... 941 System Settings..................................................................... 941 Upload Logs to USB.................................................................. 941 Diagnostics......................................................................... 941 SECTION N: OPERATOR CAB ............................................................................ 949 TRUCK CAB AND COMPONENTS........................................................................ 951 TRUCK CAB AND COMPONENTS.................................................................... 953 TRUCK CAB............................................................................... 953 Description......................................................................... 953 Removal............................................................................. 954 Installation........................................................................ 955 CAB DOOR................................................................................ 956 Removal............................................................................. 956 Installation........................................................................ 956 Door Adjustment..................................................................... 956 Door Jamb Bolt Adjustment........................................................... 957 Door Handle Plunger Adjustment...................................................... 958 Replace Door Glass.................................................................. 959 Replace Door Window Regulator....................................................... 963 Replacing the Door Handle or Latch Assembly......................................... 964 Replacing the Door and Door Hinge Seal.............................................. 964 Removing the Door Opening Seal...................................................... 965 Installation........................................................................ 965 GLASS REPLACEMENT....................................................................... 966 Adhesive-bonded Windows............................................................. 966 Replacement Procedure............................................................... 966 WINDSHIELD & REAR GLASS................................................................. 968 Removal............................................................................. 968 Installation........................................................................ 968 CAB COMPONENTS ................................................................................. 971 CAB COMPONENTS.............................................................................. 973 WINDSHIELD WIPERS....................................................................... 973 WIPER MOTOR......................................................................... 973 Removal......................................................................... 973 Installation.................................................................... 973 WIPER ARM........................................................................... 973 Removal......................................................................... 973 Installation.................................................................... 974 WIPER LINKAGE....................................................................... 974 Removal......................................................................... 974 Installation.................................................................... 974 WINDSHIELD WASHER....................................................................... 975 Operation........................................................................... 975 Service............................................................................. 975 OPERATOR SEAT........................................................................... 976 Adjustment.......................................................................... 976 Inspection.......................................................................... 977 Removal............................................................................. 977 Installation........................................................................ 977 PASSENGER SEAT.......................................................................... 978 Inspection.......................................................................... 978 Removal............................................................................. 978 Installation........................................................................ 978 SEAT BELT............................................................................... 979 Removal............................................................................. 979 Installation........................................................................ 979 OPERATOR COMFORT ............................................................................... 981 HEATER / AIR CONDITIONER.................................................................... 983 Fan Speed Control Knob.................................................................. 983 Temperature Control Knob................................................................ 983 Air Flow Directional Knob............................................................... 983 Heater/Air Conditioner Vents............................................................ 984 COMPONENTS.................................................................................. 984 Fuse and Circuit Breaker................................................................ 984 Relays.................................................................................. 984 Heater Core............................................................................. 984 Fan Motor And Speed Control............................................................. 985 Actuators............................................................................... 985 Cab Air Filter.......................................................................... 985 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.................................................... 988 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES................................................... 988 PRINCIPLES OF REFRIGERATION................................................................. 988 Air Conditioning........................................................................ 988 Refrigeration - The Act Of Cooling...................................................... 989 The Refrigeration Cycle................................................................. 989 AIR CONDITIONER SYSTEM COMPONENTS........................................................... 990 Compressor (Refrigerant Pump)........................................................... 990 Service Valves.......................................................................... 990 Condenser............................................................................... 990 Receiver-Drier.......................................................................... 990 Expansion Block Valve................................................................... 991 Accumulator............................................................................. 991 Evaporator.............................................................................. 991 ELECTRICAL CIRCUIT.......................................................................... 992 Thermostat.............................................................................. 992 Compressor Clutch....................................................................... 992 Trinary™ Switch......................................................................... 993 SYSTEM SERVICING............................................................................ 994 SERVICE TOOLS AND EQUIPMENT................................................................. 995 Recovery/Recycle Station................................................................ 995 Leak Detector........................................................................... 995 Service Valves.......................................................................... 996 Vacuum Pump............................................................................. 996 Manifold Gauge Set...................................................................... 997 Installing Manifold Gauge Set........................................................... 998 Purging Air From Service Hoses.......................................................... 998 SYSTEM PERFORMANCE TEST..................................................................... 999 SYSTEM OIL..................................................................................1000 Handling and Reusing PAG Oil............................................................1000 Oil Quantity............................................................................1000 Checking System Oil.....................................................................1000 REFRIGERANT.................................................................................1001 Recycled Refrigerant....................................................................1001 Reclaimed Refrigerant...................................................................1001 Refrigerant Quantity....................................................................1001 R-134a Refrigerant Containers...........................................................1002 SYSTEM LEAK TESTING.........................................................................1002 Electronic Leak Detector................................................................1003 Tracer Dyes.............................................................................1003 Soap and Water..........................................................................1003 RECOVERING AND RECYCLING THE REFRIGERANT....................................................1003 Draining Oil from the Previous Recovery Cycle...........................................1003 Performing the Recovery Cycle...........................................................1003 Performing the Recycling Procedure......................................................1004 Evacuating and Charging the A/C System..................................................1004 SYSTEM REPAIR...............................................................................1004 System Flushing.........................................................................1004 A/C DRIVE BELT CHECKOUT PROCEDURE...........................................................1005 Pulley Alignment........................................................................1005 Belt Tension Check......................................................................1005 COMPONENT REPLACEMENT.......................................................................1007 Hoses and Fittings......................................................................1007 Lines...................................................................................1007 Expansion Valve.........................................................................1007 Receiver-Drier..........................................................................1007 Thermostat..............................................................................1007 Compressor..............................................................................1008 Accumulator.............................................................................1008 Clutch..................................................................................1008 Servicing the Compressor Clutch.........................................................1009 Pulley Removal..........................................................................1011 Clutch Coil Check.......................................................................1012 Pulley Installation.....................................................................1012 Clutch Assembly Installation............................................................1012 EVACUATING THE SYSTEM.......................................................................1014 CHARGING THE A/C SYSTEM.....................................................................1016 Preliminary Checks......................................................................1017 Diagnosis Of Gauge Readings And System Performance......................................1017 OPERATOR CAB CONTROLS...........................................................................1025 OPERATOR CAB AND CONTROLS...................................................................1028 STEERING WHEEL AND CONTROLS.............................................................1029 Horn Button.........................................................................1029 Tilt / Telescope Lever..............................................................1029 Multi-Function Turn Signal Switch...................................................1029 STEERING COLUMN.........................................................................1030 Removal.............................................................................1030 Steering Column Inspection..........................................................1030 Installation........................................................................1030 STEERING WHEEL..........................................................................1031 Removal.............................................................................1031 Installation........................................................................1031 PEDALS..................................................................................1033 Service Brake Pedal.................................................................1033 Dynamic Retarding...................................................................1033 Dynamic Retard Pedal................................................................1033 Throttle/Accelerator Pedal..........................................................1033 GRADE/SPEED RETARD CHART................................................................1034 OVERHEAD PANEL AND DISPLAYS.............................................................1035 CENTER CONSOLE..........................................................................1036 Directional Control Lever...........................................................1036 Override/Fault Reset Switch.........................................................1037 Engine Stop Switch..................................................................1037 L.H. Window Control Switch..........................................................1037 R.H. Window Control Switch..........................................................1037 Hoist Control Lever.................................................................1037 Raising The Dump Body...............................................................1037 Lowering The Dump Body..............................................................1037 Retard Speed Control (RSC) Adjust Dial..............................................1038 Retard Speed Control (RSC) Switch...................................................1038 Data Store Button...................................................................1039 VHMS Snapshot In Progress Light.....................................................1039 Link Energized Light................................................................1039 Service Engine Light................................................................1039 DIAGNOSTIC PORTS....................................................................1039 VHMS Diagnostic Port................................................................1039 Interface Module (IM) Diagnostic Port...............................................1039 Payload Meter Diagnostic Port.......................................................1039 Truck Control Interface (TCI) Diagnostic Port.......................................1039 Propulsion System Controller (PSC) Diagnostic Port..................................1039 Engine Diagnostic Port (CENSE)......................................................1039 Engine Diagnostic Port (QUANTUM)....................................................1039 HEATER / AIR CONDITIONER................................................................1040 Fan Speed Control Knob..............................................................1040 Temperature Control Knob............................................................1040 Air Flow Directional Knob...........................................................1040 Heater/Air Conditioner Vents........................................................1040 INSTRUMENT PANEL........................................................................1041 Control Symbols.....................................................................1041 Key Switch..........................................................................1043 Starting............................................................................1043 Rotating Beacon Light Switch (Optional).............................................1043 Heated Mirror Switch (Optional).....................................................1043 Rest Switch.........................................................................1043 Wheel Brake Lock Control............................................................1044 Hazard Warning Lights...............................................................1044 Cab/Air Conditioner Vents...........................................................1044 Engine Oil Pressure Gauge...........................................................1044 Right Turn Signal Indicator.........................................................1044 Tachometer..........................................................................1044 High Beam Indicator.................................................................1045 Speedometer/Payload Meter Display...................................................1045 Left Turn Signal Indicator..........................................................1045 Water Temperature Gauge.............................................................1045 Lamp Test Switch....................................................................1045 Light Switch........................................................................1045 Ladder Light Switch.................................................................1045 Manual Backup Switch................................................................1046 Fog Lights (Optional)...............................................................1046 Payload Meter Switch................................................................1046 Panel Light Dimmer..................................................................1046 Hydraulic Oil Temperature Gauge.....................................................1046 Hourmeter...........................................................................1046 Fuel Level Gauge....................................................................1046 OVERHEAD STATUS / WARNING INDICATORS....................................................1047 Status / Warning Indicator Light Symbols............................................1048 KOMTRAX PLUS............................................................................1054 Operation...........................................................................1054 Interface Module....................................................................1055 Basic Precautions...................................................................1055 SECTION P: LUBRICATION AND SERVICE .................................................................1057 LUBRICATION AND SERVICE.........................................................................1059 LUBRICATION AND SERVICE.....................................................................1061 830E SERVICE CAPACITIES.................................................................1061 HYDRAULIC TANK SERVICE..................................................................1061 Adding Oil..........................................................................1061 COOLANT LEVEL CHECK.....................................................................1062 Radiator Filling Procedure..........................................................1062 Coolant Specifications..............................................................1062 Unacceptable Practices..............................................................1062 WHEEL MOTOR SERVICE.....................................................................1062 RESERVE ENGINE OIL SYSTEM (Optional)....................................................1063 Reserve Oil Tank Filling Procedure (Remote fill)....................................1063 Inline Screen.......................................................................1063 QUICK FILL SERVICE CENTER...............................................................1064 LUBRICATION CHART.......................................................................1065 10 HOUR (DAILY) INSPECTION..............................................................1066 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................1069 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................1070 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1071 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1075 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................1077 2500 HOUR MAINTENANCE CHECKS............................................................1078 5000 HOUR MAINTENANCE CHECKS............................................................1078 AUTOMATIC LUBRICATION SYSTEM ...................................................................1079 AUTOMATIC LUBRICATION SYSTEM................................................................1081 GENERAL DESCRIPTION.....................................................................1081 SYSTEM COMPONENTS.......................................................................1083 Filter..............................................................................1083 Hydraulic Motor and Pump............................................................1083 Grease Reservoir....................................................................1083 Pressure Reducing Valve.............................................................1083 Flow Control Valve..................................................................1083 Solenoid Valve......................................................................1083 Vent Valve..........................................................................1083 Lubrication Cycle Timer.............................................................1083 Over Pressure Cut Off Switch........................................................1083 Grease Pressure Failure Switch......................................................1083 Injectors...........................................................................1083 Relief Valve (unloader valve).......................................................1083 SYSTEM OPERATION........................................................................1084 Normal Operation....................................................................1084 Lubricant Required For System.......................................................1085 System Priming......................................................................1085 Filter Assembly.....................................................................1085 LUBRICANT PUMP..........................................................................1086 Pump Housing Oil Level..............................................................1086 Pump Pressure Control...............................................................1086 INJECTORS (SL-1 Series “H”).............................................................1087 Injector Specifications.............................................................1087 Injector Adjustment.................................................................1087 INJECTOR OPERATION......................................................................1088 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1089 Daily Lubrication System Inspection.................................................1089 250 Hour Inspection.................................................................1089 1000 Hour Inspection................................................................1089 SYSTEM CHECKOUT.........................................................................1090 Lubrication Controller Check........................................................1090 Lubrication Controller Components...................................................1090 Lubrication Controller Adjustment...................................................1090 SYSTEM TROUBLESHOOTING CHART................................................................1092 SECTION Q: A;PHABETICAL INDEX ......................................................................1095 SECTION R: SYSTEM SCHEMATICS .......................................................................1099 HE484 Electrical Schematic - Heater A/C Controls ...............................................1101 HH360 Hydraulic Schematic - Brake System .......................................................1102 HH366 Hydraulic Schematic - Steering & Hoist ...................................................1103 HH364 Hydraulic Schematic - Retractable Ladder System ..........................................1105 HE485 Electrical Schematic - Retractable Ladder System.........................................1106 XS6300 ELECTRICAL SYSTEM SCHEMATIC .............................................................1108 XS6301......................................................................................1108 XS6302......................................................................................1109 XS6303......................................................................................1110 XS6304......................................................................................1111 XS6305......................................................................................1112 XS6306......................................................................................1113 XS6307-2....................................................................................1114 XS6308......................................................................................1115 XS6309......................................................................................1116 XS6310-1....................................................................................1117 XS6311-2 ...................................................................................1118 XS6312-1....................................................................................1119 XS6313......................................................................................1120 XS6314......................................................................................1121 XS6315-1....................................................................................1122 XS6316-1....................................................................................1123 XS6317-2....................................................................................1124 XS6318......................................................................................1125 XS6319......................................................................................1126 XS6320-1....................................................................................1127 XS6321......................................................................................1128 XS6322-1....................................................................................1129 XS6323......................................................................................1130 XS6324-1....................................................................................1131 XS6325-1....................................................................................1132 XS6326-2....................................................................................1133 XS6326-2-pg.2...............................................................................1134 XS6327-2....................................................................................1135 XS6328......................................................................................1136 XS6329......................................................................................1137 XS6330......................................................................................1138 XS6331......................................................................................1139 XS6332-2....................................................................................1140 XS6333......................................................................................1141 XS6334......................................................................................1142 XS6335......................................................................................1143
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