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Komatsu 830E-1AC Dump Truck Shop Manual A30561 & up – PDF DOWNLOAD
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Komatsu 830E-1AC Dump Truck Shop Manual
SERIAL NUMBERS : A30561 & UP
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Description
Komatsu 830E-1AC Dump Truck Shop Manual
FILE DETAILS:
Komatsu 830E-1AC Dump Truck Shop Manual
Language : English
Pages : 1154
Downloadable : Yes
File Type : PDF
Size: 32.4 MB
Book Code: CEBM024002
DESCRIPTION:
Komatsu 830E-1AC Dump Truck Shop Manual
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.
TABLE OF CONTENTS:
Komatsu 830E-1AC Dump Truck Shop Manual
COVER .............................................................................................. 1 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.............................................................................. 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 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 SECTION B3 DUMP BODY INDEX...................................................................... 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 REMOVAL & INSTALLATION TOOLING.............................................................. 197 DISASSEMBLY................................................................................. 200 CLEANING AND INSPECTION..................................................................... 210 ASSEMBLY.................................................................................... 214 TEST PROCEDURE.............................................................................. 228 SECTION D ELECTRICAL SYSTEM (24VDC) ................................................................ 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 switch and magnet)........................... 267 Proximity switch operation...................................................... 267 Service......................................................................... 267 BODY-UP SWITCH...................................................................... 268 Adjust the body up switch....................................................... 268 HOIST LIMIT SWITCH.................................................................. 269 Operation....................................................................... 269 Adjust the hoist limit switch................................................... 270 FUSE BLOCK CHARTS................................................................... 272 CIRCUIT BREAKER CHART............................................................... 274 CIRCUIT BREAKERS.................................................................... 274 KOMTRAX Plus SYSTEM ............................................................................ 275 KOMTRAX Plus COMPONENTS..................................................................... 277 KOMTRAX Plus BASIC FEATURES............................................................. 277 Gather Data......................................................................... 277 Convert and Record Data............................................................. 277 Communicate Data to Off-Board Systems............................................... 278 USING THE KOMTRAX Plus SYSTEM........................................................... 279 Turning the KOMTRAX Plus System ON.................................................. 279 Normal KOMTRAX Plus Operation....................................................... 279 Turning the KOMTRAX Plus System OFF................................................. 280 Downloading from the KOMTRAX Plus Controller........................................ 280 KOMTRAX Plus DATA ITEMS................................................................. 281 Fault Codes......................................................................... 281 Machine History..................................................................... 281 KOMTRAX Plus History................................................................ 281 Snapshots........................................................................... 282 Manual Snapshots.................................................................... 282 Trends.............................................................................. 284 Histogram (Load Map) Data........................................................... 284 Haul Cycle Data..................................................................... 285 Alarm and Snapshot Triggers......................................................... 286 Satellite Features.................................................................. 286 KOMTRAX Plus DIAGNOSTIC FEATURES........................................................ 288 Fault History....................................................................... 288 KOMTRAX Plus LED Digits............................................................. 288 KOMTRAX Plus CONTROLLER................................................................. 288 Removal............................................................................. 289 Installation........................................................................ 289 KOMTRAX Plus SOFTWARE....................................................................... 291 NECESSARY SOFTWARE...................................................................... 291 NECESSARY TOOLS......................................................................... 291 KOMTRAX Plus SYSTEM SET UP.................................................................. 292 KOMTRAX Plus Controller................................................................. 292 KOMTRAX Plus CONTROLLER..................................................................... 292 KOMTRAX Plus TOOL BOX................................................................... 292 Installation........................................................................ 292 KOMTRAX Plus SETTING TOOL............................................................... 292 Installation........................................................................ 292 KOMTRAX Plus INITIALIZATION PROCEDURE....................................................... 293 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE.............................................. 293 KOMTRAX Plus Setting Tool software program.......................................... 293 Select Operation.................................................................... 293 KOMTRAX Plus Setting Function....................................................... 294 Machine Information Setting(1)...................................................... 294 Machine Information Setting(2)...................................................... 294 Date & Time Setting................................................................. 294 GCC Setting......................................................................... 295 Setting Summary..................................................................... 295 2. KOMTRAX Plus SNAPSHOT PROCEDURE...................................................... 296 3. KOMTRAX Plus DOWNLOAD PROCEDURE...................................................... 297 4. LOCATION OF DOWNLOAD FILES........................................................... 297 5. KOMTRAX Plus FTP UPLOAD PROCEDURE.................................................... 298 6. KOMTRAX Plus INITIALIZATION FORMS.................................................... 299 WHEN REPLACING A KOMTRAX Plus CONTROLLER.................................................... 300 To Set: Date & Time; Satellite; Payload Meter........................................... 302 Review Setting Information.............................................................. 304 KOMTRAX Plus CONTROLLER CHECKOUT........................................................ 305 KOMTRAX Plus Controller............................................................. 305 Necessary Equipment:................................................................ 305 Preliminary......................................................................... 306 KOMTRAX Plus Controller Checkout Procedure.......................................... 307 ORBCOMM CONTROLLER.......................................................................... 309 Removal................................................................................. 309 Installation............................................................................ 309 INTERFACE MODULE ............................................................................... 311 INTERFACE MODULE............................................................................ 313 Removal................................................................................. 313 Installation............................................................................ 313 SENSORS................................................................................. 314 Temperature Sensors................................................................. 314 Pressure Sensors.................................................................... 314 INTERFACE MODULE SOFTWARE................................................................... 315 NECESSARY SOFTWARE...................................................................... 315 NECESSARY TOOLS......................................................................... 315 FLASHBURN PROGRAM....................................................................... 316 Installation........................................................................ 316 INTERFACE MODULE APPLICATION CODE....................................................... 316 Installation........................................................................ 316 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM................................. 316 Installation........................................................................ 316 Using The Program................................................................... 316 INTERFACE MODULE CHECKOUT............................................................... 317 Interface Module.................................................................... 317 Necessary Equipment:................................................................ 317 Preliminary......................................................................... 318 Checking Inputs And Outputs From The Interface Module............................... 318 Check Analog Inputs To The Interface Module......................................... 322 Check CAN RPC & J1939 Interfaces To The IM.......................................... 322 Check Outputs From The Interface Module............................................. 322 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES ................................ 325 KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING........................... 327 TROUBLESHOOTING......................................................................... 327 GENERAL............................................................................. 327 Structure and Purpose........................................................... 327 TROUBLESHOOTING..................................................................... 328 Communications Networks......................................................... 328 Coaxial Cable................................................................... 328 FAULT CODES......................................................................... 329 Fault History................................................................... 329 KOMTRAX Plus LED Display Fault Codes............................................ 330 Chassis Fault Codes............................................................. 331 Engine Fault Codes.............................................................. 335 FAULT TREE ANALYSIS................................................................. 341 Unable to connect to KOMTRAX Plus from laptop PC................................ 341 Flashing Error Code N4-23 (PLM III Communications Fault)........................ 342 Flashing Error Code N4-22 (Engine Communications Fault)......................... 343 No Data Received By WebCARE..................................................... 344 Coaxial Cable Troubleshooting................................................... 345 KOMTRAX PLUS FORMS ............................................................................. 347 KOMTRAX PLUS FORMS.......................................................................... 349 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 349 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 350 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 351 KOMTRAX PLUS INITIALIZATION FORM........................................................ 353 SECTION E ELECTRIC PROPULSION ...................................................................... 355 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 357 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 359 GENERAL SYSTEM DESCRIPTION.............................................................. 359 SYSTEM COMPONENTS....................................................................... 361 Propulsion System Controller (PSC).................................................. 361 Truck Control Interface (TCI)....................................................... 362 Diagnostic Information Display (DID) Panel.......................................... 363 DID Panel Event Codes............................................................... 363 PSC SOFTWARE FUNCTIONS.................................................................. 382 Input Processing.................................................................... 382 State Machine....................................................................... 382 DC Link State....................................................................... 385 Engine Control...................................................................... 386 ALTERNATOR FIELD CONTROL................................................................ 386 Desired Three-Phase Voltage......................................................... 386 Desired DC Link Voltage............................................................. 386 Self-Load........................................................................... 387 Propel Torque Control............................................................... 387 Retard Torque Control............................................................... 387 Wheel Slide Control................................................................. 388 Resistor Grid Control............................................................... 388 Chopper Voltage Control............................................................. 388 EVENT DETECTION AND PROCESSING.......................................................... 388 Power-On Tests...................................................................... 388 Initiated Tests..................................................................... 389 Periodic Tests...................................................................... 389 EVENT RESTRICTIONS...................................................................... 389 EVENT LOGGING AND STORAGE............................................................... 389 Event History Buffer................................................................ 390 Data Packs.......................................................................... 390 To Record and Save a Data Pack to a Disk............................................ 390 Event Reset......................................................................... 391 SERIAL DATA COMMUNICATIONS.............................................................. 391 PSC - TCI Communications Processing................................................. 391 PSC - PTU Communications Processing................................................. 391 Inverter Communications Processing.................................................. 392 OUTPUT PROCESSING....................................................................... 392 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 392 Fast Start.......................................................................... 392 Engine Shutdown/Engine Not Running.................................................. 392 Limp Home Mode...................................................................... 393 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 394 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 402 Removal............................................................................. 402 Installation........................................................................ 402 Disassembly......................................................................... 402 Assembly............................................................................ 402 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 403 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 405 AC DRIVE SYSTEM MAINTENANCE............................................................. 405 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 406 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 406 SYSTEM CHECKOUT......................................................................... 407 Battery and Control Circuit Checks - Battery Power OFF.............................. 407 Battery and Control Circuit Checks - Battery Power ON............................... 410 Checks with Key Switch OFF.......................................................... 411 Checks with Key Switch ON........................................................... 411 CPU Battery Checks.................................................................. 411 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 412 TCI PROGRAMMING......................................................................... 412 PSC PROGRAMMING......................................................................... 413 INVERTER PROGRAMMING.................................................................... 413 CPU RESET............................................................................... 413 PSC CHECKOUT............................................................................ 414 PSC Digital Input Checks............................................................ 414 PSC Digital Output Checks........................................................... 418 TCI CHECKOUT............................................................................ 419 Modular Mining Communication Port Check............................................. 419 TCI Digital Input Checks............................................................ 419 TCI Digital Output Tests............................................................ 425 CALIBRATIONS............................................................................ 428 Speedometer......................................................................... 428 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 428 ERASING EVENTS.......................................................................... 428 PSC................................................................................. 428 TCI................................................................................. 429 GATE DRIVER POWER CONVERTER TEST........................................................ 429 LOAD TESTING............................................................................ 430 Preparation......................................................................... 430 Alternator Speed Sensor Checks...................................................... 430 Battery Boost Check................................................................. 430 Brake Circuit Switch Checks......................................................... 431 Hoist & Steering Circuit Switch Checks.............................................. 431 Link Energized Checks............................................................... 431 Loadbox Test........................................................................ 433 TROUBLESHOOTING......................................................................... 437 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 437 Phase Module and Chopper Module Troubleshooting..................................... 437 PHASE MODULE REPLACEMENT................................................................ 438 Phase Module Removal................................................................ 438 Phase Module Installation........................................................... 438 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS .......................................................... 439 TIRES AND RIMS.................................................................................. 441 TIRES AND RIMS.............................................................................. 443 FRONT TIRES AND RIMS.................................................................... 443 Removal............................................................................. 443 Installation........................................................................ 445 REAR TIRES AND RIMS..................................................................... 445 Removal............................................................................. 445 Installation........................................................................ 446 RIM AND TIRE............................................................................ 448 Tire Removal........................................................................ 448 Rim And Tire Preparation............................................................ 448 Lubricants.......................................................................... 449 Tire Installation................................................................... 449 FRONT WHEEL HUB AND SPINDLES.................................................................... 451 FRONT WHEEL HUB AND SPINDLE................................................................. 453 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 453 Removal............................................................................. 453 Spindle Removal Procedure (Optional) (off of the truck)............................. 456 Installation........................................................................ 458 Disassembly......................................................................... 461 Cleaning and Inspection............................................................. 461 Assembly............................................................................ 462 Wheel Bearing Adjustment (Tire Removed)............................................. 464 Wheel Bearing Adjustment (Tire mounted)............................................. 465 OIL SAMPLING PROCEDURE.................................................................. 466 Oil Sampling Guidelines............................................................. 467 Procedure........................................................................... 467 OIL DRAIN AND REFILL PROCEDURE.......................................................... 467 STEERING CYLINDERS...................................................................... 468 Spherical Bearing Wear Limits....................................................... 468 Removal............................................................................. 469 Installation........................................................................ 469 Bearing Replacement (Steering cylinder and tie rod)................................. 469 TIE ROD................................................................................. 471 Removal............................................................................. 471 Installation........................................................................ 471 Disassembly......................................................................... 472 Assembly............................................................................ 472 TOE-IN ADJUSTMENT....................................................................... 473 REAR AXLE HOUSING ATTACHMENT.................................................................... 475 REAR AXLE HOUSING ATTACHMENT................................................................ 477 PIVOT PIN............................................................................... 477 Removal............................................................................. 477 Installation........................................................................ 477 PIVOT EYE BEARING....................................................................... 478 Disassembly......................................................................... 478 Assembly............................................................................ 478 PIVOT EYE REPAIR........................................................................ 479 Removal............................................................................. 479 Installation........................................................................ 479 Disassembly......................................................................... 479 Assembly............................................................................ 479 ANTI-SWAY BAR........................................................................... 480 Removal............................................................................. 480 Installation........................................................................ 480 Disassembly......................................................................... 480 Cleaning and Inspection............................................................. 480 Assembly............................................................................ 480 REAR AXLE HOUSING............................................................................... 481 REAR AXLE HOUSING........................................................................... 483 REAR AXLE HOUSING....................................................................... 483 Removal............................................................................. 483 Installation........................................................................ 483 WHEEL MOTOR............................................................................. 484 Removal............................................................................. 484 Cleaning and Inspection............................................................. 484 Installation........................................................................ 485 WHEEL MOTOR GEAR OIL.................................................................... 488 Change/Filter The Gear case Oil..................................................... 488 Oil................................................................................. 488 Remove And Clean Magnetic Plugs..................................................... 488 Flushing The Gearbox................................................................ 488 Check Gear Case Oil Level........................................................... 488 SECTION H SUSPENSIONS .............................................................................. 489 FRONT SUSPENSION................................................................................ 491 FRONT SUSPENSION............................................................................ 493 Removal................................................................................. 493 Installation............................................................................ 494 TURN-OF-THE-NUT Tightening Procedure.................................................... 496 Upper Mounting Joint - 60° Advance.................................................. 496 Lower Mounting Joint - 90° Advance.................................................. 498 Inspection.......................................................................... 498 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 499 Bearing Structure Removal........................................................... 499 Bearing Structure Installation...................................................... 499 MAJOR SUSPENSION REBUILD................................................................ 500 Disassembly......................................................................... 500 Assembly............................................................................ 501 PRESSURE TEST........................................................................... 502 REAR SUSPENSIONS ............................................................................... 503 REAR SUSPENSIONS............................................................................ 504 Removal................................................................................. 504 Installation............................................................................ 507 ROD DOWN SUSPENSION..................................................................... 508 Disassembly......................................................................... 508 Cleaning and Inspection............................................................. 508 Assembly............................................................................ 510 PRESSURE TEST........................................................................... 512 Suspension pressure test............................................................ 512 OILING AND CHARGING PROCEDURE................................................................... 513 OILING AND CHARGING PROCEDURE............................................................... 515 GENERAL................................................................................. 515 EQUIPMENT LIST.......................................................................... 515 HYDRAIR® CHARGING KIT................................................................... 516 Installation of Charging Kit........................................................ 516 Removal of Charging Kit............................................................. 516 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 517 FRONT SUSPENSION........................................................................ 517 Front Suspension Oiling............................................................. 517 Front Suspension Nitrogen Charging.................................................. 519 REAR SUSPENSION - ROD DOWN.............................................................. 521 Rear Suspension Oiling (Rod Down Only).............................................. 521 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 523 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 525 SECTION J BRAKE CIRCUIT ............................................................................ 527 BRAKE CIRCUIT................................................................................... 529 BRAKE CIRCUIT............................................................................... 531 OPERATION............................................................................... 531 SERVICE BRAKE CIRCUIT OPERATION......................................................... 531 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 533 PARKING BRAKE CIRCUIT................................................................... 533 Normal Operation (key switch on, engine running).................................... 533 BRAKE LOCK CIRCUIT...................................................................... 534 WARNING CIRCUIT......................................................................... 534 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 537 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 539 BRAKE VALVE............................................................................. 539 Rebuild Criteria.................................................................... 539 Removal............................................................................. 539 Installation........................................................................ 541 DISASSEMBLY............................................................................. 543 Cleaning and Inspection............................................................. 545 ASSEMBLY................................................................................ 545 Actuator Base Threaded Inserts...................................................... 545 Boot and Cap........................................................................ 545 Valve Body Seal Installation........................................................ 546 Regulator Sleeve O-Ring Installation................................................ 546 Actuator Plunger O-ring Installation................................................ 547 Assembly of Valve................................................................... 547 VALVE BENCH TEST AND ADJUSTMENT......................................................... 549 Test Set Up Procedure............................................................... 550 Brake Valve Output Pressure Adjustment.............................................. 550 Final Test and Adjustment........................................................... 551 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 552 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 554 Installation of Retard Pedal To Brake Pedal......................................... 554 HYDRAULIC BRAKE ACCUMULATORS............................................................ 555 Brake Accumulator Bleed Down Procedure.............................................. 555 Removal............................................................................. 555 Installation........................................................................ 555 Disassembly......................................................................... 555 Cleaning and Inspection............................................................. 557 Assembly............................................................................ 557 Charging Procedure.................................................................. 559 BRAKE MANIFOLD.......................................................................... 560 Removal............................................................................. 560 Removal............................................................................. 560 Installation........................................................................ 561 Disassembly......................................................................... 561 Cleaning and Inspection............................................................. 562 Assembly............................................................................ 562 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 563 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 565 EQUIPMENT REQUIRED...................................................................... 567 INITIAL SYSTEM SET-UP................................................................... 568 PARKING BRAKE........................................................................... 568 BRAKE SYSTEM CHECK-OUT.................................................................. 569 BRAKE LOCK.............................................................................. 569 FAILURE MODES CHECK-OUT................................................................. 570 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 571 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 574 WHEEL SPEED FRONT DISC BRAKES................................................................... 577 BRAKE CALIPER............................................................................... 579 Caliper Removal......................................................................... 579 Installation............................................................................ 580 Disassembly............................................................................. 581 Assembly................................................................................ 581 Cleaning and Inspection................................................................. 582 BRAKE LINING................................................................................ 583 Replacement............................................................................. 583 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE..................................... 585 GENERAL................................................................................. 585 Safety Precautions.................................................................. 585 Front Brake Conditioning............................................................ 585 BRAKE BLEEDING PROCEDURES............................................................... 586 ARMATURE SPEED REAR DISC BRAKES................................................................. 587 ARMATURE SPEED REAR DISC BRAKES............................................................. 589 REAR BRAKES............................................................................. 589 CALIPER AND DISC.................................................................... 589 Removal......................................................................... 589 Installation.................................................................... 591 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 593 BRAKE BLEEDING PROCEDURE............................................................ 594 Service Brake................................................................... 594 Park Brake...................................................................... 594 CALIPER............................................................................. 595 Disassembly..................................................................... 595 PISTON SUBASSEMBLY.................................................................. 598 Disassembly..................................................................... 598 PREPARATION FOR ASSEMBLY............................................................ 599 Clean Parts..................................................................... 599 For Rough Metal Parts........................................................... 600 Dry and Inspect Parts........................................................... 600 Corrosion Protection............................................................ 600 INSPECTION.......................................................................... 600 Caliper Parts................................................................... 600 Shoes, Linings and End Plates................................................... 601 Inspect linings................................................................. 601 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 601 Piston Assembly Adjuster Grip Force............................................. 602 Adjuster Force.................................................................. 604 Piston Return Spring............................................................ 606 ASSEMBLY............................................................................ 607 Adjuster and Pin Assembly....................................................... 607 Piston Subassembly.............................................................. 608 Brake Caliper................................................................... 609 PERIODIC INSPECTIONS................................................................ 615 Shoes, Linings and End Plates................................................... 615 Inspect the following areas for fluid leaks..................................... 615 Dust Boots...................................................................... 615 Brake Disc...................................................................... 615 BRAKE LINING........................................................................ 616 Replacement..................................................................... 616 BRAKE DISC.......................................................................... 616 Inspection...................................................................... 616 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................... 617 GENERAL......................................................................... 617 SAFETY PRECAUTIONS.............................................................. 617 Rear Brake Conditioning..................................................... 618 SECTION L HYDRAULIC SYSTEM......................................................................... 621 HYDRAULIC SYSTEM................................................................................ 623 HYDRAULIC SYSTEM............................................................................ 625 HYDRAULIC SYSTEM OPERATION.............................................................. 625 COMPONENT DESCRIPTION................................................................... 626 Hoist Pump.......................................................................... 626 Steering/Brake Pump................................................................. 626 Tank................................................................................ 626 High Pressure Hydraulic Filters..................................................... 626 Bleeddown Manifold.................................................................. 626 Steering System Accumulators........................................................ 626 DISABLED TRUCK CONNECTORS............................................................... 628 GENERAL............................................................................. 628 STEERING AND BRAKE SYSTEM........................................................... 628 Hookup.......................................................................... 628 HOIST SYSTEM........................................................................ 629 Hookup.......................................................................... 629 Dumping Procedure............................................................... 629 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 631 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 633 HOIST PUMP.............................................................................. 633 Removal............................................................................. 633 Installation........................................................................ 634 Disassembly......................................................................... 636 Inspection Of Parts................................................................. 639 Assembly............................................................................ 640 HYDRAULIC TANK.......................................................................... 646 Filling Instructions................................................................ 646 Removal............................................................................. 646 Installation........................................................................ 647 HYDRAULIC TANK STRAINERS................................................................ 648 Removal............................................................................. 648 Inspect and Clean................................................................... 648 Installation........................................................................ 649 HYDRAULIC TANK BREATHERS................................................................ 649 HOIST CIRCUIT FILTERS................................................................... 650 FILTER ELEMENT REPLACEMENT.............................................................. 651 Removal............................................................................. 651 Installation........................................................................ 651 INDICATOR SWITCH........................................................................ 651 STEERING CIRCUIT................................................................................ 653 STEERING CIRCUIT............................................................................ 655 STEERING CIRCUIT OPERATION.............................................................. 655 COMPONENT DESCRIPTION................................................................... 656 STEERING CONTROL UNIT............................................................... 656 FLOW AMPLIFIER...................................................................... 656 No Steer........................................................................ 658 Steering Left................................................................... 660 Steering Right.................................................................. 662 No Steer, External Shock Load................................................... 664 BLEED DOWN MANIFOLD................................................................. 666 ACCUMULATORS........................................................................ 669 Low Precharge Warning Switch.................................................... 669 HIGH PRESSURE FILTER................................................................ 669 STEERING/BRAKE PUMP................................................................. 669 Operation....................................................................... 670 PRINCIPLE OF OPERATION.............................................................. 672 Full Pump Volume:............................................................... 672 Half Pump Volume:............................................................... 672 Neutral Position:............................................................... 673 STEERING CIRCUIT COMPONENT REPAIR............................................................... 675 STEERING CIRCUIT COMPONENT REPAIR........................................................... 677 BLEED DOWN MANIFOLD..................................................................... 677 Removal............................................................................. 677 Installation........................................................................ 677 ACCUMULATOR............................................................................. 678 Removal............................................................................. 678 Installation........................................................................ 679 Disassembly......................................................................... 679 Cleaning and Inspection............................................................. 680 Assembly............................................................................ 680 LEAK TESTING............................................................................ 682 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 683 Temperature During Precharge........................................................ 686 ACCUMULATOR STORAGE PROCEDURES.......................................................... 686 Instructions For Storing Bladder Accumulators....................................... 686 Installation........................................................................ 687 Bladder Storage Procedures.......................................................... 687 FLOW AMPLIFIER.......................................................................... 688 Removal............................................................................. 688 Installation........................................................................ 688 Disassembly......................................................................... 690 Reassembly.......................................................................... 691 STEERING CONTROL UNIT................................................................... 692 Removal............................................................................. 692 Spline Inspection................................................................... 692 Installation........................................................................ 693 Disassembly......................................................................... 693 Cleaning and Inspection............................................................. 694 Assembly............................................................................ 695 STEERING CYLINDER....................................................................... 699 Disassembly......................................................................... 699 Inspection and Cleaning............................................................. 699 Assembly............................................................................ 699 Testing............................................................................. 699 STEERING CIRCUIT FILTER................................................................. 700 Filter Element Replacement.......................................................... 700 Removal............................................................................. 701 Installation........................................................................ 701 Indicator Switch.................................................................... 701 STEERING AND BRAKE PUMP................................................................. 702 Removal............................................................................. 702 Installation........................................................................ 703 Disassembly......................................................................... 704 Control Piston Group................................................................ 704 Valve Plate Group................................................................... 705 Rotating Group...................................................................... 705 Swashblock Group.................................................................... 706 Driveshaft Group.................................................................... 706 INSPECTION.............................................................................. 706 Control Piston Group................................................................ 706 Valve Plate Group................................................................... 706 Rotating Group...................................................................... 706 Swashblock Group.................................................................... 710 Driveshaft Group.................................................................... 710 Compensator Block and Unloader Module............................................... 710 Stroke Adjuster Assembly............................................................ 710 ASSEMBLY................................................................................ 710 Swashblock Group.................................................................... 710 Driveshaft Group.................................................................... 711 Rotating Group...................................................................... 712 Control Piston Group................................................................ 712 Valve Plate Group................................................................... 713 HOIST CIRCUIT................................................................................... 715 HOIST CIRCUIT............................................................................... 717 HOIST CIRCUIT OPERATION................................................................. 717 COMPONENT DESCRIPTION................................................................... 718 Hydraulic Tank...................................................................... 718 Hoist Pump.......................................................................... 718 High Pressure Filters............................................................... 718 Hoist Valve......................................................................... 719 Hoist Pilot Valve................................................................... 720 Hoist-up Limit Solenoid............................................................. 720 Pilot Operated Check Valve.......................................................... 720 Counterbalance Valve Manifold....................................................... 721 HOIST SYSTEM OPERATION MODES............................................................ 722 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 722 Power Up Operation (Figure 7-7)..................................................... 724 Hold Operation (Figure 7-8)......................................................... 726 Power Down Operation (Figure 7-9)................................................... 728 Float Operation (Figure 7-10)....................................................... 730 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 733 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 735 HOIST VALVE............................................................................. 735 Removal............................................................................. 735 Installation........................................................................ 735 O-Ring Replacement.................................................................. 736 INLET SECTION........................................................................... 737 Disassembly......................................................................... 737 Cleaning and Inspection............................................................. 738 Assembly............................................................................ 738 SPOOL SECTION........................................................................... 738 Disassembly......................................................................... 738 Cleaning and Inspection............................................................. 741 Assembly............................................................................ 741 HOIST PILOT VALVE....................................................................... 742 Removal............................................................................. 742 Installation........................................................................ 742 Disassembly......................................................................... 743 Cleaning and Inspection............................................................. 744 Assembly............................................................................ 745 BODY UP LIMIT SOLENOID.................................................................. 746 PILOT OPERATED CHECK VALVE.............................................................. 746 HOIST CYLINDERS......................................................................... 746 Removal............................................................................. 746 Installation........................................................................ 747 Disassembly......................................................................... 748 Cleaning and Inspection............................................................. 750 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 751 Quill Installation.................................................................. 751 Installation of Check Balls and Plugs in Quill...................................... 752 Assembly of Cylinder................................................................ 753 Pressure Testing.................................................................... 754 OVERCENTER MANIFOLD..................................................................... 755 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 757 HYDRAULIC CHECKOUT PROCEDURE................................................................ 759 STEERING AND BRAKE PUMP................................................................. 759 Pressure Check And Adjustment Procedure............................................. 759 BLEEDDOWN MANIFOLD...................................................................... 761 SHOCK & SUCTION VALVES.................................................................. 761 Shock & Suction Valve Settings...................................................... 761 LEAKAGE TESTS........................................................................... 763 Steering Control Unit & Flow Amplifier.............................................. 763 Bleeddown Manifold.................................................................. 763 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 764 LOW STEERING PRESSURE SWITCH............................................................ 766 CHECKING HOIST SYSTEM PRESSURES......................................................... 773 Hoist System Relief Pressure Adjustment............................................. 773 Power Down Relief Pressure Adjustment............................................... 774 HOIST COUNTERBALANCE VALVE.............................................................. 775 Preparation:........................................................................ 775 Counterbalance Valve Pressure Check Only:........................................... 775 Counterbalance Valve Adjustment..................................................... 776 OIL CLEANLINESS CHECK................................................................... 779 SECTION M OPTIONS AND SPECIAL TOOLS ................................................................ 781 HEATER OPTIONS ................................................................................. 783 GENERAL INFORMATION......................................................................... 785 TROUBLESHOOTING............................................................................. 785 HEATER ELEMENT.............................................................................. 785 Removal................................................................................. 785 Installation............................................................................ 786 GENERAL..................................................................................... 787 Maintenance............................................................................. 787 HEATING ELEMENT............................................................................. 787 Removal................................................................................. 787 Installation............................................................................ 788 THERMOSTAT.................................................................................. 788 Removal................................................................................. 788 Installation............................................................................ 788 GENERAL INFORMATION......................................................................... 789 TROUBLESHOOTING............................................................................. 789 HEATER ELEMENT.............................................................................. 789 Removal................................................................................. 789 Installation............................................................................ 790 SPECIAL TOOLS................................................................................... 791 NITROGEN CHARGING VALVE..................................................................... 791 ROLL-OUT ASSEMBLY........................................................................... 791 EYE BOLT.................................................................................... 791 OFFSET WRENCH............................................................................... 792 TORQUE ADAPTER.............................................................................. 792 HANDLE...................................................................................... 792 SEAL INSTALLER.............................................................................. 792 SLEEVE ALIGNMENT TOOLS...................................................................... 793 QUICK DISCONNECT COUPLING................................................................... 793 HARNESS..................................................................................... 793 SEAL INSTALLATION RING...................................................................... 793 BELT TENSION TESTER......................................................................... 794 BELT ALIGNMENT TOOL......................................................................... 794 SOCKETS AND ADAPTERS........................................................................ 794 DUST CAPS................................................................................... 794 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 795 PAYLOAD DATA MANAGER........................................................................ 795 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 795 MISCELLANEOUS SERVICE TOOLS................................................................. 796 BRAKE PISTON TOOL........................................................................... 797 HIGH VOLTAGE TOOLS.......................................................................... 800 2000 VDC METER.............................................................................. 800 GROUNDING STICKS............................................................................ 800 BODY PAD SPACER TOOL........................................................................ 801 RADIATOR SHUTTERS .............................................................................. 803 RADIATOR SHUTTERS........................................................................... 805 OPERATION............................................................................... 805 Hydraulic Circuit................................................................... 805 Electrical Circuit:................................................................. 806 MAINTENANCE AND REPAIR.................................................................. 806 TROUBLESHOOTING......................................................................... 807 Hydraulic Troubleshooting........................................................... 810 Electrical Troubleshooting.......................................................... 812 PAYLOAD METER III ™ ............................................................................ 813 OPERATION SECTION........................................................................... 817 Introduction............................................................................ 817 Data Summary........................................................................ 817 Data Gathering...................................................................... 817 COMPONENT DESCRIPTION................................................................... 818 System Diagram...................................................................... 818 Suspension Pressure Sensors......................................................... 818 Inclinometer........................................................................ 818 Operator Display.................................................................... 818 Operator Switch..................................................................... 819 Speed Input......................................................................... 819 Body-Up Switch...................................................................... 819 Brake Lock Switch................................................................... 819 Payload Meter....................................................................... 819 Communications Ports................................................................ 819 Key Switch Input.................................................................... 820 Payload Meter Power................................................................. 820 Load Lights......................................................................... 820 Wiring and Termination.............................................................. 821 TCI Outputs......................................................................... 821 OPERATOR’S DISPLAY AND SWITCH........................................................... 822 Reading the Speedometer............................................................. 822 Reading the Load Display............................................................ 822 Using the Operator ID............................................................... 822 Using the Load and Ton Counter...................................................... 822 Total Ton Counter................................................................... 822 Total Load Counter.................................................................. 823 Clearing the Counters............................................................... 823 Viewing Live Sensor Data............................................................ 823 Other Display Messages.............................................................. 823 PAYLOAD OPERATION & CALCULATION......................................................... 824 Description of Haul Cycle States.................................................... 824 Haul Cycle Description.............................................................. 824 Load Calculation.................................................................... 825 Carry Back.......................................................................... 825 Measurement Accuracy................................................................ 825 SOURCES FOR PAYLOAD ERROR............................................................... 825 Payload Error....................................................................... 825 Loading Conditions.................................................................. 826 Pressure Sensors.................................................................... 826 Swingloads.......................................................................... 826 Speed and Distance.................................................................. 826 HAUL CYCLE DATA......................................................................... 826 Haul Cycle Warning Flags............................................................ 828 Frame Torque Data................................................................... 829 Sprung Weight Data.................................................................. 829 Maximum Speed Data.................................................................. 829 Alarm Records....................................................................... 829 Fault Code Data..................................................................... 830 PC SOFTWARE OVERVIEW.................................................................... 831 System Configuration................................................................ 831 Installing the PLMIII Software...................................................... 831 DOWNLOADING DATA........................................................................ 832 PLM III SYSTEM CONFIGURATION............................................................ 833 Starting Communications............................................................. 833 Displayed Payload Units............................................................. 833 Time Units.......................................................................... 833 Connection Menu..................................................................... 833 Connecting to the Payload Meter..................................................... 834 Configure the Payload Meter......................................................... 834 Setting the Date and Time........................................................... 834 Setting the Truck Type.............................................................. 835 Setting the Gauge Display Units..................................................... 835 Setting the Frame Serial Number..................................................... 835 Setting the Truck Number............................................................ 835 Setting the Komatsu Distributor..................................................... 835 Setting the Komatsu Customer........................................................ 835 Clean Truck Tare.................................................................... 836 Inclinometer Calibration............................................................ 836 DATA ANALYSIS........................................................................... 837 Creating a Query.................................................................... 837 Sorting on Truck Unit Number........................................................ 837 Sorting on Truck Type............................................................... 837 Sorting on Date Range............................................................... 838 Sorting on Time Range............................................................... 838 Payload Detail Screen............................................................... 839 Creating Reports.................................................................... 839 Summary - one page report........................................................... 840 Detailed - multi-page report........................................................ 840 Creating Graphs..................................................................... 841 Exporting Data...................................................................... 841 CSV Export.......................................................................... 841 Compressed.......................................................................... 842 Importing Data...................................................................... 843 Deleting Haul Cycle Records......................................................... 843 Viewing Alarms...................................................................... 844 Deleting Alarm Records.............................................................. 844 TROUBLESHOOTING SECTION................................................................. 845 TROUBLESHOOTING..................................................................... 845 Viewing Active Alarms........................................................... 845 Real-Time Data Display.......................................................... 845 Testing the Payload Lights...................................................... 845 Creating Log Files of Inputs.................................................... 846 Daily Inspections............................................................... 846 Periodic Maintenance............................................................ 846 Abnormal Displays at Power-Up................................................... 847 No Payload Display When Key Switch is Turned ON................................. 848 No Display on Speedometer....................................................... 849 No Display on Operator Display.................................................. 849 No Communications With PC....................................................... 850 Load Lights Don’t Light During Loading.......................................... 851 Load Lights Remain ON........................................................... 852 Load Lights Remain ON During Dumping............................................ 852 Display Doesn't Clear When The Load Is Dumped................................... 852 Calibration Problems............................................................ 853 Alarm 1 - Left Front Pressure High.............................................. 854 Alarm 2 - Left Front Pressure Low............................................... 854 Troubleshoot Wiring to Left Front Suspension.................................... 854 Alarm 3 - Right Front Pressure High............................................. 855 Alarm 4 - Right Front Pressure Low.............................................. 855 Troubleshoot Wiring to Right Front Suspension................................... 855 Alarm 5 -Left Rear Pressure High................................................ 856 Alarm 6 - Left Rear Pressure Low................................................ 856 Troubleshoot Wiring to Left Rear Suspension..................................... 856 Alarm 7 - Right Rear Pressure High.............................................. 857 Alarm 8 - Right Rear Pressure Low............................................... 857 Troubleshoot Wiring to Right Rear Suspension.................................... 857 Alarm 9 - Inclinometer High..................................................... 858 Alarm 10 - Inclinometer Low..................................................... 858 Troubleshoot Inclinometer Wiring................................................ 858 Alarm 13 - Body Up Input Failure................................................ 859 Alarm 16 - Memory Write Failure................................................. 860 Alarm 17 - Memory Read Failure.................................................. 860 Alarm 18........................................................................ 861 Alarm 19........................................................................ 861 Alarm 22........................................................................ 861 Operator Switch Doesn't Work.................................................... 862 Alarm 26 - User Switch Fault - SELECT........................................... 862 Alarm 27 - User Switch Fault - SET.............................................. 862 Connector Map................................................................... 863 Connectors...................................................................... 864 PLMIII CHECK OUT PROCEDURE.............................................................. 865 General Description................................................................. 865 Tools Required...................................................................... 865 Checkout Procedure.................................................................. 865 PLMIII CHECKOUT PROCEDURE CONFIRMATION.............................................. 869 Flashburn Programming........................................................... 869 Confirmation Checklist.......................................................... 871 RESERVE ENGINE OIL SYSTEM ..................................................................... 873 RESERVE ENGINE OIL SYSTEM................................................................... 875 Operation............................................................................... 876 LED Monitor Light....................................................................... 876 Tank Fill Control (Optional)............................................................ 877 Filling Procedure (Remote Fill Feature)................................................. 877 SERVICE................................................................................. 878 Every 10 Hours, or once each shift:................................................. 878 Every 500 Hours..................................................................... 878 Changing Oil........................................................................ 878 TROUBLESHOOTING......................................................................... 879 Circuit Fuse........................................................................ 879 SYSTEM ELECTRICAL SCHEMATICS............................................................ 880 RETRACTABLE LADDER SYSTEM....................................................................... 881 RETRACTABLE LADDER SYSTEM................................................................... 886 GENERAL SAFETY.......................................................................... 886 LADDER SYSTEM DESCRIPTION............................................................... 886 LADDER SYSTEM OPERATION................................................................. 886 Normal Operation.................................................................... 886 Emergency Operation................................................................. 888 Limit Switch Operation.............................................................. 888 IN-CAB CONTROL PANEL.................................................................... 888 IN-CAB CONTROL PANEL FEATURES........................................................... 890 Digital Display Screen.............................................................. 890 Command Buttons..................................................................... 890 IN-CAB CONTROL PANEL FUNCTIONS.......................................................... 892 Timing Control...................................................................... 892 Ladder System Status................................................................ 892 Fault Code Identification........................................................... 892 Ladder System Configuration......................................................... 893 In-Cab Control Panel Lockout........................................................ 893 Automatic Raising................................................................... 893 Diagnostics......................................................................... 893 Maintenance......................................................................... 893 USING THE IN-CAB CONTROL PANEL.......................................................... 894 Raising the Ladder.................................................................. 894 Lowering the Ladder................................................................. 895 USING THE GROUND LEVEL CONTROL BOX...................................................... 896 Raising the Ladder.................................................................. 896 Lowering the Ladder................................................................. 896 POWER PACK OPERATION.................................................................... 897 MAINTENANCE............................................................................. 901 Safety During Maintenance........................................................... 901 Unplanned Ladder Movements.......................................................... 901 Automatic Ladder Raising............................................................ 901 Automatic Accumulator Recharging (Ladder in UP position)............................ 902 PREVENTIVE MAINTENANCE PROCEDURES....................................................... 903 Daily Inspection.................................................................... 903 250 Hour Inspection................................................................. 903 5000 Hour Inspection................................................................ 903 SERVICING............................................................................... 904 Check Reservoir Oil Level........................................................... 904 Changing RLS Fluid.................................................................. 904 Cleaning the RLS.................................................................... 905 RLS DIAGNOSTICS......................................................................... 905 Description of Diagnostics Features................................................. 905 Continuous System Monitoring........................................................ 906 Historic System Data Review......................................................... 907 Comms Integrity Monitoring.......................................................... 907 Log and Service Information......................................................... 907 System Event Logs................................................................... 908 SECURITY ACCESS LEVELS.................................................................. 909 Access Level 1 – NONE............................................................... 909 Access Level 2 – RESTRICTED......................................................... 909 Access Level 3 – COMPLETE........................................................... 909 User Access Privileges.............................................................. 910 USER ID – PASSWORD...................................................................... 911 Sequential Field Value Selection Options............................................ 911 Password Character Table............................................................ 911 USER ID – NEW USER SETUP................................................................ 912 SYSTEM FAULTS........................................................................... 912 Fault Type 1: Communications error.................................................. 913 Fault Type 2: 10A/15A fuse blown.................................................... 913 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected........... 914 Fault Type 8: Power pack recharge too long.......................................... 914 Fault Type 9: Inhibit relay fail.................................................... 915 Fault Types 10, 11: Light/Siren relay failure....................................... 915 Fault Type 12: Ladder came off upper limit.......................................... 916 Fault Type 13: Ladder did not reach limit........................................... 916 Fault Type 14: Ladder stayed on limit............................................... 917 Fault Type 15: Low oil level........................................................ 917 Fault Type 16: System voltage over 18V during movement.............................. 918 Fault Type 17: System voltage under 18V............................................. 918 Fault Type 18: System voltage over 31V.............................................. 919 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)...... 919 Fault Type 21: Accumulator recharge > than once/hour................................ 920 Fault Type 22: System raised by park brake.......................................... 920 Fault Types 23, 24: Levels 1 and 2 service overdue.................................. 921 Fault Type 25: Levels 1 and 2 service complete...................................... 921 DATA MANAGEMENT......................................................................... 922 Log Files........................................................................... 922 Generating Reports.................................................................. 923 MENU DIAGRAMS........................................................................... 929 Controller Config................................................................... 929 Contact Information................................................................. 929 Show Recent Logs.................................................................... 929 System Settings..................................................................... 929 Upload Logs to USB.................................................................. 929 Diagnostics......................................................................... 929 CAMERA SYSTEM .................................................................................. 937 CAMERA SYSTEM............................................................................... 938 CAMERA SYSTEM........................................................................... 938 General............................................................................. 938 Operation........................................................................... 938 Camera Switch....................................................................... 939 CAMERA MONITOR.......................................................................... 940 General............................................................................. 940 CAMERA CONTROLLER....................................................................... 941 General............................................................................. 941 Removal............................................................................. 941 Installation........................................................................ 941 Camera Controller Pins.............................................................. 941 CAMERA SWITCHER......................................................................... 942 General............................................................................. 942 Removal............................................................................. 942 Installation........................................................................ 942 SETUP AND CHECKOUT PROCEDURE............................................................ 943 General............................................................................. 943 STEP 1 - Switch Function............................................................ 943 STEP 2 - Monitor System Settings to Default......................................... 943 STEP 4 - Monitor Settings - System Settings Unique.................................. 945 STEP 4 - Monitor Settings - System Settings Unique - Cameras........................ 947 STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay................ 949 STEP 6 - Monitor Settings - System Settings Unique - Standby Mode................... 950 STEP 7 - Integrated Functions Check................................................. 951 SECTION N OPERATOR CAB ............................................................................. 953 TRUCK CAB AND COMPONENTS........................................................................ 955 TRUCK CAB AND COMPONENTS.................................................................... 957 TRUCK CAB............................................................................... 957 Description......................................................................... 957 Removal............................................................................. 958 Installation........................................................................ 959 CAB DOOR................................................................................ 960 Removal............................................................................. 960 Installation........................................................................ 960 Door Adjustment..................................................................... 960 Door Jamb Bolt Adjustment........................................................... 961 Door Handle Plunger Adjustment...................................................... 962 Replace Door Glass.................................................................. 963 Replace Door Window Regulator....................................................... 967 Replacing the Door Handle or Latch Assembly......................................... 968 Replacing the Door and Door Hinge Seal.............................................. 968 Removing the Door Opening Seal...................................................... 969 Installation........................................................................ 969 GLASS REPLACEMENT....................................................................... 970 Adhesive-bonded Windows............................................................. 970 Replacement Procedure............................................................... 970 WINDSHIELD & REAR GLASS................................................................. 972 Removal............................................................................. 972 Installation........................................................................ 972 CAB COMPONENTS ................................................................................. 975 CAB COMPONENTS.............................................................................. 977 WINDSHIELD WIPERS....................................................................... 977 WIPER MOTOR......................................................................... 977 Removal......................................................................... 977 Installation.................................................................... 977 WIPER ARM........................................................................... 977 Removal......................................................................... 977 Installation.................................................................... 978 WIPER LINKAGE....................................................................... 978 Removal......................................................................... 978 Installation.................................................................... 978 WINDSHIELD WASHER....................................................................... 979 Operation........................................................................... 979 Service............................................................................. 979 OPERATOR SEAT (STANDARD SEAT)........................................................... 980 Adjustment.......................................................................... 980 Inspection.......................................................................... 981 Removal............................................................................. 981 Installation........................................................................ 981 PASSENGER SEAT (STANDARD SEAT).......................................................... 982 Inspection.......................................................................... 982 Removal............................................................................. 982 Installation........................................................................ 982 SEAT BELT REPLACEMENT (STANDARD SEATS).................................................. 983 Removal............................................................................. 983 Installation........................................................................ 983 OPERATOR’S SEAT (OPTIONAL SEAT)..................................................... 985 Seat Belts...................................................................... 985 Adjustment...................................................................... 985 PASSENGER SEAT (OPTIONAL SEAT)...................................................... 986 Seat Belts...................................................................... 986 Adjustment...................................................................... 986 SEAT BELT REPLACEMENT (OPTIONAL SEATS).................................................. 987 General............................................................................. 987 Removal............................................................................. 987 OPERATOR COMFORT................................................................................ 991 OPERATOR COMFORT............................................................................ 993 HEATER / AIR CONDITIONER................................................................ 993 Fan Speed Control Knob.............................................................. 993 Temperature Control Knob............................................................ 993 Air Flow Directional Knob........................................................... 993 Heater/Air Conditioner Vents........................................................ 994 COMPONENTS.............................................................................. 994 Fuse and Circuit Breaker............................................................ 994 Relays.............................................................................. 994 Heater Core......................................................................... 994 Fan Motor And Speed Control......................................................... 995 Actuators........................................................................... 995 Cab Air Filter...................................................................... 995 ENVIRONMENTAL IMPACT OF AIR CONDITIONING................................................ 998 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 998 PRINCIPLES OF REFRIGERATION............................................................. 998 Air Conditioning.................................................................... 998 Refrigeration - The Act Of Cooling.................................................. 999 The Refrigeration Cycle............................................................. 999 AIR CONDITIONER SYSTEM COMPONENTS.......................................................1000 Compressor (Refrigerant Pump).......................................................1000 Service Valves......................................................................1000 Condenser...........................................................................1000 Receiver-Drier......................................................................1000 Expansion Block Valve...............................................................1001 Accumulator.........................................................................1001 Evaporator..........................................................................1001 ELECTRICAL CIRCUIT......................................................................1002 Thermostat..........................................................................1002 Compressor Clutch...................................................................1002 Trinary™ Switch.....................................................................1003 SYSTEM SERVICING........................................................................1004 SERVICE TOOLS AND EQUIPMENT.............................................................1005 Recovery/Recycle Station............................................................1005 Leak Detector.......................................................................1005 Service Valves......................................................................1006 Vacuum Pump.........................................................................1006 Manifold Gauge Set..................................................................1007 Installing Manifold Gauge Set.......................................................1008 Purging Air From Service Hoses......................................................1008 SYSTEM PERFORMANCE TEST.................................................................1009 SYSTEM OIL..............................................................................1010 Handling and Reusing PAG Oil........................................................1010 Oil Quantity........................................................................1010 Checking System Oil.................................................................1011 REFRIGERANT.............................................................................1012 Recycled Refrigerant................................................................1012 Reclaimed Refrigerant...............................................................1012 Refrigerant Quantity................................................................1012 R-134a Refrigerant Containers.......................................................1012 SYSTEM LEAK TESTING.....................................................................1013 Electronic Leak Detector............................................................1013 Tracer Dyes.........................................................................1013 Soap and Water......................................................................1013 RECOVERING AND RECYCLING THE REFRIGERANT................................................1013 Draining Oil from the Previous Recovery Cycle.......................................1013 Performing the Recovery Cycle.......................................................1014 Performing the Recycling Procedure..................................................1014 Evacuating and Charging the A/C System..............................................1014 SYSTEM REPAIR...........................................................................1014 System Flushing.....................................................................1015 A/C DRIVE BELT CHECKOUT PROCEDURE.......................................................1016 Pulley Alignment....................................................................1016 Belt Tension Check..................................................................1016 COMPONENT REPLACEMENT...................................................................1018 Hoses and Fittings..................................................................1018 Lines...............................................................................1018 Expansion Valve.....................................................................1018 Receiver-Drier......................................................................1018 Thermostat..........................................................................1018 Compressor..........................................................................1019 Accumulator.........................................................................1019 Clutch..............................................................................1019 EVACUATING THE SYSTEM...................................................................1020 CHARGING THE A/C SYSTEM.................................................................1022 TROUBLESHOOTING.........................................................................1023 Preliminary Checks..................................................................1023 Diagnosis Of Gauge Readings And System Performance..................................1023 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS..........................................1024 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..........................................1030 OPERATOR CAB CONTROLS...........................................................................1031 OPERATOR CAB AND CONTROLS...................................................................1035 STEERING WHEEL AND CONTROLS.............................................................1036 Horn Button.........................................................................1036 Tilt / Telescope Lever..............................................................1036 Multi-Function Turn Signal Switch...................................................1036 STEERING COLUMN.........................................................................1037 Removal.............................................................................1037 Steering Column Inspection..........................................................1037 Installation........................................................................1038 STEERING WHEEL..........................................................................1038 Removal.............................................................................1038 Installation........................................................................1038 PEDALS..................................................................................1040 Service Brake Pedal.................................................................1040 Dynamic Retarding...................................................................1040 Dynamic Retard Pedal................................................................1040 Throttle/Accelerator Pedal..........................................................1040 GRADE/SPEED RETARD CHART................................................................1041 OVERHEAD PANEL AND DISPLAYS.............................................................1042 CENTER CONSOLE..........................................................................1043 Directional Control Lever...........................................................1043 Override/Fault Reset Switch.........................................................1044 Engine Stop Switch..................................................................1044 L.H. Window Control Switch..........................................................1044 R.H. Window Control Switch..........................................................1044 Hoist Control Lever.................................................................1044 Raising The Dump Body...............................................................1044 Lowering The Dump Body..............................................................1044 Retard Speed Control (RSC) Adjust Dial..............................................1045 Retard Speed Control (RSC) Switch...................................................1045 Data Store Button...................................................................1046 KOMTRAX Plus Snapshot In Progress Light.............................................1046 Link Energized Light................................................................1046 Service Engine Light................................................................1046 DIAGNOSTIC PORTS....................................................................1046 KOMTRAX Plus Diagnostic Port........................................................1046 Interface Module (IM) Diagnostic Port...............................................1046 Payload Meter Diagnostic Port.......................................................1046 Truck Control Interface (TCI) Diagnostic Port.......................................1046 Propulsion System Controller (PSC) Diagnostic Port..................................1046 Engine Diagnostic Port (CENSE)......................................................1046 Engine Diagnostic Port (QUANTUM)....................................................1046 HEATER / AIR CONDITIONER................................................................1047 Fan Speed Control Knob..............................................................1047 Temperature Control Knob............................................................1047 Air Flow Directional Knob...........................................................1047 Heater/Air Conditioner Vents........................................................1047 INSTRUMENT PANEL........................................................................1048 Control Symbols.....................................................................1048 Key Switch..........................................................................1050 Starting............................................................................1050 Grid Dryer (Optional)...............................................................1050 Camera System (Optional)............................................................1050 Rotating Beacon Light Switch (Optional).............................................1050 Heated Mirror Switch (Optional).....................................................1050 Rest Switch.........................................................................1051 Wheel Brake Lock Control............................................................1051 Hazard Warning Lights...............................................................1051 Cab/Air Conditioner Vents...........................................................1052 Engine Oil Pressure Gauge...........................................................1052 Right Turn Signal Indicator.........................................................1052 Tachometer..........................................................................1052 High Beam Indicator.................................................................1052 Speedometer/Payload Meter Display...................................................1052 Left Turn Signal Indicator..........................................................1052 Water Temperature Gauge.............................................................1052 Lamp Test Switch....................................................................1053 Light Switch........................................................................1053 Ladder Light Switch.................................................................1053 Manual Backup Switch................................................................1053 Fog Lights (Optional)...............................................................1053 Payload Meter Switch................................................................1053 Panel Light Dimmer..................................................................1054 Hydraulic Oil Temperature Gauge.....................................................1054 Hourmeter...........................................................................1054 Fuel Level Gauge....................................................................1054 OVERHEAD STATUS / WARNING INDICATORS....................................................1055 Status / Warning Indicator Light Symbols............................................1056 REAR AXLE LIGHT BAR.....................................................................1062 Backup Lights.......................................................................1062 Retard Lights.......................................................................1062 Brake Light.........................................................................1062 Backup Alarm........................................................................1062 KOMTRAX PLUS............................................................................1063 Operation...........................................................................1063 Interface Module....................................................................1065 Basic Precautions...................................................................1065 KOMATSU WIRELESS BRIDGE (Optional)......................................................1066 General Information.................................................................1066 Communication Setup.................................................................1066 Switching to the KWB_SETUP Network..................................................1066 Setting the Computer Subnet Mask and IP Address.....................................1067 Properties..........................................................................1067 Setting Up the KWB..................................................................1068 Adding Encryption...................................................................1068 Final Computer Settings.............................................................1068 Data Downloading....................................................................1069 Resetting the KWB...................................................................1069 KWB Lights..........................................................................1069 SECTION P LUBRICATION AND SERVICE ..................................................................1071 LUBRICATION AND SERVICE.........................................................................1073 LUBRICATION AND SERVICE.....................................................................1075 830E SERVICE CAPACITIES.................................................................1075 HYDRAULIC TANK SERVICE..................................................................1075 Adding Oil..........................................................................1075 COOLANT LEVEL CHECK.....................................................................1076 Radiator Filling Procedure..........................................................1076 Coolant Specifications..............................................................1076 Unacceptable Practices..............................................................1076 WHEEL MOTOR SERVICE.....................................................................1076 RESERVE ENGINE OIL SYSTEM (Optional)....................................................1077 Reserve Oil Tank Filling Procedure (Remote fill)....................................1077 Inline Screen.......................................................................1077 QUICK FILL SERVICE CENTER...............................................................1078 LUBRICATION CHART.......................................................................1079 10 HOUR (DAILY) INSPECTION..............................................................1080 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................1083 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.....................................1084 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1085 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1089 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................1091 2500 HOUR MAINTENANCE CHECKS............................................................1092 5000 HOUR MAINTENANCE CHECKS............................................................1092 AUTOMATIC LUBRICATION SYSTEM ...................................................................1093 AUTOMATIC LUBRICATION SYSTEM................................................................1095 GENERAL DESCRIPTION.....................................................................1095 SYSTEM COMPONENTS.......................................................................1097 Filter..............................................................................1097 Hydraulic Motor and Pump............................................................1097 Grease Reservoir....................................................................1097 Pressure Reducing Valve.............................................................1097 Flow Control Valve..................................................................1097 Solenoid Valve......................................................................1097 Vent Valve..........................................................................1097 Lubrication Cycle Timer.............................................................1097 Over Pressure Cut Off Switch........................................................1097 Grease Pressure Failure Switch......................................................1097 Injectors...........................................................................1097 Relief Valve (unloader valve).......................................................1097 SYSTEM OPERATION........................................................................1098 Normal Operation....................................................................1098 Lubricant Required For System.......................................................1099 System Priming......................................................................1099 Filter Assembly.....................................................................1099 LUBRICANT PUMP..........................................................................1100 Pump Housing Oil Level..............................................................1100 Pump Pressure Control...............................................................1100 INJECTORS (SL-1 Series “H”).............................................................1101 Injector Specifications.............................................................1101 Injector Adjustment.................................................................1101 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1103 Daily Lubrication System Inspection.................................................1103 250 Hour Inspection.................................................................1103 1000 Hour Inspection................................................................1103 SYSTEM CHECKOUT.........................................................................1104 Lubrication Controller Check........................................................1104 Lubrication Controller Components...................................................1104 Lubrication Controller Adjustment...................................................1104 SYSTEM TROUBLESHOOTING CHART............................................................1106 SECTION Q ALPHABETICAL INDEX .......................................................................1109 SECTION R SYSTEM SCHEMATICS ........................................................................1113 HE484 ELECTRICAL SCHEMATIC .....................................................................1115 HH360 HYDRAULIC BRAKE SCHEMATIC ................................................................1116 EM7611 HYDRAULIC SCHEMATIC .....................................................................1117 HH364 SCHEMATIC RETRACTABLE LADDER SYSTEM......................................................1118 XS6800 ELECTRICAL SCHEMATIC ....................................................................1119 XS6801-2....................................................................................1119 XS6802-0....................................................................................1120 XS6803-0....................................................................................1121 XS6804-0....................................................................................1122 XS6805-0....................................................................................1123 XS6806-0....................................................................................1124 XS6807-1....................................................................................1125 XS6808-1....................................................................................1126 XS6809-0....................................................................................1127 XS6810-2....................................................................................1128 XS6811-0....................................................................................1129 XS6812-1....................................................................................1130 XS6813-0....................................................................................1131 XS6814-0....................................................................................1132 XS6815-1....................................................................................1133 XS6816-0....................................................................................1134 XS6817-1....................................................................................1135 XS6818-1....................................................................................1136 XS6819-1....................................................................................1137 XS6820-1....................................................................................1138 XS6821-0....................................................................................1139 XS6822-1....................................................................................1140 XS6823-0....................................................................................1141 XS6824-1....................................................................................1142 XS6825-2....................................................................................1143 XS6826-3....................................................................................1144 XS6827-2....................................................................................1145 XS6828-0....................................................................................1146 XS6829-1....................................................................................1147 XS6830-0....................................................................................1148 XS6831-0....................................................................................1149 XS6832-2....................................................................................1150 XS6833-1....................................................................................1151 XS6834-0....................................................................................1152 XS6835-0....................................................................................1153
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