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KOMATSU 830E-1AC Dump Truck Shop Repair Manual Sn A40851 & UP – PDF DOWNLOAD
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KOMATSU 830E-1AC Dump Truck Shop Repair Manual
SERIAL NUMBERS : A40851 & UP
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Description
KOMATSU 830E-1AC Dump Truck Shop Repair Manual
FILE DETAILS:
KOMATSU 830E-1AC Dump Truck Shop Repair Manual
LANGUAGE:ENGLISH
PAGES:1344
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU 830E-1AC DUMP TRUCK SHOP REPAIR MANUAL SN A40851 & UP – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU 830E-1AC Dump Truck Shop Repair Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of metric (SI) and U.S. standard units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs) torque. All torque specifications have ±10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 830E-1AC Dump Truck Shop Repair Manual
COVER ....................................................................................................................... 1 WARNING - OEM PARTS ......................................................................................................... 4 FOREWORD .................................................................................................................... 5 TABLE OF CONTENTS ........................................................................................................... 7 SECTION A - GENERAL INFORMATION............................................................................................. 9 MAJOR COMPONENT DESCRIPTION.............................................................................................. 11 Truck And Engine..................................................................................................... 11 Main Control Cabinet................................................................................................. 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 DUMP BODY ............................................................................................................... 135 DUMP BODY............................................................................................................ 137 Removal.......................................................................................................... 137 Installation..................................................................................................... 138 BODY PADS........................................................................................................ 139 Removal...................................................................................................... 139 Installation................................................................................................. 139 Adjustment................................................................................................... 140 BODY GUIDE....................................................................................................... 141 BODY-UP RETENTION CABLE.......................................................................................... 142 BODY POSITION INDICATOR.......................................................................................... 142 HOIST LIMIT SWITCH............................................................................................... 142 BODY UP SWITCH................................................................................................... 142 ROCK EJECTORS.................................................................................................... 143 Inspection................................................................................................... 143 FUEL TANK................................................................................................................ 145 FUEL TANK............................................................................................................ 146 Removal.......................................................................................................... 146 Installation..................................................................................................... 146 Repair........................................................................................................... 148 Cleaning......................................................................................................... 148 FUEL TANK BREATHER VALVE......................................................................................... 148 Disassembly.................................................................................................. 148 Assembly..................................................................................................... 148 FUEL GAUGE SENDER................................................................................................ 149 Removal...................................................................................................... 149 Operation.................................................................................................... 150 Specifications:.............................................................................................. 150 QUICK FILL FUEL RECEIVERS........................................................................................ 151 SECTION C - ENGINE .......................................................................................................... 153 POWER MODULE............................................................................................................. 155 POWER MODULE......................................................................................................... 157 PREPARATION...................................................................................................... 157 Removal...................................................................................................... 157 Installation................................................................................................. 162 COOLING SYSTEM........................................................................................................... 167 COOLING SYSTEM DESCRIPTION........................................................................................... 169 RADIATOR......................................................................................................... 170 Removal...................................................................................................... 170 Installation................................................................................................. 173 Radiator Filling Procedure................................................................................... 174 REPAIRING THE RADIATOR............................................................................................... 175 Internal Inspection.............................................................................................. 175 External Cleaning................................................................................................ 175 Disassembly...................................................................................................... 175 Cleaning and Inspection.......................................................................................... 176 Assembly......................................................................................................... 176 Pressure Testing................................................................................................. 178 COOLANT SYSTEM TROUBLESHOOTING....................................................................................... 178 POWER TRAIN.............................................................................................................. 179 ALTERNATOR REMOVAL PROCEDURE......................................................................................... 181 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)................................................................. 181 ENGINE/ALTERNATOR MATING............................................................................................. 183 General Instructions............................................................................................. 183 Measuring Procedure.............................................................................................. 183 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine.................................................... 185 ENGINE............................................................................................................... 186 Removal.......................................................................................................... 186 Service.......................................................................................................... 187 Installation..................................................................................................... 187 AIR CLEANERS ............................................................................................................ 189 AIR CLEANERS......................................................................................................... 191 OPERATION........................................................................................................ 191 SERVICING THE AIR CLEANERS....................................................................................... 191 Replacing The Elements....................................................................................... 192 AIR CLEANER ASSEMBLY CLEANING.................................................................................... 193 Primary Element Cleaning..................................................................................... 193 Precleaner Section Cleaning.................................................................................. 195 AIR INTAKE TROUBLESHOOTING....................................................................................... 196 FAN CLUTCH .............................................................................................................. 197 FAN CLUTCH........................................................................................................... 199 REMOVAL & INSTALLATION TOOLING................................................................................... 199 DISASSEMBLY...................................................................................................... 202 CLEANING AND INSPECTION.......................................................................................... 212 ASSEMBLY......................................................................................................... 216 TEST PROCEDURE................................................................................................... 230 SECTION D - 24VDC ELECTRICAL SYSTEM ........................................................................................ 231 24VDC ELECTRIC SUPPLY SYSTEM............................................................................................. 233 24VDC ELECTRIC SUPPLY SYSTEM......................................................................................... 235 ELECTRICAL SYSTEM DESCRIPTION.................................................................................... 235 BATTERIES........................................................................................................ 235 Maintenance and Service...................................................................................... 235 Troubleshooting.............................................................................................. 235 BATTERY SUPPLY SYSTEM............................................................................................ 237 24VDC Battery Charging Alternator............................................................................ 237 Battery Box.................................................................................................. 237 Removal...................................................................................................... 237 Installation................................................................................................. 238 Battery Control Box.......................................................................................... 238 24VDC Auxiliary Battery Receptacles.......................................................................... 238 Engine Start Relay........................................................................................... 238 ISOLATION BOX ASSEMBLY........................................................................................... 238 Engine Shutdown Switch....................................................................................... 238 Access Ladder Light Switch................................................................................... 238 Battery Disconnect Switches.................................................................................. 238 Propel Lockout Lever......................................................................................... 239 LED Lights................................................................................................... 239 AUXILIARY CONTROL CABINET........................................................................................ 240 24VDC to 12VDC Converter..................................................................................... 240 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE).............................................................. 241 Operation.................................................................................................... 241 Engine Oil Pressure Switch................................................................................... 241 Check Valve.................................................................................................. 241 MAINTENANCE...................................................................................................... 241 Prelube System Operation Checks.............................................................................. 241 Check Valve.................................................................................................. 241 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT....................................................................... 242 24VDC ELECTRIC START SYSTEM.......................................................................................... 244 CRANKING MOTORS.................................................................................................. 244 Operation.................................................................................................... 244 Removal...................................................................................................... 244 Installation................................................................................................. 244 CRANKING MOTOR TROUBLESHOOTING................................................................................... 245 Preliminary Inspection....................................................................................... 245 No-Load Test................................................................................................. 245 Interpreting Results of Tests................................................................................ 246 Disassembly.................................................................................................. 246 Cleaning and Inspection...................................................................................... 247 Armature Servicing........................................................................................... 249 Field Coil Checks............................................................................................ 249 Field Coil Removal........................................................................................... 249 SOLENOID CHECKS.................................................................................................. 250 Test......................................................................................................... 250 Assembly..................................................................................................... 251 Bearing Replacement:......................................................................................... 251 Motor Assembly:.............................................................................................. 251 Pinion Clearance............................................................................................. 252 MAGNETIC SWITCH.................................................................................................. 252 Removal...................................................................................................... 252 Installation................................................................................................. 252 Coil Test.................................................................................................... 253 24VDC ELECTRICAL SYSTEM COMPONENTS....................................................................................... 255 24 VDC ELECTRICAL SYSTEM COMPONENTS.................................................................................. 257 TRUCK SHUTDOWN PROCEDURE......................................................................................... 257 BRAKE WARNING BUZZER............................................................................................. 257 AUXILIARY CONTROL CABINET COMPONENTS............................................................................. 257 Interface Module............................................................................................. 258 Payload Meter................................................................................................ 258 24VDC to 12VDC Converter..................................................................................... 258 Circuit Breaker (CB60)....................................................................................... 258 Inclinometer................................................................................................. 258 Vehicle Electrical Center (VEC).............................................................................. 259 Pump Module Service Light Timer.............................................................................. 259 Power Distribution Terminals................................................................................. 259 Ground Terminal.............................................................................................. 259 Relays....................................................................................................... 260 Engine Service Light Timer................................................................................... 260 RTMR1 - VEC Block............................................................................................ 261 VEC-89....................................................................................................... 262 VEC-90....................................................................................................... 264 VEC-91....................................................................................................... 266 MAGNETIC SWITCHES................................................................................................ 268 Body position switches (With proximity switch and magnet).................................................... 268 Proximity switch operation............................................................................... 268 Service.................................................................................................. 268 BODY-UP SWITCH............................................................................................... 269 Adjust the body up switch................................................................................ 269 HOIST LIMIT SWITCH........................................................................................... 270 Operation................................................................................................ 270 Adjust the hoist limit switch............................................................................ 271 KOMTRAX Plus SYSTEM ..................................................................................................... 273 KOMTRAX Plus COMPONENTS.............................................................................................. 275 KOMTRAX Plus BASIC FEATURES...................................................................................... 275 Gather Data.................................................................................................. 275 Convert and Record Data...................................................................................... 275 Communicate Data to Off-Board Systems........................................................................ 276 USING THE KOMTRAX Plus SYSTEM.................................................................................... 277 Turning the KOMTRAX Plus System ON........................................................................... 277 Normal KOMTRAX Plus Operation................................................................................ 277 Turning the KOMTRAX Plus System OFF.......................................................................... 278 Downloading from the KOMTRAX Plus Controller................................................................. 278 KOMTRAX Plus DATA ITEMS.......................................................................................... 279 Fault Codes.................................................................................................. 279 Machine History.............................................................................................. 279 KOMTRAX Plus History......................................................................................... 279 Snapshots.................................................................................................... 280 Manual Snapshots............................................................................................. 280 Trends....................................................................................................... 282 Histogram (Load Map) Data.................................................................................... 282 Haul Cycle Data.............................................................................................. 283 Alarm and Snapshot Triggers.................................................................................. 284 Satellite Features........................................................................................... 284 KOMTRAX Plus DIAGNOSTIC FEATURES................................................................................. 286 Fault History................................................................................................ 286 KOMTRAX Plus LED Digits...................................................................................... 286 KOMTRAX Plus CONTROLLER.......................................................................................... 286 Removal...................................................................................................... 287 Installation................................................................................................. 287 KOMTRAX Plus SOFTWARE............................................................................................ 289 NECESSARY SOFTWARE........................................................................................... 289 NECESSARY TOOLS.............................................................................................. 289 KOMTRAX Plus SYSTEM SET UP................................................................................... 290 KOMTRAX Plus Controller.................................................................................. 290 KOMTRAX Plus CONTROLLER...................................................................................... 290 KOMTRAX Plus TOOL BOX.................................................................................... 290 Installation......................................................................................... 290 KOMTRAX Plus SETTING TOOL................................................................................ 290 Installation......................................................................................... 290 KOMTRAX Plus INITIALIZATION PROCEDURE........................................................................ 291 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE............................................................... 291 KOMTRAX Plus Setting Tool software program........................................................... 291 Select Operation..................................................................................... 291 KOMTRAX Plus Setting Function........................................................................ 292 Machine Information Setting(1)....................................................................... 292 Machine Information Setting(2)....................................................................... 292 Date & Time Setting.................................................................................. 292 GCC Setting.......................................................................................... 293 Setting Summary...................................................................................... 293 2. KOMTRAX Plus SNAPSHOT PROCEDURE....................................................................... 294 3. KOMTRAX Plus DOWNLOAD PROCEDURE....................................................................... 295 4. LOCATION OF DOWNLOAD FILES............................................................................ 295 5. KOMTRAX Plus FTP UPLOAD PROCEDURE..................................................................... 296 6. KOMTRAX Plus INITIALIZATION FORMS..................................................................... 297 WHEN REPLACING A KOMTRAX Plus CONTROLLER..................................................................... 298 To Set: Date & Time; Satellite; Payload Meter............................................................ 300 Review Setting Information............................................................................... 302 KOMTRAX Plus CONTROLLER CHECKOUT......................................................................... 303 KOMTRAX Plus Controller.............................................................................. 303 Necessary Equipment:................................................................................. 303 Preliminary.......................................................................................... 304 KOMTRAX Plus Controller Checkout Procedure........................................................... 305 ORBCOMM CONTROLLER....................................................................................... 307 Removal.............................................................................................. 307 Installation......................................................................................... 307 INTERFACE MODULE ........................................................................................................ 309 INTERFACE MODULE..................................................................................................... 311 Removal.......................................................................................................... 311 Installation..................................................................................................... 311 SENSORS.......................................................................................................... 312 Temperature Sensors.......................................................................................... 312 Pressure Sensors............................................................................................. 312 INTERFACE MODULE SOFTWARE............................................................................................ 313 NECESSARY SOFTWARE............................................................................................... 313 NECESSARY TOOLS.................................................................................................. 313 FLASHBURN PROGRAM................................................................................................ 314 Installation................................................................................................. 314 INTERFACE MODULE APPLICATION CODE................................................................................ 314 Installation................................................................................................. 314 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM.......................................................... 314 Installation................................................................................................. 314 Using The Program............................................................................................ 314 INTERFACE MODULE CHECKOUT........................................................................................ 315 Interface Module............................................................................................. 315 Necessary Equipment:......................................................................................... 315 Preliminary.................................................................................................. 316 Checking Inputs And Outputs From The Interface Module........................................................ 316 Check Analog Inputs To The Interface Module.................................................................. 320 Check CAN RPC & J1939 Interfaces To The IM................................................................... 320 Check Outputs From The Interface Module...................................................................... 320 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES ......................................................... 323 KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING.................................................... 325 TROUBLESHOOTING.................................................................................................. 325 GENERAL...................................................................................................... 325 Structure and Purpose.................................................................................... 325 TROUBLESHOOTING.............................................................................................. 326 Communications Networks.................................................................................. 326 Coaxial Cable............................................................................................ 326 FAULT CODES.................................................................................................. 327 Fault History............................................................................................ 327 KOMTRAX Plus LED Display Fault Codes..................................................................... 328 Chassis Fault Codes...................................................................................... 329 Engine Fault Codes....................................................................................... 333 FAULT TREE ANALYSIS.......................................................................................... 339 Unable to connect to KOMTRAX Plus from laptop PC......................................................... 339 Flashing Error Code N4-23 (PLM III Communications Fault)................................................. 340 Flashing Error Code N4-22 (Engine Communications Fault).................................................. 341 No Data Received By WebCARE.............................................................................. 342 Coaxial Cable Troubleshooting............................................................................ 343 KOMTRAX PLUS FORMS ..................................................................................................... 345 KOMTRAX PLUS FORMS................................................................................................... 347 KOMTRAX PLUS INITIALIZATION CHECK LIST........................................................................... 347 KOMTRAX PLUS DATA DOWNLOAD....................................................................................... 348 KOMTRAX PLUS INITIALIZATION CHECK LIST........................................................................... 349 KOMTRAX PLUS INITIALIZATION FORM................................................................................. 351 SECTION E - ELECTRIC PROPULSION SYSTEM INDEX................................................................................ 353 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX.............................................................................. 355 ELECTRICAL PROPULSION SYSTEM COMPONENTS.............................................................................. 357 GENERAL SYSTEM DESCRIPTION....................................................................................... 357 SYSTEM COMPONENTS................................................................................................ 359 Drive System Controller (DSC)................................................................................ 359 Diagnostic Information Display (DID) Panel................................................................... 360 DID Panel Event Codes........................................................................................ 360 DSC SOFTWARE FUNCTIONS........................................................................................... 379 Input Processing............................................................................................. 379 State Machine................................................................................................ 379 DC Link State................................................................................................ 382 Engine Control............................................................................................... 383 ALTERNATOR FIELD CONTROL......................................................................................... 383 Desired Three-Phase Voltage.................................................................................. 383 Desired DC Link Voltage...................................................................................... 383 Self-Load.................................................................................................... 384 Propel Torque Control........................................................................................ 384 Retard Torque Control........................................................................................ 384 Wheel Slide Control.......................................................................................... 385 Resistor Grid Control........................................................................................ 385 Chopper Voltage Control...................................................................................... 385 EVENT DETECTION AND PROCESSING................................................................................... 385 Power-On Tests............................................................................................... 385 Initiated Tests.............................................................................................. 386 Periodic Tests............................................................................................... 386 EVENT RESTRICTIONS............................................................................................... 386 EVENT LOGGING AND STORAGE........................................................................................ 386 Event History Buffer......................................................................................... 387 Data Packs................................................................................................... 387 Event Reset.................................................................................................. 387 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS......................................................................... 388 Fast Start................................................................................................... 388 Engine Shutdown/Engine Not Running........................................................................... 388 Limp Home Mode............................................................................................... 388 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS............................................................ 389 ELECTRONIC ACCELERATOR AND RETARD PEDALS......................................................................... 396 Removal...................................................................................................... 396 Installation................................................................................................. 396 Disassembly.................................................................................................. 396 Assembly..................................................................................................... 396 PHASE MODULE REPLACEMENT......................................................................................... 397 Removal...................................................................................................... 397 Installation................................................................................................. 397 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX...................................................................... 399 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE........................................................................ 401 AC DRIVE SYSTEM MAINTENANCE...................................................................................... 401 NORMAL TRUCK SHUTDOWN PROCEDURE.................................................................................. 402 TEST EQUIPMENT................................................................................................... 403 HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS.................................................................. 403 REST MODE ACTIVATION............................................................................................. 403 INITIAL CHECKOUT PROCEDURES...................................................................................... 404 Circuit Continuity and Resistance Checks..................................................................... 404 Megger Test for Grounds...................................................................................... 404 Troubleshooting for Grounds.................................................................................. 407 Low Voltage Power Supply Checks.............................................................................. 408 Drive System Controller (DCS) Card Checks.................................................................... 409 Propulsion System Software Installation...................................................................... 409 DSC Manual Test Procedures................................................................................... 412 Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks................................. 414 Set Truck ID Number.......................................................................................... 418 Control Cabinet Pressure Switch Check........................................................................ 419 CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX).................................................................. 420 Verifying DSC Software Version............................................................................... 420 Resetting and Erasing DSC Event Data......................................................................... 421 ENGINE RUNNING TESTS............................................................................................. 422 Battery Boost Circuit Verification........................................................................... 422 Selector Switch Check........................................................................................ 424 Ground Detection Network Tests............................................................................... 427 Self Load Engine Test (Loadbox) Procedure.................................................................... 431 DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL....................................................................... 433 DID Panel Display Selection.................................................................................. 433 DID Modes Display............................................................................................ 435 Function Key F1 - DID Events or Faults Display............................................................... 436 Function Key F4 - DID Menu Display........................................................................... 439 DID Self Load Engine Test (Loadbox).......................................................................... 440 DID Link Capacitance Test.................................................................................... 442 DID Speedometer Test......................................................................................... 443 DID View Software Version.................................................................................... 444 DID View Overspeed Setting................................................................................... 445 DID View Data Menu........................................................................................... 446 DID Inverter Cutout Menu..................................................................................... 451 DID Truck Configuration Menu................................................................................. 452 Language Selection........................................................................................... 457 VIEWING EVENT AND STATISTICAL DATA............................................................................... 458 Viewing the DSC Event Summary, Trigger Data, and Data Packs.................................................. 458 Viewing the Statistical Data................................................................................. 460 LOGIC SCREENS.................................................................................................... 461 DATALOGGER FUNCTION.............................................................................................. 463 Setting Up the Datalogger.................................................................................... 463 Starting the Datalogger...................................................................................... 465 UPLOADING DATA................................................................................................... 467 Consolidated Truck Data Save................................................................................. 467 USB Drive.................................................................................................... 468 TROUBLESHOOTING FAULT CODES (A001-A139) INDEX............................................................................ 469 Fault Code A001: Left front suspension pressure sensor signal is high................................................ 471 Related circuit diagram.......................................................................................... 471 Fault Code A002: Left front suspension pressure sensor signal is low................................................. 472 Related circuit diagram.......................................................................................... 472 Fault Code A003: Right front suspension pressure sensor signal is high............................................... 473 Related circuit diagram.......................................................................................... 473 Fault Code A004: Right front suspension pressure sensor signal is low................................................ 474 Related circuit diagram.......................................................................................... 474 Fault Code A005: Left rear suspension pressure sensor signal is high................................................. 475 Related circuit diagram.......................................................................................... 475 Fault Code A006: Left rear suspension pressure sensor signal is low.................................................. 476 Related circuit diagram.......................................................................................... 476 Fault Code A007: Right rear suspension pressure sensor signal is high................................................ 477 Related circuit diagram.......................................................................................... 477 Fault Code A008: Right rear suspension pressure sensor signal is low................................................. 478 Related circuit diagram.......................................................................................... 478 Fault Code A009: Incline sensor signal is high....................................................................... 479 Related circuit diagram.......................................................................................... 479 Fault Code A010: Incline sensor signal is low........................................................................ 480 Related circuit diagram.......................................................................................... 480 Fault Code A011: Payload meter speed sensor signal has failed........................................................ 481 Related circuit diagram.......................................................................................... 481 Fault Code A013: Body up switch has failed........................................................................... 482 Related circuit diagram.......................................................................................... 482 Fault Code A014: Payload meter checksum computation has failed....................................................... 483 Related circuit diagram.......................................................................................... 483 Fault Code A016: Payload meter write to flash memory has failed...................................................... 484 Related circuit diagram.......................................................................................... 484 Fault Code A017: Payload meter flash memory read has failed.......................................................... 485 Related circuit diagram.......................................................................................... 485 Fault Code A018: Right rear flat suspension cylinder warning......................................................... 486 Related circuit diagram.......................................................................................... 487 Fault Code A019: Left rear flat suspension cylinder warning.......................................................... 488 Related circuit diagram.......................................................................................... 489 Fault Code A022: Carryback load is excessive......................................................................... 490 Related circuit diagram.......................................................................................... 491 Fault Code A101: High pressure detected across a hydraulic pump filter............................................... 492 Related circuit diagram.......................................................................................... 493 Fault Code A103: Hydraulic oil tank temperature sensor is reading low................................................ 494 Related circuit diagram.......................................................................................... 494 Fault Code A104: Hydraulic oil tank temperature sensor is reading high............................................... 495 Related circuit diagram.......................................................................................... 495 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level.......................... 496 Related circuit diagram.......................................................................................... 497 Fault Code A107: GE has generated a propel system caution............................................................ 498 Related circuit diagram.......................................................................................... 498 Fault Code A108: GE has generated a propel system temperature caution................................................ 499 Related circuit diagram.......................................................................................... 499 Fault Code A109: GE has generated a propel system reduced level signal............................................... 500 Related circuit diagram.......................................................................................... 500 Fault Code A111 & A247: Low steering pressure warning................................................................ 502 Related circuit diagram.......................................................................................... 503 Fault Code A115: Low steering precharge pressure is detected......................................................... 504 Related circuit diagram.......................................................................................... 505 Fault Code A117 & A261: Low brake accumulator pressure warning....................................................... 506 Related circuit diagram.............................................................................................. 507 Fault Code A118: Brake pressure is low while brake lock is activated................................................. 508 Related circuit diagram.............................................................................................. 509 Fault Code A123: GE has generated a reduced retarding caution........................................................ 510 Related circuit diagram.......................................................................................... 510 Fault Code A124: GE has generated a no propel / no retard warning.................................................... 511 Related circuit diagram.......................................................................................... 511 Fault Code A125: GE has generated a no propel warning................................................................ 512 Related circuit diagram.......................................................................................... 512 Fault Code A126: Oil level in the hydraulic tank is low.............................................................. 513 Related circuit diagram.......................................................................................... 513 Fault Code A127: IM furnished +5 volt output for sensors is low...................................................... 514 Related circuit diagram.......................................................................................... 515 Fault Code A128: IM furnished +5 volt output for sensors is high..................................................... 516 Related circuit diagram.......................................................................................... 517 Fault Code A139 & A310: Low fuel level warning....................................................................... 518 Related circuit diagram.......................................................................................... 519 TROUBLESHOOTING FAULT CODES (A152-A246) INDEX............................................................................ 521 Fault Code A152: Starter failure..................................................................................... 523 Fault Code A153: Battery voltage is low with truck in operation...................................................... 524 Fault Code A154: Battery charging voltage is excessive............................................................... 525 Fault Code A155: Battery charging voltage is low..................................................................... 526 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level........................ 527 Fault Code A184: J1939 data link is not connected.................................................................... 528 Fault Code A190: Auto lube control has detected an incomplete lube cycle............................................. 529 Fault Code A193: Hydraulic tank oil temperature is high.............................................................. 530 Fault Code A198: Hoist pressure 1 sensor is high..................................................................... 531 Fault Code A199: Hoist pressure 2 sensor is high..................................................................... 532 Fault Code A200: Steering pressure sensor is high.................................................................... 533 Fault Code A201: Brake pressure sensor is high....................................................................... 534 Fault Code A202: Hoist pressure 1 sensor is low...................................................................... 535 Fault Code A203: Hoist pressure 2 sensor is low...................................................................... 536 Fault Code A204: Steering pressure sensor is low..................................................................... 537 Fault Code A205: Brake pressure sensor is low........................................................................ 538 Fault Code A206: Ambient temperature sensor is high.................................................................. 539 Fault Code A207: Ambient temperature sensor is low................................................................... 540 Fault Code A212: Bad truck speed signal.............................................................................. 541 Fault Code A213: Parking brake should have applied but is detected as not having applied............................. 542 Fault Code A214: Parking brake should have released but is detected as not having released........................... 544 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit............. 546 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted........................... 547 Fault Code A230: Parking brake has been requested while truck still moving........................................... 548 Fault Code A231: Dump body is up while traveling or intending to travel.............................................. 549 Fault Code A235: Steering accumulator is in the process of being bled down........................................... 550 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds.................................... 551 Fault Code A237: The CAN/RPC connection to the display is open....................................................... 552 Fault Code A240: The keyswitch input to the interface module is open................................................. 553 Fault Code A242: The fuel gauge within the display panel is defective................................................ 554 Fault Code A243: The engine coolant temp gauge within the display panel is defective................................. 555 Fault Code A244: The drive system temp gauge within the display panel is defective................................... 556 Fault Code A245: The hydraulic oil temp gauge within the display panel is defective.................................. 557 Fault Code A246: Payload meter reports truck overload................................................................ 558 TROUBLESHOOTING FAULT CODES (A248-A292) INDEX............................................................................ 559 Fault Code A248: The status indicator module within the display panel is defective................................... 561 Fault Code A249: The red warning lamp within the display panel is shorted............................................ 562 Fault Code A250: Battery voltage is low with the truck parked........................................................ 563 Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground................ 565 Fault Code A252: Start enable output circuit is either open or shorted to ground..................................... 566 Fault Code A253: Steering bleed circuit is not open while running.................................................... 567 Fault Code A255: IM has detected a fault on IM output 1N............................................................. 568 Fault Code A256: The red warning lamp within the display panel (driven by IM) is open................................ 569 Fault Code A257: Payload CAN/RPC is not connected.................................................................... 570 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective..................................... 571 Fault Code A260: Parking brake failure............................................................................... 572 Fault Code A262: Steering bleed valve circuit open during shutdown................................................... 574 Fault Code A264: Parking brake relay circuit is defective............................................................ 575 Fault Code A265: Service brake failure............................................................................... 576 Fault Code A266: Selector lever was not in park while attempting to crank engine..................................... 577 Fault Code A267: Parking brake was not set while attempting to crank engine.......................................... 578 Fault Code A268: Secondary engine shutdown while cranking............................................................ 579 Fault Code A270: Brake lock switch power supply is not on when required.............................................. 580 Fault Code A271: Shifter not in gear................................................................................. 582 Fault Code A272: Brake lock switch power supply is not off when required............................................. 583 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit.............. 585 Fault Code A274: A brake setting fault has been detected............................................................. 586 Fault Code A275: A starter has been detected as engaged without a cranking attempt................................... 587 Fault Code A276: The drive system data link is not connected......................................................... 588 Fault Code A277: Parking brake applied while loading................................................................. 589 Fault Code A278: Service brake applied while loading................................................................. 590 Fault Code A279: Low steering pressure switch is defective........................................................... 591 Fault Code A280: Steering accumulator Bleed Down switch is defective................................................. 592 Fault Code A281: Brake lock degradation switch is defective.......................................................... 593 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7.... 594 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set.......................... 595 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated............. 596 Fault Code A285: The parking brake was not set when the key switch was turned off.................................... 597 Fault Code A286: A fault was detected in the shutdown delay relay circuit............................................ 598 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off................ 599 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX............................................................................ 601 Fault Code A303: Shifter is defective................................................................................ 603 Fault Code A304: Auto lube grease level is low....................................................................... 604 Fault Code A305: Auto lube circuit is defective...................................................................... 605 Fault Code A307: Both GE inverters are disabled...................................................................... 606 Fault Code A309: No brakes applied when expected..................................................................... 607 Fault Code A311: Brake lock switch is on when it should not be....................................................... 608 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings................................... 609 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings.................................. 610 Fault Code A315: DC-DC converter 12 volt circuit is low.............................................................. 611 Fault Code A316: Starter engagement has been attempted with engine running........................................... 612 Fault Code A318: Unexpected power loss to interface module........................................................... 613 Fault Code A320: Propel system caution wire input not same as serial input........................................... 614 Fault Code A321: Propel system temperature caution wire input not same as serial input............................... 615 Fault Code A322: Propel system at reduced level wire input not same as serial input.................................. 616 Fault Code A323: Propel system at reduced retard level wire input not same as serial input........................... 617 Fault Code A324: GE link voltage wire input not same as serial input................................................. 618 Fault Code A325: No Propel/Retard wire input not same as serial input................................................ 619 Fault Code A326: No Propel wire input not same as serial input....................................................... 620 Fault Code A327: GE Propel System at Rest or Not Ready wire input not same as serial input........................... 621 Fault Code A328: Drive system not powered up......................................................................... 622 Fault Code A329: Body down wire input not same as serial input....................................................... 623 Fault Code A330: Dynamic retard switch input not same as serial input................................................ 624 Fault Code A332: Seat belt not buckled............................................................................... 625 Fault Code A334: Selector lever not in park when propel was either not ready or at rest.............................. 627 Fault Code A350: Overload on output 1B............................................................................... 628 Fault Code A351: Overload on output 1E............................................................................... 629 Fault Code A352: Overload on output 1H............................................................................... 630 Fault Code A353: Overload on output 1J............................................................................... 631 Fault Code A354: Overload on output 1K............................................................................... 632 Fault Code A355: Overload on output 1L............................................................................... 633 Fault Code A356: Overload on output 1M............................................................................... 634 Fault Code A357: Overload on output 1N............................................................................... 635 Fault Code A358: Overload on output 1P............................................................................... 636 Fault Code A359: Overload on output 1R............................................................................... 637 Fault Code A360: Overload on output 1S............................................................................... 638 Fault Code A361: Overload on output 1T............................................................................... 639 Fault Code A362: Overload on output 1U............................................................................... 640 Fault Code A363: Overload on output 1X............................................................................... 641 Fault Code A364: Overload on output 1Y............................................................................... 642 Fault Code A365: Overload on output 1Z............................................................................... 643 SECTION G - DRIVE AXLE, SPINDLE, AND WHEELS ................................................................................ 645 TIRES AND RIMS........................................................................................................... 647 TIRES AND RIMS....................................................................................................... 649 FRONT TIRES AND RIMS............................................................................................. 649 Removal...................................................................................................... 649 Installation................................................................................................. 651 REAR TIRES AND RIMS.............................................................................................. 651 Removal...................................................................................................... 651 Installation................................................................................................. 652 RIM AND TIRE..................................................................................................... 654 Tire Removal................................................................................................. 654 Rim And Tire Preparation..................................................................................... 654 Lubricants................................................................................................... 655 Tire Installation............................................................................................ 655 FRONT WHEEL HUB AND SPINDLES............................................................................................. 657 FRONT WHEEL HUB AND SPINDLE.......................................................................................... 659 WHEEL HUB AND SPINDLE ASSEMBLY................................................................................... 659 Removal...................................................................................................... 659 Spindle Removal Procedure (Optional) (off of the truck)...................................................... 662 Installation................................................................................................. 664 Disassembly.................................................................................................. 667 Cleaning and Inspection...................................................................................... 667 Assembly..................................................................................................... 668 Wheel Bearing Adjustment (Tire Removed)...................................................................... 670 Wheel Bearing Adjustment (Tire mounted)...................................................................... 671 OIL SAMPLING PROCEDURE........................................................................................... 672 Oil Sampling Guidelines...................................................................................... 673 Procedure.................................................................................................... 673 OIL DRAIN AND REFILL PROCEDURE................................................................................... 673 STEERING CYLINDERS............................................................................................... 674 Spherical Bearing Wear Limits................................................................................ 674 Removal...................................................................................................... 675 Installation................................................................................................. 675 Bearing Replacement (Steering cylinder and tie rod).......................................................... 675 TIE ROD.......................................................................................................... 677 Removal...................................................................................................... 677 Installation................................................................................................. 677 Disassembly.................................................................................................. 677 Assembly..................................................................................................... 678 TOE-IN ADJUSTMENT................................................................................................ 679 REAR AXLE HOUSING ATTACHMENT............................................................................................. 681 REAR AXLE HOUSING ATTACHMENT......................................................................................... 683 PIVOT PIN........................................................................................................ 683 Removal...................................................................................................... 683 Installation................................................................................................. 683 PIVOT EYE BEARING................................................................................................ 684 Disassembly.................................................................................................. 684 Assembly..................................................................................................... 684 PIVOT EYE REPAIR................................................................................................. 685 Removal...................................................................................................... 685 Installation................................................................................................. 685 Disassembly.................................................................................................. 685 Assembly..................................................................................................... 685 ANTI-SWAY BAR.................................................................................................... 686 Removal...................................................................................................... 686 Installation................................................................................................. 686 Disassembly.................................................................................................. 686 Cleaning and Inspection...................................................................................... 686 Assembly..................................................................................................... 686 REAR AXLE HOUSING........................................................................................................ 687 REAR AXLE HOUSING.................................................................................................... 689 REAR AXLE HOUSING................................................................................................ 689 Removal...................................................................................................... 689 Installation................................................................................................. 689 WHEEL MOTOR...................................................................................................... 690 Removal...................................................................................................... 690 Cleaning and Inspection...................................................................................... 690 Installation................................................................................................. 691 WHEEL MOTOR GEAR OIL............................................................................................. 694 Change/Filter The Gear case Oil.............................................................................. 694 Oil.......................................................................................................... 694 Remove And Clean Magnetic Plugs.............................................................................. 694 Flushing The Gearbox......................................................................................... 694 Check Gear Case Oil Level.................................................................................... 694 SECTION H SUSPENSIONS INDEX.................................................................................................. 695 FRONT SUSPENSION......................................................................................................... 697 FRONT SUSPENSION..................................................................................................... 699 Removal.......................................................................................................... 699 Installation..................................................................................................... 700 TURN-OF-THE-NUT Tightening Procedure............................................................................. 702 Upper Mounting Joint - 60° Advance........................................................................... 702 Lower Mounting Joint - 90° Advance........................................................................... 704 Inspection................................................................................................... 704 MINOR REPAIR ONLY (Lower Bearing Structure & Seals).............................................................. 705 Bearing Structure Removal.................................................................................... 705 Bearing Structure Installation............................................................................... 705 MAJOR SUSPENSION REBUILD......................................................................................... 706 Disassembly.................................................................................................. 706 Assembly..................................................................................................... 707 PRESSURE TEST.................................................................................................... 709 REAR SUSPENSIONS ........................................................................................................ 711 REAR SUSPENSIONS..................................................................................................... 712 Removal.......................................................................................................... 712 Installation..................................................................................................... 715 ROD DOWN SUSPENSION.............................................................................................. 716 Disassembly.................................................................................................. 716 Cleaning and Inspection...................................................................................... 716 Assembly..................................................................................................... 718 PRESSURE TEST.................................................................................................... 720 Suspension pressure test..................................................................................... 720 OIL AND CHARGING PROCEDURE .............................................................................................. 721 OILING AND CHARGING PROCEDURE........................................................................................ 723 GENERAL.......................................................................................................... 723 EQUIPMENT LIST................................................................................................... 723 HYDRAIR® CHARGING KIT............................................................................................ 724 Installation of Charging Kit................................................................................. 724 Removal of Charging Kit...................................................................................... 724 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS................................................................ 725 FRONT SUSPENSION................................................................................................. 725 Front Suspension Oiling...................................................................................... 725 Front Suspension Nitrogen Charging........................................................................... 727 REAR SUSPENSION - ROD DOWN....................................................................................... 729 Rear Suspension Oiling (Rod Down Only)....................................................................... 729 Rear Suspension Nitrogen Charging (Rod Down Only)............................................................ 731 OIL AND NITROGEN SPECIFICATIONS CHART............................................................................ 733 SECTION J - BRAKE CIRCUIT ................................................................................................... 735 BRAKE CIRCUIT............................................................................................................ 737 BRAKE CIRCUIT........................................................................................................ 739 OPERATION........................................................................................................ 739 SERVICE BRAKE CIRCUIT OPERATION.................................................................................. 739 SECONDARY BRAKING AND AUTOMATIC APPLY............................................................................ 741 PARKING BRAKE CIRCUIT............................................................................................ 741 Normal Operation (key switch on, engine running)............................................................. 741 BRAKE LOCK CIRCUIT............................................................................................... 742 WARNING CIRCUIT.................................................................................................. 742 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................................... 745 BRAKE CIRCUIT COMPONENT SERVICE...................................................................................... 747 BRAKE VALVE...................................................................................................... 747 Rebuild Criteria............................................................................................. 747 Removal...................................................................................................... 747 Installation................................................................................................. 749 DISASSEMBLY...................................................................................................... 751 Cleaning and Inspection...................................................................................... 753 ASSEMBLY......................................................................................................... 753 Actuator Base Threaded Inserts............................................................................... 753 Boot and Cap................................................................................................. 753 Valve Body Seal Installation................................................................................. 754 Regulator Sleeve O-Ring Installation......................................................................... 754 Actuator Plunger O-ring Installation......................................................................... 755 Assembly of Valve............................................................................................ 755 VALVE BENCH TEST AND ADJUSTMENT.................................................................................. 757 Test Set Up Procedure........................................................................................ 758 Brake Valve Output Pressure Adjustment....................................................................... 758 Final Test and Adjustment.................................................................................... 759 Installation Of Brake Pedal Actuator Assembly to Brake Valve................................................. 760 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)............................. 762 Installation of Retard Pedal To Brake Pedal.................................................................. 762 HYDRAULIC BRAKE ACCUMULATORS..................................................................................... 763 Brake Accumulator Bleed Down Procedure....................................................................... 763 Removal...................................................................................................... 763 Installation................................................................................................. 763 Disassembly.................................................................................................. 763 Cleaning and Inspection...................................................................................... 765 Assembly..................................................................................................... 765 Charging Procedure........................................................................................... 767 BRAKE MANIFOLD................................................................................................... 768 Removal...................................................................................................... 768 Removal...................................................................................................... 768 Installation................................................................................................. 769 Disassembly.................................................................................................. 769 Cleaning and Inspection...................................................................................... 770 Assembly..................................................................................................... 770 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................................................ 771 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................................................... 773 EQUIPMENT REQUIRED............................................................................................... 774 INITIAL SYSTEM SET-UP............................................................................................ 776 PARKING BRAKE.................................................................................................... 776 BRAKE SYSTEM CHECK-OUT........................................................................................... 777 BRAKE LOCK....................................................................................................... 777 FAILURE MODES CHECK-OUT.......................................................................................... 778 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING........................................................................ 779 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET........................................................ 782 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET........................................................ 783 FRONT BRAKES............................................................................................................. 785 WHEEL SPEED FRONT DISC BRAKES........................................................................................ 787 BRAKE CALIPER.................................................................................................... 787 Caliper Removal.............................................................................................. 787 Installation................................................................................................. 788 Disassembly.................................................................................................. 789 Assembly..................................................................................................... 789 Cleaning and Inspection...................................................................................... 790 BRAKE LINING..................................................................................................... 791 Replacement.................................................................................................. 791 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.......................................................... 793 GENERAL...................................................................................................... 793 Safety Precautions....................................................................................... 793 Front Brake Conditioning................................................................................. 793 BRAKE BLEEDING PROCEDURES.................................................................................... 794 ARMATURE SPEED REAR DISC BRAKES.......................................................................................... 795 ARMATURE SPEED REAR DISC BRAKES...................................................................................... 797 REAR BRAKES...................................................................................................... 797 CALIPER AND DISC............................................................................................. 797 Removal.................................................................................................. 797 Installation............................................................................................. 799 PARK BRAKE ADJUSTMENT PROCEDURE.............................................................................. 801 BRAKE BLEEDING PROCEDURE..................................................................................... 802 Service Brake............................................................................................ 802 Park Brake............................................................................................... 802 CALIPER...................................................................................................... 803 Disassembly.............................................................................................. 803 PISTON SUBASSEMBLY........................................................................................... 806 Disassembly.............................................................................................. 806 PREPARATION FOR ASSEMBLY..................................................................................... 807 Clean Parts.............................................................................................. 807 For Rough Metal Parts.................................................................................... 808 Dry and Inspect Parts.................................................................................... 808 Corrosion Protection..................................................................................... 808 INSPECTION................................................................................................... 808 Caliper Parts............................................................................................ 808 Shoes, Linings and End Plates............................................................................ 809 Inspect linings.......................................................................................... 809 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC)............................................. 809 Piston Assembly Adjuster Grip Force...................................................................... 810 Adjuster Force........................................................................................... 812 Piston Return Spring..................................................................................... 814 ASSEMBLY..................................................................................................... 815 Adjuster and Pin Assembly................................................................................ 815 Piston Subassembly....................................................................................... 816 Brake Caliper............................................................................................ 817 PERIODIC INSPECTIONS......................................................................................... 823 Shoes, Linings and End Plates............................................................................ 823 Inspect the following areas for fluid leaks.............................................................. 823 Dust Boots............................................................................................... 823 Brake Disc............................................................................................... 823 BRAKE LINING................................................................................................. 824 Replacement.............................................................................................. 824 BRAKE DISC................................................................................................... 824 Inspection............................................................................................... 824 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................................................ 825 GENERAL...................................................................................................... 825 SAFETY PRECAUTIONS........................................................................................... 825 Rear Brake Conditioning.................................................................................. 826 SECTION L - HYDRAULIC SYSTEM................................................................................................ 829 HYDRAULIC SYSTEM......................................................................................................... 831 HYDRAULIC SYSTEM..................................................................................................... 833 HYDRAULIC SYSTEM OPERATION....................................................................................... 833 COMPONENT DESCRIPTION............................................................................................ 834 Hoist Pump................................................................................................... 834 Steering/Brake Pump.......................................................................................... 834 Tank......................................................................................................... 834 High Pressure Hydraulic Filters.............................................................................. 834 Bleeddown Manifold........................................................................................... 834 Steering System Accumulators................................................................................. 834 DISABLED TRUCK CONNECTORS........................................................................................ 836 GENERAL...................................................................................................... 836 STEERING AND BRAKE SYSTEM.................................................................................... 836 Hookup................................................................................................... 836 HOIST SYSTEM................................................................................................. 837 Hookup................................................................................................... 837 Dumping Procedure........................................................................................ 837 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................................................ 839 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................................... 841 HOIST PUMP....................................................................................................... 841 Removal...................................................................................................... 841 Installation................................................................................................. 842 Disassembly.................................................................................................. 844 Inspection Of Parts.......................................................................................... 847 Assembly..................................................................................................... 848 HYDRAULIC TANK................................................................................................... 854 Filling Instructions......................................................................................... 854 Removal...................................................................................................... 854 Installation................................................................................................. 855 HYDRAULIC TANK STRAINERS......................................................................................... 856 Removal...................................................................................................... 856 Inspect and Clean............................................................................................ 856 Installation................................................................................................. 857 HYDRAULIC TANK BREATHERS......................................................................................... 857 HOIST CIRCUIT FILTERS............................................................................................ 858 FILTER ELEMENT REPLACEMENT....................................................................................... 859 Removal...................................................................................................... 859 Installation................................................................................................. 859 INDICATOR SWITCH................................................................................................. 859 STEERING CIRCUIT......................................................................................................... 861 STEERING CIRCUIT..................................................................................................... 863 STEERING CIRCUIT OPERATION....................................................................................... 863 COMPONENT DESCRIPTION............................................................................................ 864 STEERING CONTROL UNIT........................................................................................ 864 FLOW AMPLIFIER............................................................................................... 864 No Steer................................................................................................. 866 Steering Left............................................................................................ 868 Steering Right........................................................................................... 870 No Steer, External Shock Load............................................................................ 872 BLEED DOWN MANIFOLD.......................................................................................... 874 ACCUMULATORS................................................................................................. 877 Low Precharge Warning Switch............................................................................. 877 HIGH PRESSURE FILTER......................................................................................... 877 STEERING/BRAKE PUMP.......................................................................................... 877 Operation................................................................................................ 878 PRINCIPLE OF OPERATION....................................................................................... 880 Full Pump Volume:........................................................................................ 880 Half Pump Volume:........................................................................................ 880 Neutral Position:........................................................................................ 881 STEERING CIRCUIT COMPONENT REPAIR........................................................................................ 883 STEERING CIRCUIT COMPONENT REPAIR.................................................................................... 885 BLEED DOWN MANIFOLD.............................................................................................. 885 Removal...................................................................................................... 885 Installation................................................................................................. 885 ACCUMULATOR...................................................................................................... 886 Removal...................................................................................................... 886 Installation................................................................................................. 887 Disassembly.................................................................................................. 887 Cleaning and Inspection...................................................................................... 888 Assembly..................................................................................................... 888 LEAK TESTING..................................................................................................... 890 STEERING ACCUMULATOR CHARGING PROCEDURE.......................................................................... 891 Temperature During Precharge................................................................................. 894 ACCUMULATOR STORAGE PROCEDURES................................................................................... 894 Instructions For Storing Bladder Accumulators................................................................ 894 Installation................................................................................................. 895 Bladder Storage Procedures................................................................................... 895 FLOW AMPLIFIER................................................................................................... 896 Removal...................................................................................................... 896 Installation................................................................................................. 896 Disassembly.................................................................................................. 898 Reassembly................................................................................................... 899 STEERING CONTROL UNIT............................................................................................ 900 Removal...................................................................................................... 900 Spline Inspection............................................................................................ 900 Installation................................................................................................. 901 Disassembly.................................................................................................. 901 Cleaning and Inspection...................................................................................... 902 Assembly..................................................................................................... 903 STEERING CYLINDER................................................................................................ 907 Disassembly.................................................................................................. 907 Inspection and Cleaning...................................................................................... 907 Assembly..................................................................................................... 907 Testing...................................................................................................... 907 STEERING CIRCUIT FILTER.......................................................................................... 908 Filter Element Replacement................................................................................... 908 Removal...................................................................................................... 909 Installation................................................................................................. 909 Indicator Switch............................................................................................. 909 STEERING AND BRAKE PUMP.......................................................................................... 910 Removal...................................................................................................... 910 Installation................................................................................................. 911 Disassembly.................................................................................................. 912 Control Piston Group......................................................................................... 912 Valve Plate Group............................................................................................ 913 Rotating Group............................................................................................... 913 Swashblock Group............................................................................................. 914 Driveshaft Group............................................................................................. 914 INSPECTION....................................................................................................... 914 Control Piston Group......................................................................................... 914 Valve Plate Group............................................................................................ 914 Rotating Group............................................................................................... 914 Swashblock Group............................................................................................. 918 Driveshaft Group............................................................................................. 918 Compensator Block and Unloader Module........................................................................ 918 Stroke Adjuster Assembly..................................................................................... 918 ASSEMBLY......................................................................................................... 918 Swashblock Group............................................................................................. 918 Driveshaft Group............................................................................................. 919 Rotating Group............................................................................................... 920 Control Piston Group......................................................................................... 920 Valve Plate Group............................................................................................ 921 HOIST CIRCUIT............................................................................................................ 923 HOIST CIRCUIT........................................................................................................ 925 HOIST CIRCUIT OPERATION.......................................................................................... 925 COMPONENT DESCRIPTION............................................................................................ 926 Hydraulic Tank............................................................................................... 926 Hoist Pump................................................................................................... 926 High Pressure Filters........................................................................................ 926 Hoist Valve.................................................................................................. 927 Hoist Pilot Valve............................................................................................ 928 Hoist-up Limit Solenoid...................................................................................... 928 Pilot Operated Check Valve................................................................................... 928 Counterbalance Valve Manifold................................................................................ 929 HOIST SYSTEM OPERATION MODES..................................................................................... 930 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)................................................. 930 Power Up Operation (Figure 7-7).............................................................................. 932 Hold Operation (Figure 7-8).................................................................................. 934 Power Down Operation (Figure 7-9)............................................................................ 936 Float Operation (Figure 7-10)................................................................................ 938 HOIST CIRCUIT COMPONENT REPAIR........................................................................................... 941 HOIST CIRCUIT COMPONENT REPAIR....................................................................................... 943 HOIST VALVE...................................................................................................... 943 Removal...................................................................................................... 943 Installation................................................................................................. 943 O-Ring Replacement........................................................................................... 944 INLET SECTION.................................................................................................... 945 Disassembly.................................................................................................. 945 Cleaning and Inspection...................................................................................... 946 Assembly..................................................................................................... 946 SPOOL SECTION.................................................................................................... 946 Disassembly.................................................................................................. 946 Cleaning and Inspection...................................................................................... 949 Assembly..................................................................................................... 949 HOIST PILOT VALVE................................................................................................ 950 Removal...................................................................................................... 950 Installation................................................................................................. 950 Disassembly.................................................................................................. 951 Cleaning and Inspection...................................................................................... 952 Assembly..................................................................................................... 953 BODY UP LIMIT SOLENOID........................................................................................... 954 PILOT OPERATED CHECK VALVE....................................................................................... 954 HOIST CYLINDERS.................................................................................................. 954 Removal...................................................................................................... 954 Installation................................................................................................. 955 Disassembly.................................................................................................. 956 Cleaning and Inspection...................................................................................... 958 ASSEMBLY OF QUILL AND CYLINDER................................................................................... 959 Quill Installation........................................................................................... 959 Installation of Check Balls and Plugs in Quill............................................................... 960 Assembly of Cylinder......................................................................................... 961 Pressure Testing............................................................................................. 962 OVERCENTER MANIFOLD.............................................................................................. 963 HYDRAULIC CHECKOUT PROCEDURE............................................................................................. 965 HYDRAULIC CHECKOUT PROCEDURE......................................................................................... 967 STEERING AND BRAKE PUMP.......................................................................................... 967 Pressure Check And Adjustment Procedure...................................................................... 967 BLEEDDOWN MANIFOLD............................................................................................... 969 SHOCK & SUCTION VALVES........................................................................................... 969 Shock & Suction Valve Settings............................................................................... 969 LEAKAGE TESTS.................................................................................................... 971 Steering Control Unit & Flow Amplifier....................................................................... 971 Bleeddown Manifold........................................................................................... 971 ACCUMULATOR BLEED DOWN PROCEDURE................................................................................. 972 LOW STEERING PRESSURE SWITCH..................................................................................... 974 CHECKING HOIST SYSTEM PRESSURES.................................................................................. 981 Hoist System Relief Pressure Adjustment...................................................................... 981 Power Down Relief Pressure Adjustment........................................................................ 982 HOIST COUNTERBALANCE VALVE................................................................................... 983 Preparation:............................................................................................. 983 Counterbalance Valve Pressure Check Only:................................................................ 983 Counterbalance Valve Adjustment.......................................................................... 984 OIL CLEANLINESS CHECK........................................................................................ 987 SECTION M - OPTIONS AND SPECIAL TOOLS ....................................................................................... 989 SECTION M7 HEATER OPTIONS INDEX.......................................................................................... 991 GENERAL INFORMATION.................................................................................................. 993 TROUBLESHOOTING...................................................................................................... 993 HEATER ELEMENT....................................................................................................... 993 Removal.......................................................................................................... 993 Installation..................................................................................................... 994 GENERAL.............................................................................................................. 995 Maintenance...................................................................................................... 995 HEATING ELEMENT...................................................................................................... 995 Removal.......................................................................................................... 995 Installation..................................................................................................... 996 THERMOSTAT........................................................................................................... 996 Removal.......................................................................................................... 996 Installation..................................................................................................... 996 GENERAL INFORMATION.................................................................................................. 997 TROUBLESHOOTING...................................................................................................... 997 HEATER ELEMENT....................................................................................................... 997 Removal.......................................................................................................... 997 Installation..................................................................................................... 998 SPECIAL TOOLS............................................................................................................ 999 NITROGEN CHARGING VALVE.............................................................................................. 999 ROLL-OUT ASSEMBLY.................................................................................................... 999 EYE BOLT............................................................................................................. 999 OFFSET WRENCH........................................................................................................1000 TORQUE ADAPTER.......................................................................................................1000 HANDLE...............................................................................................................1000 SEAL INSTALLER.......................................................................................................1000 SLEEVE ALIGNMENT TOOLS...............................................................................................1001 QUICK DISCONNECT COUPLING............................................................................................1001 HARNESS..............................................................................................................1001 SEAL INSTALLATION RING...............................................................................................1001 SOCKETS AND ADAPTERS.................................................................................................1002 DUST CAPS............................................................................................................1002 HYDRAULIC SYSTEM FLUSHING TOOLS......................................................................................1003 MISCELLANEOUS SERVICE TOOLS..........................................................................................1004 PAYLOAD DATA MANAGER.................................................................................................1004 HYDRAULIC SYSTEM VACUUM PUMP.........................................................................................1004 BRAKE PISTON TOOL....................................................................................................1005 HIGH VOLTAGE TOOLS...................................................................................................1008 0-2000 VDC CUSTOM METER KIT (58B-06-00800)...........................................................................1008 BODY PAD SPACER TOOL.................................................................................................1009 RADIATOR SHUTTERS .......................................................................................................1011 RADIATOR SHUTTERS....................................................................................................1013 OPERATION........................................................................................................1013 Hydraulic Circuit............................................................................................1013 Electrical Circuit:..........................................................................................1014 MAINTENANCE AND REPAIR...........................................................................................1014 TROUBLESHOOTING..................................................................................................1015 Hydraulic Troubleshooting....................................................................................1018 Electrical Troubleshooting...................................................................................1020 PAYLOAD METER III ™ ....................................................................................................1021 OPERATION SECTION....................................................................................................1025 Introduction.....................................................................................................1025 Data Summary.................................................................................................1025 Data Gathering...............................................................................................1025 COMPONENT DESCRIPTION............................................................................................1026 System Diagram...............................................................................................1026 Suspension Pressure Sensors..................................................................................1026 Inclinometer.................................................................................................1026 Operator Display.............................................................................................1026 Operator Switch..............................................................................................1027 Speed Input..................................................................................................1027 Body-Up Switch...............................................................................................1027 Brake Lock Switch............................................................................................1027 Payload Meter................................................................................................1027 Communications Ports.........................................................................................1027 Key Switch Input.............................................................................................1028 Payload Meter Power..........................................................................................1028 Load Lights..................................................................................................1028 Wiring and Termination.......................................................................................1029 TCI Outputs..................................................................................................1029 OPERATOR’S DISPLAY AND SWITCH....................................................................................1030 Reading the Speedometer......................................................................................1030 Reading the Load Display.....................................................................................1030 Using the Operator ID........................................................................................1030 Using the Load and Ton Counter...............................................................................1030 Total Ton Counter............................................................................................1030 Total Load Counter...........................................................................................1031 Clearing the Counters........................................................................................1031 Viewing Live Sensor Data.....................................................................................1031 Other Display Messages.......................................................................................1031 PAYLOAD OPERATION & CALCULATION..................................................................................1032 Description of Haul Cycle States.............................................................................1032 Haul Cycle Description.......................................................................................1032 Load Calculation.............................................................................................1033 Carry Back...................................................................................................1033 Measurement Accuracy.........................................................................................1033 SOURCES FOR PAYLOAD ERROR........................................................................................1033 Payload Error................................................................................................1033 Loading Conditions...........................................................................................1034 Pressure Sensors.............................................................................................1034 Swingloads...................................................................................................1034 Speed and Distance...........................................................................................1034 HAUL CYCLE DATA..................................................................................................1034 Haul Cycle Warning Flags.....................................................................................1036 Frame Torque Data............................................................................................1037 Sprung Weight Data...........................................................................................1037 Maximum Speed Data...........................................................................................1037 Alarm Records................................................................................................1037 Fault Code Data..............................................................................................1038 PC SOFTWARE OVERVIEW.............................................................................................1039 System Configuration.........................................................................................1039 Installing the PLMIII Software...............................................................................1039 DOWNLOADING DATA.................................................................................................1040 PLM III SYSTEM CONFIGURATION.....................................................................................1041 Starting Communications......................................................................................1041 Displayed Payload Units......................................................................................1041 Time Units...................................................................................................1041 Connection Menu..............................................................................................1041 Connecting to the Payload Meter..............................................................................1042 Configure the Payload Meter..................................................................................1042 Setting the Date and Time....................................................................................1042 Setting the Truck Type.......................................................................................1043 Setting the Gauge Display Units..............................................................................1043 Setting the Frame Serial Number..............................................................................1043 Setting the Truck Number.....................................................................................1043 Setting the Komatsu Distributor..............................................................................1043 Setting the Komatsu Customer.................................................................................1043 Clean Truck Tare Calibration.................................................................................1044 Inclinometer Calibration.....................................................................................1044 DATA ANALYSIS....................................................................................................1045 Creating a Query.............................................................................................1045 Sorting on Truck Unit Number.................................................................................1045 Sorting on Truck Type........................................................................................1045 Sorting on Date Range........................................................................................1046 Sorting on Time Range........................................................................................1046 Payload Detail Screen........................................................................................1047 Creating Reports.............................................................................................1047 Summary - one page report....................................................................................1048 Detailed - multi-page report.................................................................................1048 Creating Graphs..............................................................................................1049 Exporting Data...............................................................................................1049 CSV Export...................................................................................................1049 Compressed...................................................................................................1050 Importing Data...............................................................................................1051 Deleting Haul Cycle Records..................................................................................1051 Viewing Alarms...............................................................................................1052 Deleting Alarm Records.......................................................................................1052 TROUBLESHOOTING SECTION..............................................................................................1053 TROUBLESHOOTING..................................................................................................1053 Viewing Active Alarms........................................................................................1053 Real-Time Data Display.......................................................................................1053 Testing the Payload Lights...................................................................................1053 Creating Log Files of Inputs.................................................................................1054 Daily Inspections............................................................................................1054 Periodic Maintenance.........................................................................................1054 Abnormal Displays at Power-Up................................................................................1055 No Payload Display When Key Switch is Turned ON..............................................................1056 No Display on Speedometer....................................................................................1057 No Display on Operator Display...............................................................................1057 No Communications With PC....................................................................................1058 Load Lights Don’t Light During Loading.......................................................................1059 Load Lights Remain ON........................................................................................1060 Load Lights Remain ON During Dumping.........................................................................1060 Display Doesn't Clear When The Load Is Dumped................................................................1060 Calibration Problems.........................................................................................1061 Alarm 1 - Left Front Pressure High...........................................................................1062 Alarm 2 - Left Front Pressure Low............................................................................1062 Troubleshoot Wiring to Left Front Suspension.................................................................1062 Alarm 3 - Right Front Pressure High..........................................................................1063 Alarm 4 - Right Front Pressure Low...........................................................................1063 Troubleshoot Wiring to Right Front Suspension................................................................1063 Alarm 5 -Left Rear Pressure High.............................................................................1064 Alarm 6 - Left Rear Pressure Low.............................................................................1064 Troubleshoot Wiring to Left Rear Suspension..................................................................1064 Alarm 7 - Right Rear Pressure High...........................................................................1065 Alarm 8 - Right Rear Pressure Low............................................................................1065 Troubleshoot Wiring to Right Rear Suspension.................................................................1065 Alarm 9 - Inclinometer High..................................................................................1066 Alarm 10 - Inclinometer Low..................................................................................1066 Troubleshoot Inclinometer Wiring.............................................................................1066 Alarm 13 - Body Up Input Failure.............................................................................1067 Alarm 16 - Memory Write Failure..............................................................................1068 Alarm 17 - Memory Read Failure...............................................................................1068 Alarm 18.....................................................................................................1069 Alarm 19.....................................................................................................1069 Alarm 22.....................................................................................................1069 Operator Switch Doesn't Work.................................................................................1070 Alarm 26 - User Switch Fault - SELECT........................................................................1070 Alarm 27 - User Switch Fault - SET...........................................................................1070 Connector Map................................................................................................1071 Connectors...................................................................................................1072 PLMIII CHECK OUT PROCEDURE...........................................................................................1073 General Description..............................................................................................1073 Tools Required...................................................................................................1073 Checkout Procedure...............................................................................................1073 PLMIII CHECKOUT PROCEDURE CONFIRMATION...........................................................................1077 Flashburn Programming........................................................................................1077 Confirmation Checklist.......................................................................................1079 RESERVE ENGINE OIL SYSTEM ..............................................................................................1081 RESERVE ENGINE OIL SYSTEM............................................................................................1083 Operation........................................................................................................1084 LED Monitor Light................................................................................................1084 Tank Fill Control (Optional).....................................................................................1085 Filling Procedure (Remote Fill Feature)..........................................................................1085 SERVICE..........................................................................................................1086 Every 10 Hours, or once each shift:..........................................................................1086 Every 500 Hours..............................................................................................1086 Changing Oil.................................................................................................1086 TROUBLESHOOTING..................................................................................................1087 Circuit Fuse.................................................................................................1087 SYSTEM ELECTRICAL SCHEMATICS.....................................................................................1088 RETRACTABLE LADDER SYSTEM................................................................................................1089 RETRACTABLE LADDER SYSTEM............................................................................................1094 GENERAL SAFETY...................................................................................................1094 LADDER SYSTEM DESCRIPTION........................................................................................1094 LADDER SYSTEM OPERATION..........................................................................................1094 Normal Operation.............................................................................................1094 Emergency Operation..........................................................................................1096 Limit Switch Operation.......................................................................................1096 IN-CAB CONTROL PANEL.............................................................................................1096 IN-CAB CONTROL PANEL FEATURES....................................................................................1098 Digital Display Screen.......................................................................................1098 Command Buttons..............................................................................................1098 IN-CAB CONTROL PANEL FUNCTIONS...................................................................................1100 Timing Control...............................................................................................1100 Ladder System Status.........................................................................................1100 Fault Code Identification....................................................................................1100 Ladder System Configuration..................................................................................1101 In-Cab Control Panel Lockout.................................................................................1101 Automatic Raising............................................................................................1101 Diagnostics..................................................................................................1101 Maintenance..................................................................................................1101 USING THE IN-CAB CONTROL PANEL...................................................................................1102 Raising the Ladder...........................................................................................1102 Lowering the Ladder..........................................................................................1103 USING THE GROUND LEVEL CONTROL BOX...............................................................................1104 Raising the Ladder...........................................................................................1104 Lowering the Ladder..........................................................................................1104 POWER PACK OPERATION.............................................................................................1105 MAINTENANCE......................................................................................................1109 Safety During Maintenance....................................................................................1109 Unplanned Ladder Movements...................................................................................1109 Automatic Ladder Raising.....................................................................................1109 Automatic Accumulator Recharging (Ladder in UP position).....................................................1110 PREVENTIVE MAINTENANCE PROCEDURES................................................................................1111 Daily Inspection.............................................................................................1111 250 Hour Inspection..........................................................................................1111 5000 Hour Inspection.........................................................................................1111 SERVICING........................................................................................................1112 Check Reservoir Oil Level....................................................................................1112 Changing RLS Fluid...........................................................................................1112 Cleaning the RLS.............................................................................................1113 RLS DIAGNOSTICS..................................................................................................1113 Description of Diagnostics Features..........................................................................1113 Continuous System Monitoring.................................................................................1114 Historic System Data Review..................................................................................1115 Comms Integrity Monitoring...................................................................................1115 Log and Service Information..................................................................................1115 System Event Logs............................................................................................1116 SECURITY ACCESS LEVELS...........................................................................................1117 Access Level 1 – NONE........................................................................................1117 Access Level 2 – RESTRICTED..................................................................................1117 Access Level 3 – COMPLETE....................................................................................1117 User Access Privileges.......................................................................................1118 USER ID – PASSWORD...............................................................................................1119 Sequential Field Value Selection Options.....................................................................1119 Password Character Table.....................................................................................1119 USER ID – NEW USER SETUP.........................................................................................1120 SYSTEM FAULTS....................................................................................................1120 Fault Type 1: Communications error...........................................................................1121 Fault Type 2: 10A/15A fuse blown.............................................................................1121 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected....................................1122 Fault Type 8: Power pack recharge too long...................................................................1122 Fault Type 9: Inhibit relay fail.............................................................................1123 Fault Types 10, 11: Light/Siren relay failure................................................................1123 Fault Type 12: Ladder came off upper limit...................................................................1124 Fault Type 13: Ladder did not reach limit....................................................................1124 Fault Type 14: Ladder stayed on limit........................................................................1125 Fault Type 15: Low oil level.................................................................................1125 Fault Type 16: System voltage over 18V during movement.......................................................1126 Fault Type 17: System voltage under 18V......................................................................1126 Fault Type 18: System voltage over 31V.......................................................................1127 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)...............................1127 Fault Type 21: Accumulator recharge > than once/hour.........................................................1128 Fault Type 22: System raised by park brake...................................................................1128 Fault Types 23, 24: Levels 1 and 2 service overdue...........................................................1129 Fault Type 25: Levels 1 and 2 service complete...............................................................1129 DATA MANAGEMENT..................................................................................................1130 Log Files....................................................................................................1130 Generating Reports...........................................................................................1131 MENU DIAGRAMS....................................................................................................1137 Controller Config............................................................................................1137 Contact Information..........................................................................................1137 Show Recent Logs.............................................................................................1137 System Settings..............................................................................................1137 Upload Logs to USB...........................................................................................1137 Diagnostics..................................................................................................1137 SECTION M33 CAMERA SYSTEM INDEX..........................................................................................1145 CAMERA SYSTEM........................................................................................................1146 CAMERA SYSTEM....................................................................................................1146 General......................................................................................................1146 Operation....................................................................................................1146 Camera Switch................................................................................................1147 CAMERA MONITOR...................................................................................................1148 General......................................................................................................1148 CAMERA CONTROLLER................................................................................................1149 General......................................................................................................1149 Removal......................................................................................................1149 Installation.................................................................................................1149 Camera Controller Connector Pins.............................................................................1149 CAMERA SWITCHER..................................................................................................1150 General......................................................................................................1150 Removal......................................................................................................1150 Installation.................................................................................................1150 SETUP AND CHECKOUT PROCEDURE.....................................................................................1151 General......................................................................................................1151 STEP 1 - Switch Function.....................................................................................1151 STEP 2 - Monitor System Settings to Default..................................................................1151 STEP 4 - Monitor Settings - System Settings Unique...........................................................1153 STEP 4 - Monitor Settings - System Settings Unique - Cameras.................................................1155 STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay.........................................1157 STEP 6 - Monitor Settings - System Settings Unique - Standby Mode............................................1158 STEP 7 - Integrated Functions Check..........................................................................1159 SECTION N - OPERATOR CAB ....................................................................................................1161 TRUCK CAB AND COMPONENTS.................................................................................................1163 TRUCK CAB AND COMPONENTS.............................................................................................1165 TRUCK CAB........................................................................................................1165 Description..................................................................................................1165 Removal......................................................................................................1166 Installation.................................................................................................1167 CAB DOOR.........................................................................................................1168 Removal......................................................................................................1168 Installation.................................................................................................1168 Door Adjustment..............................................................................................1168 Door Jamb Bolt Adjustment....................................................................................1169 Door Handle Plunger Adjustment...............................................................................1170 Replace Door Glass...........................................................................................1171 Replace Door Window Regulator................................................................................1175 Replacing the Door Handle or Latch Assembly..................................................................1176 Replacing the Door and Door Hinge Seal.......................................................................1176 Removing the Door Opening Seal...............................................................................1177 Installation.................................................................................................1177 GLASS REPLACEMENT................................................................................................1178 Adhesive-bonded Windows......................................................................................1178 Replacement Procedure........................................................................................1178 WINDSHIELD & REAR GLASS..........................................................................................1180 Removal......................................................................................................1180 Installation.................................................................................................1180 CAB COMPONENTS ..........................................................................................................1183 CAB COMPONENTS.......................................................................................................1185 WINDSHIELD WIPERS................................................................................................1185 WIPER MOTOR..................................................................................................1185 Removal..................................................................................................1185 Installation.............................................................................................1185 WIPER ARM....................................................................................................1185 Removal..................................................................................................1185 Installation.............................................................................................1186 WIPER LINKAGE................................................................................................1186 Removal..................................................................................................1186 Installation.............................................................................................1186 WINDSHIELD WASHER................................................................................................1187 Operation....................................................................................................1187 Service......................................................................................................1187 OPERATOR SEAT (STANDARD SEAT)....................................................................................1188 Adjustment...................................................................................................1188 Inspection...................................................................................................1189 Removal......................................................................................................1189 Installation.................................................................................................1189 Replacing the Seat Compressor................................................................................1190 PASSENGER SEAT (STANDARD SEAT)...................................................................................1195 Inspection...................................................................................................1195 Removal......................................................................................................1195 Installation.................................................................................................1195 SEAT BELT REPLACEMENT (STANDARD SEATS - PC3230)..................................................................1196 Removal......................................................................................................1196 Installation.................................................................................................1196 SEAT BELT REPLACEMENT (STANDARD SEATS - 58E-57-00500)............................................................1198 Removal......................................................................................................1198 Installation.................................................................................................1198 OPERATOR SEAT (OPTIONAL SEAT)................................................................................1200 Seat Belts...............................................................................................1200 Adjustment...............................................................................................1200 PASSENGER SEAT (OPTIONAL SEAT)...............................................................................1201 Seat Belts...............................................................................................1201 Adjustment...............................................................................................1201 SEAT BELT REPLACEMENT (OPTIONAL SEATS)...........................................................................1202 General......................................................................................................1202 Removal......................................................................................................1202 OPERATOR COMFORT.........................................................................................................1207 OPERATOR COMFORT.....................................................................................................1209 HEATER / AIR CONDITIONER.........................................................................................1209 Fan Speed Control Knob.......................................................................................1209 Temperature Control Knob.....................................................................................1209 Air Flow Directional Knob....................................................................................1209 Heater/Air Conditioner Vents.................................................................................1210 COMPONENTS.......................................................................................................1210 Fuse and Circuit Breaker.....................................................................................1210 Relays.......................................................................................................1210 Heater Core..................................................................................................1210 Fan Motor And Speed Control..................................................................................1211 Actuators....................................................................................................1211 Cab Air Filter...............................................................................................1211 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.........................................................................1214 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES........................................................................1214 PRINCIPLES OF REFRIGERATION......................................................................................1214 Air Conditioning.............................................................................................1214 Refrigeration - The Act Of Cooling...........................................................................1215 The Refrigeration Cycle......................................................................................1215 AIR CONDITIONER SYSTEM COMPONENTS................................................................................1216 Compressor (Refrigerant Pump)................................................................................1216 Service Valves...............................................................................................1216 Condenser....................................................................................................1216 Receiver-Drier...............................................................................................1216 Expansion Block Valve........................................................................................1217 Accumulator..................................................................................................1217 Evaporator...................................................................................................1217 ELECTRICAL CIRCUIT...............................................................................................1218 Thermostat...................................................................................................1218 Compressor Clutch............................................................................................1218 Trinary™ Switch..............................................................................................1219 SYSTEM SERVICING.................................................................................................1220 SERVICE TOOLS AND EQUIPMENT......................................................................................1221 Recovery/Recycle Station.....................................................................................1221 Leak Detector................................................................................................1221 Service Valves...............................................................................................1222 Vacuum Pump..................................................................................................1222 Manifold Gauge Set...........................................................................................1223 Installing Manifold Gauge Set................................................................................1224 Purging Air From Service Hoses...............................................................................1224 SYSTEM PERFORMANCE TEST..........................................................................................1225 SYSTEM OIL.......................................................................................................1226 Handling and Reusing PAG Oil.................................................................................1226 Oil Quantity.................................................................................................1226 Checking System Oil..........................................................................................1227 REFRIGERANT......................................................................................................1228 Recycled Refrigerant.........................................................................................1228 Reclaimed Refrigerant........................................................................................1228 Refrigerant Quantity.........................................................................................1228 R-134a Refrigerant Containers................................................................................1228 SYSTEM LEAK TESTING..............................................................................................1229 Electronic Leak Detector.....................................................................................1229 Tracer Dyes..................................................................................................1229 Soap and Water...............................................................................................1229 RECOVERING AND RECYCLING THE REFRIGERANT.........................................................................1229 Draining Oil from the Previous Recovery Cycle................................................................1229 Performing the Recovery Cycle................................................................................1230 Performing the Recycling Procedure...........................................................................1230 Evacuating and Charging the A/C System.......................................................................1230 SYSTEM REPAIR....................................................................................................1230 System Flushing..............................................................................................1231 COMPONENT REPLACEMENT............................................................................................1232 Hoses and Fittings...........................................................................................1232 Lines........................................................................................................1232 Expansion Valve..............................................................................................1232 Receiver-Drier...............................................................................................1232 Thermostat...................................................................................................1232 Compressor...................................................................................................1233 Accumulator..................................................................................................1233 Clutch.......................................................................................................1233 EVACUATING THE SYSTEM............................................................................................1234 CHARGING THE A/C SYSTEM..........................................................................................1236 TROUBLESHOOTING......................................................................................................1237 Preliminary Checks...............................................................................................1237 Diagnosis Of Gauge Readings And System Performance...............................................................1237 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.......................................................................1238 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.......................................................................1244 OPERATOR CAB CONTROLS....................................................................................................1245 OPERATOR CAB AND CONTROLS............................................................................................1249 STEERING WHEEL AND CONTROLS......................................................................................1250 Horn Button..................................................................................................1250 Tilt / Telescope Lever.......................................................................................1250 Multi-Function Turn Signal Switch............................................................................1250 STEERING COLUMN..................................................................................................1251 Removal......................................................................................................1251 Steering Column Inspection...................................................................................1251 Installation.................................................................................................1252 STEERING WHEEL...................................................................................................1252 Removal......................................................................................................1252 Installation.................................................................................................1252 PEDALS...........................................................................................................1254 Service Brake Pedal..........................................................................................1254 Dynamic Retarding............................................................................................1254 Dynamic Retard Pedal.........................................................................................1254 Accelerator Pedal............................................................................................1254 GRADE/SPEED RETARD CHART.........................................................................................1255 OVERHEAD PANEL AND DISPLAYS......................................................................................1256 CENTER CONSOLE...................................................................................................1257 Directional Control Lever....................................................................................1257 Override/Fault Reset Switch..................................................................................1258 Engine Stop Switch...........................................................................................1258 L.H. Window Control Switch...................................................................................1258 R.H. Window Control Switch...................................................................................1258 Hoist Control Lever..........................................................................................1258 Raising The Dump Body........................................................................................1258 Lowering The Dump Body.......................................................................................1259 Retard Speed Control (RSC) Adjust Dial.......................................................................1259 Retard Speed Control (RSC) Switch............................................................................1259 Data Store Button............................................................................................1260 12V Auxiliary Power Outlets..................................................................................1260 Fire Suppression Control Outlet..............................................................................1260 Communication Radio Outlet...................................................................................1260 DIAGNOSTIC PORTS.................................................................................................1260 KOMTRAX Plus Diagnostic Port.................................................................................1260 Interface Module (IM) Diagnostic Port........................................................................1260 Payload Meter Diagnostic Port................................................................................1260 Drive System Or Modular Mining...............................................................................1260 Drive System Controller (DSC) Diagnostic Port................................................................1260 Engine Diagnostic Port (CENSE)...............................................................................1260 Engine Diagnostic Port (QUANTUM).............................................................................1260 HEATER / AIR CONDITIONER.........................................................................................1261 Fan Speed Control Knob.......................................................................................1261 Temperature Control Knob.....................................................................................1261 Air Flow Directional Knob....................................................................................1261 Heater/Air Conditioner Vents.................................................................................1261 INSTRUMENT PANEL.................................................................................................1262 Control Symbols..............................................................................................1262 Cab/Air Conditioner Vents....................................................................................1264 Status Indicator Light Panel.................................................................................1264 Hydraulic Oil Temperature Gauge..............................................................................1264 Coolant Temperature Gauge....................................................................................1264 Speedometer/Digital Display..................................................................................1264 Fuel Level Gauge.............................................................................................1264 Drive System Temperature Gauge...............................................................................1264 Hazard Warning Light Switch..................................................................................1264 Pre-Shift Brake Test Switch..................................................................................1265 Wheel Brake Lock Control.....................................................................................1265 Rest Switch..................................................................................................1265 Engine Warm Up Switch (Optional).............................................................................1266 Heated Mirror Switch (Optional)..............................................................................1266 Rotating Beacon Light Switch (Optional)......................................................................1266 Camera System Switch (Optional)..............................................................................1266 Key Switch...................................................................................................1266 Starting.....................................................................................................1266 Warning Light................................................................................................1267 Digital Display Contrast Buttons.............................................................................1267 Turn Signal Indicators.......................................................................................1267 Panel Light Dimmer...........................................................................................1267 Mode Switches................................................................................................1267 Fog Light Switch (Optional)..................................................................................1267 Manual Backup Switch.........................................................................................1268 Headlight/Panel Illumination Light Switch....................................................................1268 STATUS INDICATOR LIGHT PANEL.....................................................................................1269 Status Indicator Light Panel.................................................................................1269 DIGIT DISPLAY OPERATION..........................................................................................1272 Toggling Through Main Level Screens..........................................................................1272 Toggling Through Warning Screens.............................................................................1273 Entering Payload Meter Data..................................................................................1274 KOMTRAX PLUS.....................................................................................................1275 Operation....................................................................................................1275 Interface Module.............................................................................................1277 Basic Precautions............................................................................................1277 KOMATSU WIRELESS BRIDGE (Optional)...............................................................................1278 General Information..........................................................................................1278 Communication Setup..........................................................................................1278 Switching to the KWB_SETUP Network...........................................................................1278 Setting the Computer Subnet Mask and IP Address..............................................................1279 Properties...................................................................................................1279 Setting Up the KWB...........................................................................................1280 Adding Encryption............................................................................................1280 Final Computer Settings......................................................................................1280 Data Downloading.............................................................................................1281 Resetting the KWB............................................................................................1281 KWB Lights...................................................................................................1281 SECTION P - LUBRICATION AND SERVICE .........................................................................................1283 LUBRICATION AND SERVICE .................................................................................................1285 LUBRICATION AND SERVICE..............................................................................................1287 830E SERVICE CAPACITIES..........................................................................................1287 HYDRAULIC TANK SERVICE...........................................................................................1287 Adding Oil...................................................................................................1287 COOLANT LEVEL CHECK..............................................................................................1288 Radiator Filling Procedure...................................................................................1288 Coolant Specifications.......................................................................................1288 Unacceptable Practices.......................................................................................1288 WHEEL MOTOR SERVICE..............................................................................................1288 RESERVE ENGINE OIL SYSTEM (Optional).............................................................................1289 Reserve Oil Tank Filling Procedure (Remote fill).............................................................1289 Inline Screen................................................................................................1289 QUICK FILL SERVICE CENTER........................................................................................1290 LUBRICATION CHART................................................................................................1291 10 HOUR (DAILY) INSPECTION.......................................................................................1292 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................1295 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................1296 250 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................................................1297 500 HOUR LUBRICATION AND MAINTENANCE CHECKS......................................................................1301 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..........................................................1302 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS....................................................................1303 2500 HOUR MAINTENANCE CHECKS.....................................................................................1304 5000 HOUR MAINTENANCE CHECKS.....................................................................................1304 INJECTOR OPERATION...........................................................................................1314 AUTOMATIC LUBRICATION SYSTEM ............................................................................................1305 AUTOMATIC LUBRICATION SYSTEM.........................................................................................1307 GENERAL DESCRIPTION..............................................................................................1307 SYSTEM COMPONENTS................................................................................................1309 Filter.......................................................................................................1309 Hydraulic Motor and Pump.....................................................................................1309 Grease Reservoir.............................................................................................1309 Pressure Reducing Valve......................................................................................1309 Flow Control Valve...........................................................................................1309 Solenoid Valve...............................................................................................1309 Vent Valve...................................................................................................1309 Over Pressure Cut Off Switch.................................................................................1309 Grease Pressure Failure Switch...............................................................................1309 Injectors....................................................................................................1309 Interface Module.............................................................................................1309 Relief Valve (unloader valve)................................................................................1309 SYSTEM OPERATION.................................................................................................1310 Normal Operation.............................................................................................1310 Lubricant Required For System................................................................................1311 Filter Assembly..............................................................................................1311 LUBRICANT PUMP...................................................................................................1312 Pump Housing Oil Level.......................................................................................1312 Pump Pressure Control........................................................................................1312 INJECTORS (SL-1 Series “H”)......................................................................................1313 Injector Specifications......................................................................................1313 Injector Adjustment..........................................................................................1313 PREVENTIVE MAINTENANCE PROCEDURES................................................................................1315 Daily Lubrication System Inspection..........................................................................1315 250 Hour Inspection..........................................................................................1315 1000 Hour Inspection.........................................................................................1315 SYSTEM CHECKOUT..................................................................................................1316 Lubrication Cycle Operation..................................................................................1316 SYSTEM TROUBLESHOOTING CHART.....................................................................................1317 SECTION R - SYSTEM SCHEMATICS ...............................................................................................1319 HYDRAULIC BRAKE SCHEMATIC................................................................................................1321 HYDRAULIC SCHEMATIC......................................................................................................1322 RETRACTABLE LADDER SYSTEM................................................................................................1323 ELECTRICAL SCHEMATIC.....................................................................................................1324
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